DAELIM DAYSTAR VL125E Service Manual Download | Manualshive

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9-4

Cylinder Head / Valve

Remove the cam chain from camshaft.
In order to separate the cam chain from the
crank case, bind it with the thread or a string.
Remove the camshaft.

Camshaft Holder Disassembly

Remove the end of the rocker arm spring from
the dowel pins.

Remove the dowel pins from the Camshaft
holder using the following

Tools:

- Dowel pin puller set
- Sliding shaft
- Sliding weight

Put the 6mm bolt into the rocker arm shaft,
remove the rocker arm shaft, pulling the bolt.
Remove the rocker arm and rocker arm spring
Remove the other rocker arm shaft, rocker
arm, and rocker arm spring following the same
order.

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Chain

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Cam Shaft

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Dowel Pins

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

Rocker Arm Spring

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Summary of Contents for DAYSTAR VL125E

Page 1: ...cation are based on the latest product information avaliable at the time of approval for printing DAELIM reserves the right to make changes at any time without notice and without incurring any obligat...

Page 2: ...roughly wash your hands with soap and water as soon as possible after handling used oil Service Rules 1 Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents 2 Use the spe...

Page 3: ...fication Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Engine No Engine No Engine No Engine No Engine No Engine No Engine No Engine No Eng...

Page 4: ...el Capacity 16 8 Fuel Reserve Capacity 4 3 Caster Angle 32 Trail Length 147mm Front Fork Oil Capacity 280cm3 Type Oil Air Cooled 4 stroke SOHC Engine Cylinder Number arrangement 1 Cylinder 15 Bore and...

Page 5: ...Gear Ratio 5th 0 923 24 26 Gearshift Pattern Left foot operated return system 1 N 2 3 4 5 Ignition TRANSISTER Ignition Timing F Mark BTDC 18 2 1 600 150 rpm Battery Capacity 12V 10AH Spark Plug CR9EH...

Page 6: ...Tensioner Mounting Bolt 2 6 1 2 12 Cam Chain Tensioner Sealing Screw 1 6 0 4 4 Cylinder Head Cover Bolt 2 6 1 0 10 Crank Shaft Hole Cap 1 30 0 8 8 Timing Hole Cap 1 14 0 6 6 L Crank Case Cover Bolt 7...

Page 7: ...24 30 12mm Bolt nut 5 0 6 0 50 60 10mm flange bolt nut 3 5 4 5 35 45 Item Q ty Thread dia Torque Remark Brake Caliper Bracket Bolt 2 8 3 0 30 Brake Caliper Bleed Valve 1 8 0 6 6 Brake Pad pin Bolt 2 8...

Page 8: ...the ratio 1 1 Use multi purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Use moly...

Page 9: ...10 Driver 10 13 14 Remover Assy 15mm 10 Attachment 32 35mm 10 14 Remover Shaft 15mm 10 Attachment 42 47mm 10 13 14 Remover Head 10 Attachment 62 68mm 10 Sliding Weight 10 Attachment 72 78mm 10 Thread...

Page 10: ...Adapter Spark Adapter 3 16 17 16 17 17 17 Remark Description Reference section Valve Seat Cut Valve Seat Cutter 45 Valve Seat Cutter 35 Valve Seat Cutter 35 Valve Seat Cutter 60 Cutter Holder 5mm 8 8...

Page 11: ...e thoroughly before applying tape Do not use a wire or harnesse with a broken insulator Repair by wrapping then with protective tape or replace them Route wire harnesses to avoid sharp edges or corner...

Page 12: ...1 11 General Information...

Page 13: ...1 12 General Information...

Page 14: ...1 13 General Information...

Page 15: ...MEMO...

Page 16: ...brication Service Information 2 1 Specifications 2 1 Troubleshooting 2 2 Engine Oil Level Check 2 3 Engine Oil Change 2 3 Engine Oil Filter Element Change 2 4 Oil Pump 2 4 Lubrication Points 2 7 Engin...

Page 17: ...ck open Plugged oil pick up screen Oil pump worm External oil leaks High oil pressure Pressure relief valve stuck closed Plugged oil filter gallery or metering orifice In correct oil being used No oil...

Page 18: ...service classification SE or SH Viscosity SAE 10W 30 Install the oil level gauge Start the engine and let it idle for a few minutes Stop the engine and check that the oil level is at the upper level m...

Page 19: ...body Measure the pump body clearance Service Limit 0 25mm 0 010 in Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Co...

Page 20: ...r Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner...

Page 21: ...n the bolt Torque 1 1kgf m 11N m 8ft lb Install the right crank case cover Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil P...

Page 22: ...ables at their upper ends Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil Check the cable for loose replace them if necessary...

Page 23: ...MEMO...

Page 24: ...ion 14 f 550rpm Drive chain free play 50 60mm 1 968 2 362 in Rear brake pedal free play 20 30mm 0 787 1 181 in Clutch lever free play 10 20mm 0 393 0 787 in Specifications Tires Driver only Front 200k...

Page 25: ...f m 11N m Cylinder Head Cover Bolt 1 0 kgf m 10N m Valve Adjusting Nut 1 1 kgf m 11N m Timing Hole Cap 0 6 kgf m 6N m Crankshaft Hole Cap 0 8 kgf m 8N m Rear Axle Nut 8 8kgf m 88N m Tools Common Tool...

Page 26: ...rform the Pre ride inspection in the Owner s manual at each scheduled maintenance period I Inspect and clean adjust lubricate or replace if necessary R Replace L Lubricate C Clean Should serviced by a...

Page 27: ...by loosening the lock nut and turning the adjuster Tighten the lock nut Recheck the throttle free play Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel C...

Page 28: ...3 5 Maintenance Air Cleaner Loosen the four screw and remove the air cleaner case cover Loosen the three screw and remove the air cleaner element...

Page 29: ...inger Tighten it with plug wrench Torque 1 1kgf m 11N m Install the spark plug caps Valve Clearnance Perform valve inspection adjustment with the engine at normal operating temperature Below 35 95 Rem...

Page 30: ...ds Compression Pressure 14 0 f 550rpm If compression is low check the following Incorrect valve clearance adjustment Valve for leakage Exposed cylinder head from the gasket Worn piston cylinder If com...

Page 31: ...ay is within recommended range Free Play 50 60mm If necessary adjust the drive chain free play Adjust by loosening the axle nut and lock nuts in the right left chain adjusters and turning the adjustin...

Page 32: ...rollar for wear and damage and remove the chain tensioner Service limit 30 5mm RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Br...

Page 33: ...ve the right side cover The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns If electrolyte gets on your eyes flush with water for at least 15 minutes and ca...

Page 34: ...switch operation and adjust it if necessary Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Brake Hose Br...

Page 35: ...nd adjust them if necessary Brake Stop Switch Adjust the brake light switch so that the brake light may come on when the brake pedal is depressed and brake engagement begin Hold the switch body and tu...

Page 36: ...t up the main stand Check of smooth operation when pulling the low end part of the side stand If the side stand is hard coat the pivot with grease If the side stand moves too freely inspect the side s...

Page 37: ...ess is noted Tighten all nuts and bolts of the rear suspension Bolts Nuts Fasteners Check that all nuts and bolts are tightened to correct torque values Check that all cotter pins safety clips hose cl...

Page 38: ...3 in Steering Head Bearings Check that the control cables do not interfere with handle bar rotation Raise the front wheel off the ground Check that the handle bar moves freely from side to side If the...

Page 39: ...Fuel System 4 0...

Page 40: ...or with an exhausted evacuation system in an enclosed area Bending or twisting the control cables will impair smooth operation and may cause the cables stick or blind to result in loss of vehicle con...

Page 41: ...h idle hard starting or stalling starting Incorrect idle ring adjustment Lean mixture rich mixture Clogged air cleaner Faulty air cut off valve Clogged fuel system Lean mixture Clogged injector Clogge...

Page 42: ...fuel cock OFF and remove the fuel Remove a fuel tank mounting bolt Remove fuel unit wire coupler Remove the fuel tank Installation Install the fuel tank in the reverse order of removal Check for the o...

Page 43: ...e band out of the air cleaner side Remove the battery Remove the air cleaner mounting bolt Remove the air cleaner case Installation Installation is essentially the reverse order of removal Install the...

Page 44: ...ad the fault code 5 8 Fault code table 5 9 How to remove the fault code 5 10 EMS trouble shooting 5 10 6 INJECTOR 5 11 7 MAPAT 5 14 8 TPS 5 17 9 ETS 5 20 10 ISA 5 23 11 O2 Oxygen SENSOR 5 26 12 CHECKI...

Page 45: ...ause these parts may be damaged by the impact of the drop Do not touch the ECU terminal because it may be damaged by the static The ignition key off when assembly and disassembly of the ECU coupler ot...

Page 46: ...ipe and injector The fuel in tank being high pressed by fuel pump moves to the division pipe through fuel filter Next the fuel is supplied to injector being highly maintained as regulated pressure abo...

Page 47: ...5 4 EMS Engine Management System 3 TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO 6 7 8 11 13 14 15 16 36 38 were not connected 4 WIRING DIAGRAM OF THE ECU...

Page 48: ...n that happen Normally the MIL illuminates for 3 seconds when the main key is turned on Remarks 1 If the EMS has some problem and the MIL on and off engine starting and driving are temporary by the EM...

Page 49: ...inimum driving of vehicle MILon off INTAKE MIL INTAKE MILon on INTAKE INTAKE The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order intake in...

Page 50: ...r to check the malfunction of vehicle is placed in the rh side cover Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool The...

Page 51: ...ct information to driver If the MIL on when engine is working engine is able to be operated by fail safe However in the event that Injector Fuel pump Ignition coil has something wrong vehicle may not...

Page 52: ...uel pump failure EFP Intake Manifold absolute pressure signal failure IMP Throttle position signal failure TPS O2 sensor heater output failure LSH Lambda signal failure VLS Engine temperature signal f...

Page 53: ...e ignition key on off If many problems happened in the EMS parts at the same time only one defect code will is displayed by the priority order Even thought repair a fault and remove the memorized faul...

Page 54: ...Remove connector connector bolt Injector and Injector cap Replace the Injector 6 INJECTOR Be sure to check the engine is cooling because a little gasoline remains it could be still hot CAUTION Before...

Page 55: ...stance of injector 14 5 0 7 20 Remarks measuring unit for resistance resistance R 4 If there is no problem check the continuity between each terminal and ground The resistance between each terminal an...

Page 56: ...ECU coupler are a bad contact ECU terminal No 40 If there is no problem in the electric wires ECU is broken Replace the ECU with new one it rechecks 8 If the measured voltage is not normal Check the...

Page 57: ...AT connector Push by hand and pull to the front side Loosen the flange bolt 2EA Be sure to check the coupler is toward upside CAUTION It is Located on the left side of the throttle body Before disasse...

Page 58: ...ey 4 Measure the input voltage of MAPAT intake pressure sensor intake temperature sensor s coupler Input voltage 4 5 5 5 V Measuring terminal MAPAT 3 terminal MAPAT 1 terminal Remarks Measuring unit o...

Page 59: ...electricwire P G electricwire P L electricwireto see if they have been broken orhave short circuited if there is a bad contact badnessofterminalNo 3 No 26 No 27ofECUcoupler If the electric wire is no...

Page 60: ...t circuited Replace the MAPAT sensor with new one and it rechecks If the measured voltage is normal Checkthe P electricwire P G electricwire P L electricwireto see if they have been broken or have sho...

Page 61: ...he TPS coupler 4 Turn on the ignition key Input voltage 4 5 5 5 V Measuring terminal ECU NO 18 Gr B GRAY BLACK ECU NO 4 W R WHITE RED Measure the terminal voltage of TPS s coupler Measuring voltage 4...

Page 62: ...normal connect the coupler of TPS 10 Turn on the ignition key 11 Measure the TPS voltage of the wire harness to check the ECU Rotate the throttle lever measure the voltage Measuring terminal ECU No 1...

Page 63: ...NE TEMPERATURE SENSOR Remove Rh shroud comp Connector by hand ETS Replace the ETS Install in reverse order of removal It is located on the left hand side of cylinder head Before disassembly the key is...

Page 64: ...No 20 Gr L GREEN BLUE ECU No 4 W R WHITE RED Measure the terminal voltage of ETS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit for voltage voltage V If the voltage value is not normal...

Page 65: ...the ETS Engine Temperature Sensor Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil Read the temperature of thermometer depending upon oil temper...

Page 66: ...ACTUATOR Remove LH side cover Air cleaner ISA connector TPS connector Throttle cable Throttle body loosen the throttle body bolt Loosen the ISA screw Replace the ISA It is located upwards on the thro...

Page 67: ...tage of ISA 3 Disassemble the coupler of ISA measure the resistance between ISA terminals ISA resistance 31 5 38 5 20 remarks Measuring unit of resistance Resistance R 4 If there is no problem check a...

Page 68: ...easuring unit Voltage V If the measured voltage is normal Checkthe B R electricwire L G electricwire W R electricwireto see if they have been broken or have short circuited if there is a bad contact o...

Page 69: ...de Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Side Cover RH Lower Cover RH Lower Cover RH Lower Cover RH Lower Cover RH Lower Cover RH Lower Cover RH Lower Cover RH...

Page 70: ...urn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 Disassemble the coupler of oxygen O2 sensor and turn on ignition k...

Page 71: ...ULT CODE BY OXYGEN O2 SENSOR LAMBDA SIGNAL 1 Turn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 The wire harness to...

Page 72: ...istance between each terminals and ground Measuring terminal B electric wire EARTH ECU NO 32 B Y BLACK YELLOW EARTH The resistance between each terminals and ground If the measured resistance value is...

Page 73: ...adapter multi tester tool Remark Measuring unit of voltage Voltage V If the measured voltage is normal Checkthe B Y electricwire B electricwire G electric wire to see if they have been broken or have...

Page 74: ...voltage Measuring terminal ECU No 24 L B BLUE BLACK EARTH Output voltage battery voltage Remarks Measuring unit of voltage Voltage V If the measured voltage is normal Checkthe L B electricwire B elect...

Page 75: ...cated inside of the LH side cover Before disassembly the key is off Be sure to assemble the ECU ground wire The color is green 14 ECU ELECTRONIC CONTROL UNIT CAUTION CAUTION ECU ground wire ECU ground...

Page 76: ...nition coil bolt 2EA Ignition coil Locate on bottom of the fuel tank Be sure to check the engine is cooling because a little gasoline remains it is still hot Be sure to assemble the ECU Ground wire Be...

Page 77: ...Neutral S W Black coupler ENG LH Cover Loosen the bolt 8EA Stator screw CPS screw Replace the CPS Located on LH crank case cover Before disassembly the key is off Install in the reverse order of remov...

Page 78: ...ed Always replace the packing when the fuel pump is removed Before disconnecting the fuel hose release the fuel pressure by loosing the fuel hose banjo bolt at the fuel tank Always replace the sealing...

Page 79: ...5 36 EMS Engine Management System The terminal arrangement of the fuel pump The following color chart is the internal color of the fuel pump 17 FUEL PUMP...

Page 80: ...er assemble Measure the resistance between Y W YELLOW WHITE wire and G GROUND wire of fuel unit terminal Remark Measuring unit of resistance Resistance If the measured resistance value is out of stand...

Page 81: ...PAT MAPAT MAPAT MAPAT MAPAT TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS TPS THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THRO...

Page 82: ...hrottle adjust screw and adjusting nut Disconnect the Insulator mounting two bolts DISCONNECT THE THROTTLE BODY CHECKING THE THROTTLE BODY DISASSEMBLE THE THROTTLE BODY DISCONNECT The insulator and th...

Page 83: ...APAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING O RING ISA ISA ISA ISA ISA ISA I...

Page 84: ...bly Assemble the insulator gasket ADJUSTMENT OF THROTTLE CABLE INSPECTION OF SENSOR AND ACTUATOR Assemble the throttle cable Adjust the free play of the throttle grip 3 4 Connecteachsensorandtheactuat...

Page 85: ...gnostictool Pressthepower buttonofdiagnostictool SUPPLEMENT TheECUisalwaysinitialized beforetheengine isstarting Thevehicleiswarmsupenough toadjusttheidling speed By adjusting throttle adjust screw Ad...

Page 86: ...ttonofthediagnostictool Presstheenterbuttonintheinitialscreen Presstheenterinthevehiclediagnosisscreen PresstheenterbuttonontheresettingECUvalues Presstherestbuttononthefollowingscreen If the enter ke...

Page 87: ...5 44 EMS Engine Management System Presstheenterbuttonwhenitisready WhentheECUwasinitialized turnoffthelgnition keyandthenturnontheignitionkey...

Page 88: ...onofthediagnosistool Presstheenterbuttonontheinitialscreen Pressthebuttonatthevehiclediagnosticscreen Presstheenterbuttononthecurrentdata By looking the displayed figure on the idle speed actuator PWM...

Page 89: ...hecouplerofdiagnostictool Turnthelgnitionkeyon Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbuttononthecurren...

Page 90: ...ne Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbuttononthecurrentdata Check the engine rpm on the engine spe...

Page 91: ...MEMO...

Page 92: ...SERVICE INFOR 6 1 Engine Removal Installation 6 Engine Removal Installation Service Information 6 2 Engine Removal 6 3 Engine Installation 6 4...

Page 93: ...ystem The following parts or components can not be served with the engine installed in the frame Cylinder head valve Chapter 8 Cylinder piston Chapter 9 Transmission kick starter Chapter 10 Crank shaf...

Page 94: ...w Screw Screw Screw Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket...

Page 95: ...d cables Be careful not to damage any part of the frame and bolt nuts Be sure to install the cables tubes and wires to their correct positions 1 11 13 Torque Engine hanger bolts Front 1 2 7kgf m 27N m...

Page 96: ...MEMO...

Page 97: ...7 0 Clutch Gearshift...

Page 98: ...f the clutch slips check the fluid level before servicing the clutch system Specifications Item Standard Service Limit Spring Free 35 5 1 40 34 2 1 35 Disk Thickness 2 9 3 0 0 114 0 118 2 6 0 10 Clutc...

Page 99: ...plate warpage Clutch lock nut loose High fluid level or high fluid weight Clutch disengages Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play Difficult to thrust...

Page 100: ...ver Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank...

Page 101: ...ring Bolt Clutch Spring Bolt Clutch Spring Bolt Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Pl...

Page 102: ...Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Pressure Plate Pressure Plate Pressure Plate Pressure Plate...

Page 103: ...litude Service Limit 2 6mm 0 10 in Check the plate for warpage on a surface plate using a feeler gauge Service Limit 0 2mm 0 01 in If any of the disk and plate requires replacement it must be replaced...

Page 104: ...ear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thr...

Page 105: ...n with the gear shift hole Install the thrust washer into the gear shift spindle Install the gear shift spindle into the crank case aligning the teeth of the return spring with the tappet of the right...

Page 106: ...Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Thrust Washer Th...

Page 107: ...Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Extension Bar Extension Bar Extension Bar Extension Bar...

Page 108: ...Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove Key Groove...

Page 109: ...e with the clutch arm Check the clutch cable free play 3 12 Install the kick starter pedal and tighten the bolt Torque 2 2kgf m 22N m Fill the crankcase with the recommended oil 2 3 Dowel Pin Dowel Pi...

Page 110: ...MEMO...

Page 111: ...8 0 A C Generator Starter Clutch...

Page 112: ...em Standards Service Unit O D 39 622 39 635 1 5571 1 5577 39 607 1 5566 Starter Driven Gear I D 22 010 22 022 0 8665 0 8670 22 100 0 870 Starter Idle Gear I D 10 013 10 045 0 3935 0 3948 10 100 0 393...

Page 113: ...ar Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chai...

Page 114: ...eduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear St...

Page 115: ...erse order of disassembly removal Make sure that the grommet is correctly placed on the slot NOTE Flywheel Puller Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff...

Page 116: ...side magnet of rotor is attached by the bolts and nuts install them If installing the rotor with the foreign material the starter coil is damaged Install the rotor bolt temporally After fixing the fly...

Page 117: ...aft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank C...

Page 118: ...he flywheel 7 4 If the starter driven gear turns to the right when pressing the flywheel as shown it is in good condition Disassembly Remove the three socket bolts and remove the one way clutch from t...

Page 119: ...en gear I D and O D Service Limit O D 39 607mm 1 5566in I D 22 100mm 0 870in Assembly Inspect the one way clutch for wear and damage Install the way clutch fringe onto the clutch outer After coating t...

Page 120: ...MEMO...

Page 121: ...9 0 Cylinder Head Valve...

Page 122: ...nspection 9 9 Cylinder Head Assembly 9 11 Cylinder Head Assembly 9 13 Cylinder Heand Installation 9 13 Item Standard Service Limit Rocker Arm Rocker Arm I D 12 016 12 034 0 4731 0 4738 12 060 0 4748 R...

Page 123: ...stment Broken or damaged valve spring Incorrect valve timing Faulty valve seat adherence Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Refer to secti...

Page 124: ...ng Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Crank Shaft Hole Cap Crank Shaft Hole Cap Cr...

Page 125: ...aft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker A...

Page 126: ...0mm 0 4505in Inspect the cam lobe of the camshaft for wear and damage Measure the height of the cam lobe Service Limit IN 36 870mm 1 4490in EX 37 110mm 1 4584in Turn the outer race of each bearing wit...

Page 127: ...pivot bolt and remove the cam chain tensioner Remove the carburetor insulator Remove the spark plug from the cylinder head Remove the spark plug cover from the cylinder head NOTE CAUTION CAUTION Cam C...

Page 128: ...ide diameter and record it Service Limit IN 4 925mm 0 1939in EX 4 905mm 0 1931in After inserting the valve guide reamer to the combustion chamber remove the carbon deposits The incoming and outgoing o...

Page 129: ...valve guide Insert the valve guide in the top of the cylinder head Tool Valve guide driver After inserting the valve guide install the valve guide reamer in the combustion chamber of the cylinder hea...

Page 130: ...guide reamer using a valve guide dreamer without turning the valve and align the position exactly Tale off the valve inspect the opposite side of the seat with the ink attachment of valve pace side If...

Page 131: ...replacing the valve guide cut the seat part Amend the flat using a 35 cutter side by side Amend the inside using a 60 cutter side by side Amend the seat part with a standard width using a 45 cutter 35...

Page 132: ...Head Assembly Install the valve spring seat and a new stem seal Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide To avoid damage to the stem seal tu...

Page 133: ...NOTE For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder H...

Page 134: ...uede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Dow...

Page 135: ...m chain does not come off from the crankshaft timing gear Coat the camshaft with engine oil and install the cam lobe on the cylinder head with the cam lobe facing down With the timing marks on the cam...

Page 136: ...the shaft from the body by turning the tensioner shaft to the right with a small driver When dropping the cam chain tensioner lifter the shaft is proceeded by the spring power CAUTION Sealing Screw Se...

Page 137: ...rankshaft hole cap and timing hole cap Torque Crank shaft hole cap 0 8kgf m 8N m Timing hole cap 0 6kgf m 6N m Clean oil in the slot part of the cylinder head cover Place the gasket on the correct pos...

Page 138: ...MEMO...

Page 139: ...10 0 Cylinder Piston...

Page 140: ...cessive carbon deposits on piston head Troubleshooting Item Standard Service Unit I D 56 500 56 510 2 2244 2 2248 56 60 2 228 Cylinder Outer of round 0 1 0 004 Taper 0 05 0 002 Warpage 0 1 0 004 Pisto...

Page 141: ...ion and Y direction and out of round inside diameter balance of the top middle bottom parts by X or Y direction Choose the maximum value regardless of any one and settle the taper and out of round Ser...

Page 142: ...iston pin out and remove the piston Check the piston ring for damage or deterioration Remove the piston rings Be careful when removing the rings Measure the piston ring to groove clearance Service Lim...

Page 143: ...ng 90 direction Service Limit 56 37mm 2 219in Measure the piston pin hole inside diameter Service Limit 15 04mm 0 592in Measure the piston pin outside diameter Service Limit 14 96mm 0 589in Figure out...

Page 144: ...econd Ring Piston Cylinder Installation Piston Ring Installation Clean the piston domes ring lands and skirts and install the piston ring Be careful not to damage the piston and piston rings during as...

Page 145: ...ston rings with clean engine oil and install the piston ring Be careful not to damage piston rings Be careful to prevent cam chain from falling into the crankcase NOTE NOTE Piston Piston Piston Piston...

Page 146: ...ase with the slot of the cylinder Install the cylinder head refer to section 8 Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain...

Page 147: ...11 0 Crank Case Transmission Crankshaft 1 2kgf m 12N m 1 1kgf m 11N m...

Page 148: ...0 194 0 197 4 5 0 18 Shaft O D 11 976 11 994 0 4715 0 4722 11 96 0 471 Main shaft O D M3 M5 19 959 19 980 0 7858 0 7866 19 930 0 7846 C1 16 466 16 484 0 6483 0 6490 16 440 0 6472 Counter Shaft O D C2...

Page 149: ...aged Shift drum guide pin damaged Transmission jumps out of gear Gear dogs worn Shift fork shaft bent Shift drum stopper damaged Shift drum guide grooves worn Gear shift fork slot worn Engine noise Co...

Page 150: ...sket NOTE Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch...

Page 151: ...Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Fork Shift Fork Shift Fork Shift Fork Shift Fork Shift Fork Shift Fo...

Page 152: ...diameter and outside diameter Service Limit M5 outside diameter 22 930mm 0 9028in M3 M2 outside diameter 22 950mm 0 9035in C1 outside diameter 19 930mm 0 7846in M3 C2 inside diameter 20 050mm 0 7894i...

Page 153: ...tachment 42 47mm Remove the remaining bearings in the crankshaft with a bearing puller Tool Universal bearing puller If the crankshaft is removed from the left crankcase a new left crankshaft bearing...

Page 154: ...seal for wear and damaging must be replaced if necessary CAUTION X X Y Y Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft B...

Page 155: ...ocket bolt screw part with oil and install the main shaft bearing set plate Torque 1 2kg m Crankshaft Installation Coat a new light crankshaft bearing with clean engine oil and install new bearings in...

Page 156: ...n Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft C...

Page 157: ...ift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Fork Shift Fork Shift Fork Shift Fork Shift Fork Shift Fork Shift Fork Shif...

Page 158: ...her Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Gear Shift Drum Hole Gear Shift Drum Hole Gear Shift Dru...

Page 159: ...12 0 MEMO...

Page 160: ...12 1 Cooling System 12 Cooling System Service Information 12 1 Radiator 12 2 Service Information General The engine must be cool before servicing the cooling system...

Page 161: ...ver 20 of radiant heat area Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiato...

Page 162: ...at Exhaust Muffler Service Information 13 1 Side Cover Seat 13 2 Grab Rail 13 2 Rear Fender 13 3 Muffler 13 3 Tool Box 13 4 Service Information Muffler is very hot after engine stops Avoid inspection...

Page 163: ...move the rear winker and tail light code Remove the left right cap nut bolts each 4EA of the grab rail After removing push the stay pinch bolt to the inside Assembly Assembly is done in the reverse or...

Page 164: ...Rail R Grab Rail R Grab Rail R Grab Rail R Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L G...

Page 165: ...er comp Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Tool Box Tool Box Tool...

Page 166: ...13 5 MEMO...

Page 167: ...14 0 Front Wheel Front Fork Steering...

Page 168: ...im during removal and installation A jack or other support is required to support the motorcycle during front end service Specification Torque Steering Handle Bolt 2 6kgf m Brake Disk Nut 4 2kgf m Fro...

Page 169: ...e worn damage Insufficient tire pressure Worn Tire Steers to one side Steering head bearing damage loose Unevenly adjusted right and left cushions Bent front fork Bent front axle shaft wheel installed...

Page 170: ...Engine Stop Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Handle Grip Handle Grip Handle Grip Handle Grip Handle Grip Handle Grip Handle Grip H...

Page 171: ...ter attaching leave it over 1hour until drying the adhesives CAUTION Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting H...

Page 172: ...bolt of the winker switch housing with the handle bar hole and tighten the mounting bolt Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Thrott...

Page 173: ...the axle nut front axle and front wheel and right side collar Do not operate the front brake lever after removing the front wheel NOTE Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Scre...

Page 174: ...r Remove the right side collar NOTE Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedome...

Page 175: ...rom the speedometer gear box Check the gear for wear and damage Install the washer Coat the speedometer gear with grease and install it NOTE NOTE Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk...

Page 176: ...side collar Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Right Side Collar Right Side Collar Right Side Collar Righ...

Page 177: ...ter Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Box Speed...

Page 178: ...r Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket...

Page 179: ...Remove the piston rebound spring from fork tbue Remove the dust Seal CAUTION Fork Tube Bottom Case Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube F...

Page 180: ...Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Piston Ring Piston Ring Piston Ring Piston Ring Piston Ring Pis...

Page 181: ...slider bush Bottom case must be replaced if the copper portion is shown over three of quarter in teflon coating part or remarkably damaging Assembly Before installing clean each part with clean oil Sl...

Page 182: ...ly Install the back up ring Coat the ATF with the new oil seal Insert the oil seal until showing the assembling groove of bottom case set ring using the tools Tools Fork seal driver Fork seal driver b...

Page 183: ...owly Check the oil level in state of compression Oil Level 250mm Install the spring into the fork tube Make a spring face down the small side of pitch CAUTION Set Ring Fork Oil Fork Oil Oil Level Lowe...

Page 184: ...ate CAUTION NOTE Fork Tube Cap Bolt Fork Tube Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork To...

Page 185: ...Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock...

Page 186: ...r bearing Bearing Replacement Always replace the bearing and races as a set Tool Ball race driver To protect the nuts install the stem nut into the steering stem and remove the steering under bearing...

Page 187: ...nut wrench 30 32mm Extension bar After arranging the cable install the cable guide Install the front fork 13 11 NOTE Steering Stem Socket Top Bridge Top Bridge Top Bridge Top Bridge Top Bridge Top Bri...

Page 188: ...ble Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Install the parts as the below Head light Front emblem stay Brake caliper Front fender Front wheel 13 6 Ca...

Page 189: ...15 0 Rear Wheel Rear Brake Suspension...

Page 190: ...cifications Torque Values Rear Brake Arm Bolt 1 0kgf m Rear Axle Nut 8 8kgf m Rear Shock Absorber Mounting Upper Bolt 3 4kgf m Rear Shock Absorber Mounting Lower Bolt 3 4kgf m Rear Fork Pivot Bolt 4 5...

Page 191: ...ent rim Worn rear wheel bearings Faulty tire Loose axle Incorrect tire pressure Worn rear fork bush Soft suspension Weak spring Incorrect rear cushion adjuster Faulty rear damper Hard suspension Incor...

Page 192: ...aft Service Limit 0 2mm Inspect by the oscillation of rim in turning the wheel Service Limit Radial 2 0mm 0 008in Axial 2 0mm 0 008in Replace the worn bearing by turning the bearing Chain Adjuster Cha...

Page 193: ...Tools Bearing remover shaft Remover head NOTE NOTE Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Drive...

Page 194: ...tooper with the slot of the brake panel Install the drive chain into the sprocket Assembly Install the dust seal after applying the grease If the damper rubber was removed install the damper rubber NO...

Page 195: ...Service Limit 131mm 5 16in Measure the rear brake lining thickness Service Limit 2 0mm 0 08in Disassembly Open the brake shoe with hands and remove it from the brake panel Separate the split pin from...

Page 196: ...Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake...

Page 197: ...20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt...

Page 198: ...se of the strong tension of spring Inspection Measure the free length of rear cushion spring Inspect the damper rod for winding and damaging Inspect the damper unit for oil leakage Inspect the damper...

Page 199: ...joint and tighten the lock nut Torque 3 8kgf m 38N m Tools Rear cushion compressor Rear cushion compressor attachment Installation Install the rear cushion Install the bolt Torque Upper bolt 3 4kgf m...

Page 200: ...on Install the rear fork and tighten the pivot bolt Torque 4 5kgf m Install the following Rear cushion Chain cover Rear wheel R L lower cover CAUTION Chain Slider Chain Slider Chain Slider Chain Slide...

Page 201: ...16 0 Hydraulic Brake...

Page 202: ...pads can be removed without disconnecting the hydraulic system Bleed the hydraulic system if it has been disassembled A contaminated brake disk or pad reduces stopping power Discard contaminated pads...

Page 203: ...disk worn Low fluid level Clogged hydraulic system Disc bent Sticking worn caliper piston Disc Worn Contaminated master cylinder inner part Brake lever bent Brake drag Clogged hydraulic system Stickin...

Page 204: ...e while pumping the brake bleeder Repeat the above procedures until brake fluid appear in the brake bleeder Add brake fluid Check the fluid level often Add fluid when the fluid level in the master cyl...

Page 205: ...e fluid Install the diaphragm set the master cylinder cap Torque 0 13kgf m Brake Pad Replacement Always replace the brake pads in pairs to assure even disc pressure Replace the brake pads without remo...

Page 206: ...ke Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Hanger Pin Hanger Pin Han...

Page 207: ...ake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Ho...

Page 208: ...y part of brake hose and remove the piston from caliper Do not use the high pressure air or do not close the air conditioner Do not put the hand into the caliper inside Remove the piston seal and dust...

Page 209: ...Clean the piston seal dust seal with brake fluid and install of caliper into the part Install the piston into the caliper by the groove side of piston faces the pad Coat the boot with the silicon grea...

Page 210: ...ose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...

Page 211: ...Spring Spring Spring Spring Spring Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope...

Page 212: ...linder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt B...

Page 213: ...17 0 Charging System Battery Regulator Rectifier Fuse Battery AC Generator...

Page 214: ...battery gives off explosive gases keep spark flame and cigarettes away The battery fluid level should be checked regularly Fill with distilled water when necessary Quick charge a battery only in an e...

Page 215: ...system failure Loose battery connection Low power Engine running Battery undercharged Faulty battery Charging system failure Intermittent power Loose battery connection Loose charging system connectio...

Page 216: ...mble the battery holder Remove the battery cable from the battery terminal Remove the battery negative cable from the battery first then the positive cable CAUTION Terminal Terminal Terminal Terminal...

Page 217: ...arging if the electrolyte temperature exceeds 45 113 Quick charging should only be done in an emergency slow charging is preferred Assembly Assembly is essentially the reverse order of disassembly Be...

Page 218: ...e voltage leakage is over 1mA check the wire harness to be sure the connection is good and the wires are not damaged Recheck the voltage Charging Output Inspection As voltage is changeable according t...

Page 219: ...ach to the metal part of tester handle during the inspection the resistance of the human body is indicated Therefore be careful of that Must inspect using the defined tester as the below If being insp...

Page 220: ...r by removing the two flange bolts Installation is the reverse order of removal A C Generator Inspection Disconnect the 3P coupler of the generator code Measure the resistance between the yellow leads...

Page 221: ...18 0 Ignition System A C Generator Spark Plug Ignition Coil ECU...

Page 222: ...ed ON Turn the main switch OFF while serving TRANSISTOR ignition system is used and it can not be adjusted Couplers are connected to other couplers which have same colour Coil standard resistance may...

Page 223: ...een ignition coil and plug Faulty main switch Faulty ignition coil Faulty ECU unit Faulty A C generator Faulty crank position sensor ENGINE SRARTS BUT RUNS POORLY Ignition primary circuit Faulty ignit...

Page 224: ...EPLACEMENT Disconnect the high tension code from the plug and clamp Remove the primary circuit from the ignition coil Loosen the two bolts and remove the ignition coil Installation is the reverse orde...

Page 225: ...Crank Position Sensor Disconnect the AC generator 2P coupler blue green wire connector Measure the resistance between blue and green Standard Resistance 80 150 20 68 Voltage Over 0 7V If the standard...

Page 226: ...18 5 Ignition System...

Page 227: ...18 6 MEMO...

Page 228: ...19 0 Electric Starter Starter Motor Battery Starter Magnetic Switch...

Page 229: ...y starter magnetic switch Loose or disconnected wire cable Starter motor turns engine slowly Battery discharged Excessive resistance in circuit Binding in starter motor Starter motor turns but crank s...

Page 230: ...er motor cable from the motor Remove the starter motor mounting bolt and starter motor Disassembly Remove the following parts Motor case Front cover rear cover Armature Check the trust washer for posi...

Page 231: ...y between the cable terminal and Brush Case side it is OK Replace or repair them if necessary Inspect the commutator part of the armature for discoloration If over 2 segments are discolored must be re...

Page 232: ...h holder center with driving each brush into the brush holder inside Install the holder into the case aligning the projecting part of brush holder with the part of case Rear Cover Armature Brush Brush...

Page 233: ...the setting bolts exactly O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Starter Magnetic...

Page 234: ...nuity Ground Circuit Inspection Disconnect the green red wire connector of the starter magnetic switch There should be continuity between the starter magnetic wire terminals at the harness side and gr...

Page 235: ...MEMO...

Page 236: ...20 0 SERVICE Lights Switches Horn...

Page 237: ...onnecting and aligned when reconnecting To isolate an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part f...

Page 238: ...the headlight case with the index mark on the bracket Headlight Removal Remove the two headlight mounting bolts and remove the headlight from the bracket Remove the individual code from the wire CAUTI...

Page 239: ...pper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Under...

Page 240: ...Assembly is done in the reverse order of disassembly Fuel Meter Bulb Replacement Remove the hax socket bolt 3 of fuel meter Tail Light Lens Tail Light Lens Tail Light Lens Tail Light Lens Tail Light L...

Page 241: ...lb in bulb socket by turning toward anti clockwise Take off the bulb by turning toward anti clockwise and replace it Assembly is done in the reverse order of disassembly Bulb Bulb Bulb Bulb Bulb Bulb...

Page 242: ...Remove the winker coupler socket grab rail ass y Push the winker wire clamp and loosen the nut Remove the winker coupler socket Assembly is done in the reverse order of disassembly When assembling ali...

Page 243: ...Switch When happening the urgent situation during driving it is equipment for operating the engine stop to OFF position and braking the engine After checking for being RUN position before starting sta...

Page 244: ...tch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch D...

Page 245: ...ear Remove the R side cover 12 2 Disconnect the rear brake light switch wire coupler and check for continuity between terminals The switch should have continuity with the rear brake applied and no con...

Page 246: ...re coupler of fuel unit and put the main switch on Check the position of the meter indicator moving float up and down Float Position Resistance High 10 Low 90 Float Position Resistance High F Low E CA...

Page 247: ...MEMO...

Page 248: ...21 1 Wiring Diagram 21 Wiring Diagram...

Page 249: ...21 2...

Page 250: ...gs Faulty ECU Broken or shorted high tension wires Faulty crank position sensor Faulty main switch 3 Test cylinder compression Low compression Low speed of starter crank Incorrect valve clearance Faul...

Page 251: ...ogged air cleaner Clogged jets Clogged fuel tank breather Clogged muffler 5 Check ignition timing Incorrect Faulty ECU Faulty crank position sensor Flywheel is not installed properly 6 Test cylinder c...

Page 252: ...fuel mixture Use of poor quality fuel Excessive carbon build up in combustion chamber Ignition timing too advanced Faulty ECU unit or crank position sensor Valve train lubricated properly Correct Poo...

Page 253: ...Check valve timing Incorrect Cam sprocket not installed properly 4 Check valve spring tension Weak Faulty spring Correct Fuel flows freely Poor Performance At High Speed 1 If steering is heavy Too tig...

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