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DAELIM S4 50cc, Service Manual

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COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

COOLING FAN

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

RH.CRANK CASE COVER

A.C. GENERATOR /RH. CRANK CASE COVER

●

If the universal holder cannot be used, remove the
LH.crankcase cover at left side of the crankshaft, and
hold the drive face with the drive face holder.

TORQUE : 5.5kgf

·

m

TOOL : UNIVERSAL HOLDER

●

Assemble cooling fan.

(

⇨

8-2 )

●

Assemble ACG. cord coupler and connector at wire

harness, and cramp cords.

●

Assemble cooling fan cover.

RH. CRANK CASE COVER

REMOVAL

●

Disassemble the following parts.

-

Muffler

-

Cooling fan cover

-

Cooling fan

●

Remove engine oil.

●

Untie 8 flange bolts assembled at RH. Crank case

cover.

●

Disassemble RH. Crank case cover.

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Summary of Contents for S4 50cc

Page 1: ......

Page 2: ......

Page 3: ...AL PARTS LUBRICATION SYSTEM FUEL SYSTEM ENGINEREMOVAL INSTALLATION LH CRANK CASE COVER KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION ACGENERATOR CYLINDERHEAD VALVE CYLINDER PISTON TRANSMISSION CRANK...

Page 4: ......

Page 5: ...ON FRAME SERIAL NUMBER LOCATION SERIAL NUMBER LOCATION 1 1 SPECIFICATIONS 1 2 TWIST TORQUE 1 4 SYMBOLS ABBREVIATIONS 1 5 LUBRICATION OIL 1 6 WIRINGDIAGRAM 1 7 GENERAL SAFETY 1 11 CAUTION WHEN WIRING 1...

Page 6: ...VALVES ENGINEOILCAPACITY TRANSMISSIONOILCAPACITY LUBRICATIONTYPE AIRCLEANERTYPE COMPRESSIONPRESSURE INTAKEVALVEINVALVE OPEN CLOSE EXVALVE OPEN CLOSE VALVECLEARANCEINTAKE EXHAUST 1 790mm 670mm 1 102mm...

Page 7: ...GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT HIGH LOW WINKER LIGHT HIGH LOW TAIL STOP LIGHT HIGH BEAM PILOT LAMP WINKER PILOT LAMP SPEEDOMETER LAMP CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION CVt...

Page 8: ...6 0 kgf m 3 0 kgf m 1 2 kgf m 4 25 kgf m 2 25 kgf m 12 kgf m 4 0 kgf m 4 0 kgf m 3 5 kgf m 4 5 kgf m 4 0 kgf m 1 5 kgf m 4 5 kgf m 26 26 10 12 10 6 8 22 16 8 8 10 10 10 10 10 1 1 1 1 1 2 3 2 1 1 1 1 1...

Page 9: ...arts Indicates reference page Example Refer to page 3 1 Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease with the ratio...

Page 10: ...M CAMSHAFTDRIVECHAIN PISTON PISTONRINGGROVE INSIDECYLINDER CONNECTINGRODPISTONPINHOLE CONNECTINGROD CRANKSHAFT OILPUMPDRIVECHAIN COUNTERSHAFTGEAR FINALGEAR BEARING SURFACEOFO RING OILSEAL AREAOFFRICTI...

Page 11: ...WIRING DIAGRAM SERVICE INFORMATION WINKER RELAY SAI PIPE FUEL COCK CDI UNIT FUEL TANK SIDE STAND SPEEDOMETER CABLE REAR BRAKE CABLE MAGNETIC SWITCH REGULATOR RECTIFIER FUEL HOSE...

Page 12: ...SERVICE INFORMATION REGULATOR RECTIFIER MAGNETIC SWITCH IGNITION COIL ACG COUPLER FUEL TANK SAI PIPE CDI UNIT FRONT BRAKE CALIPER MUFFLER HORN WINKER RELAY...

Page 13: ...SERVICE INFORMATION SPEEDOMETER WINKER RELAY HORN KEY SET MASTER CYLINDER BRAKE HOSE...

Page 14: ...SERVICE INFORMATION FUEL TANK BATTERY CABLE ACG COUPLER CDI UNIT MAGNETIC SWITCH REGURATOR RECTIFIER SAI PIPE CARBURATOR...

Page 15: ...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...

Page 16: ...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...

Page 17: ...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 a...

Page 18: ...he 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 ins...

Page 19: ...on 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 termina...

Page 20: ...ollowing 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...

Page 21: ...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...

Page 22: ...s 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 t...

Page 23: ...NG The exhaust gas contains poisonous substance Do not keep engine idling in a closed or poorly ventilated place for a long period of time Refer to the chapter 4 about the engine fluid Stand the main...

Page 24: ...SPARKPLUG 1 2 f m CYLINDERHEADCOVERBOLT 0 9 f m VALVEADJUSTINGNUT 1 1 f m TORQUE WRENCH 8 9mm ADJUSTWRENCH COMPRESSIONGAUGE TOOL INSPECTIONS ADJUSTMENTS...

Page 25: ...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 FREQUENCY ODOMETER READING NOTE...

Page 26: ...DJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CAB...

Page 27: ...ANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYL...

Page 28: ...REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER PLUG REMOVE FAN COVER RUBBER P...

Page 29: ...DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIV...

Page 30: ...R CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLIND...

Page 31: ...If pull the lower end of side stand by hand check whether it moves smoothly If it doesn t move freely pour grease into its pivot side If it moves too freely check the side stand spring Check the axial...

Page 32: ...i REAR WHEEL 2 00 28psi 2 25 32psi WHEELS TIRES NOTE Check the tire pressure when the tires have been cooled off Check the thread the part making contact with the road surface and side for being worn...

Page 33: ...CTIONS ADJUSTMENTS LUBRICATION POINTS Unless specifically designated use generd grease to lubricate the lubrication points For stiding parts not shown here add oil or grease CONTROL CABLE LUBRICATION...

Page 34: ...M E M O...

Page 35: ...s stopped When diassembling the front wheel be careful about the turn over of the vehicle SERVICE INFORMATION 3 1 ASSEMBLY DISASEMBLYPRECEDURE 3 2 SEAT 3 2 LUGGAGE BOX 3 3 REARCARRIER 3 3 CENTER COVER...

Page 36: ...ONT FENDER FRONT WHEEL FRONTUNDERCOVER FRONTHANDLECOVER REARHANDLECOVER REARWHEELMUDGUARD REARSPLASHCOVER EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF FRAME COVERS This chart shows arrows connected in...

Page 37: ...REWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS TAPPINGSCREWS...

Page 38: ...VER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER BODYCOVER REARFENDER REARF...

Page 39: ...S SCREWS SCREWS SCREWS SCREWS SCREWS TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPING...

Page 40: ...TS WASHERBOLTS WASHERBOLTS FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPANEL FLOORPAN...

Page 41: ...OVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOVER INNERCOV...

Page 42: ...PPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPINGSCREW TAPPING...

Page 43: ...TS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS FRANGEBOLTS REARWHEELMUDGUARD REARWHEELMUDGUARD REARW...

Page 44: ...M E M O...

Page 45: ...f m TORQUE VALUES Temperaturetotheair 4 LUBRICATION SYSTEM SERVICE INFORMATION WARNING The exhaust gas contains poisonous substance Do not keep engine idling in a closed or poorly ventilated place for...

Page 46: ...ernal oil leaking Worn piston ring or incorrect piston ring installation Worn valve guide or valve stem seal Oil contamination Oil or filter not changed often enough Faulty cylinder head gasket Piston...

Page 47: ...ECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUSTINGHOLECAP TAPPETADJUS...

Page 48: ...KCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER RH CRANKCASECOVER HEXNUT HEXNUT HEXNUT HEXNUT...

Page 49: ...TERROTOR PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PUMPBODY PU...

Page 50: ...NSCREWS FANSCREWS FANSCREWS FANSCREWS FANSCREWS FANSCREWS FANSCREWS FANSCREWS LUBRICATION SYSTEM ASSEMBLY Clean all parts with fresh cleaning oil Install the inner and outer rotors into the oil pump b...

Page 51: ...HECKHOLE OILCHECKHOLE OILCHECKHOLE OILCHECKHOLE OILCHECKHOLE OILCHECKHOLE OILCHECKHOLE OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINBOLT OILDRAINB...

Page 52: ...M E M O...

Page 53: ...gine running for a long period of time in a closed or poorly ventilated area Do not excessively bend or twist cable Distorted or damaged cable may lead to mechanical malfunctions Pay particular attent...

Page 54: ...blocked Compression pressure is low Miss fire at speeding Ignition system is damaged Mixture is too lean Back firing Ignition system is damaged or works improperly Mixture is too lean Insufficient po...

Page 55: ...OR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR...

Page 56: ...CUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON TOP SET TOP SET TOP SET TOP SET TOP SET TOP SET TOP SET TOP SET TOP SET TOP...

Page 57: ...N PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION PUMP ACCELERATION...

Page 58: ...R CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR CLEAN COMPRESSED AIR SLOW JET SLOW JET SLOW JET SLO...

Page 59: ...RING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPRESSION SPRING COMPR...

Page 60: ...TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET FUEL SYSTEM Assemble accelerating pump CAUTION Assemble jet neeld fitting at assembled hole CAUTION Check throttle grip tolerance after...

Page 61: ...CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER CO ANALYZER MUFFLER MUFFLER MUF...

Page 62: ...RATING ACCELERATING PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW...

Page 63: ...CK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK SMALL D...

Page 64: ...M E M O...

Page 65: ...o protect it during the engine removal or installation The following works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 11 A C GENERATOR SECTION 8 KICK STA...

Page 66: ...NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NUT ENGINE HANGER NU...

Page 67: ...KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY JAR KEY ENGINE REMOVAL INSPECTION Lo...

Page 68: ...BELTTYPECONTINUOUSLYVARIABLE TRANSMISSION KICKSTARTER...

Page 69: ...IT MOVABLEDRIVEFACEBUSHINGINNERDIAMETER 20 000 20 021mm 20 10mm DRIVE FACE BOSS OUTER DIAMETER 19 959 19 980mm 19 91mm DRIVE BELT WIDTH 17 5mm 16 5mm WEIGHT ROLLER OUTER DIAMETER 15 920 16 080mm 15 40...

Page 70: ...ICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKDRIVENGEAR KICKSTARTERSPINDLE KICKSTARTERSPINDLE KICKSTARTERSP...

Page 71: ...SPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKRETURNSPRING KICKSPINDLEBUSHB KICKSP...

Page 72: ...IVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULLEYSUB DRIVENPULL...

Page 73: ...n and wear Replace as necessary Measure the width of the drive belt replace the belt if the service limit is exceeded SERVICE LIMIT 16 5mm NOTE Use only a genuine DAELIM replacement drive belt Do not...

Page 74: ...IVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DR...

Page 75: ...ACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE DRIVEN FACE DRIV...

Page 76: ...FREE PLAY FREE PLAY FREE PLAY FREE PLAY FREE PLAY FREE PLAY FREE PLAY FREE PLAY CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLU...

Page 77: ...FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN...

Page 78: ...MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE DRIVEN FACE DRIVEN FACE DRIVEN FACE DRIVEN FACE DRIVEN FACE DRIVEN FACE DRIVEN...

Page 79: ...RIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRI...

Page 80: ...E FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE B...

Page 81: ...ACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLATE LAMP PLAT...

Page 82: ...TINUOUSLYVARIABLE TRANSMISSION KICKSTARTER Assemble drive face to the serration side of LH Crank shaft then assemble hext nut 12mm By using drive face holde fasten drive face nut TORQUE 5 5kgf m TOOL...

Page 83: ...M E M O...

Page 84: ...A C GENERATOR RH CRANK CASE COVER...

Page 85: ...generator For the information of A C generator inspection refer to the section 15 The charging systme can be maintained without removing the engine SERVICES INFORMATION 8 1 COOLING FAN COVER 8 2 AC G...

Page 86: ...R UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL HOLDER UNIVERSAL H...

Page 87: ...LANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT A C GENERATOR RH CRANK CASE COVER Loosen the flange nit securing the fly wheel and remove the...

Page 88: ...CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER RH CRANK CASE COVER A C GENERATOR RH CRANK...

Page 89: ...N GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR OIL PUMP REDUCTION GEAR O...

Page 90: ...CYLINDER HEAD VALVES...

Page 91: ...NDER PISTON SERVICE INFORMATION GENERAL SAFETY The rocker arm and the camshaft can be served without removing the engine The oil of camshaft is supplied through the cylinder head oil hole Clean th oil...

Page 92: ...cracked cylinder head Cylinder head defect Excessive smoke Worn valve guide or valve stem Damaged valve stem seal Worn or damaged piston ring Rough idle Low cylinder compression Compression too high E...

Page 93: ...OVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD C...

Page 94: ...M 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 CHAIN SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SH...

Page 95: ...KPLUG SPARKPLUG SPARKPLUG SPARKPLUG SPARKPLUG SPARKPLUG SPARKPLUG CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER...

Page 96: ...RESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRING COMPRESSOR VALVESPRI...

Page 97: ...GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER CYLINDER HEAD VALVES VALVE GUIDE INSPECTION Insert th...

Page 98: ...d improper valve seat contact and results in the valve seat refacing not able to be performed Use cutting oil on the reamer during this operation Use cutting oil on the reamer during this operation TO...

Page 99: ...M VALVESTEM VALVESTEM VALVESTEM VALVESTEM CYLINDER HEAD VALVES For valve spring with varying pitch install the valve springs with the narrow pitch end facing down Install the spring retainer Compress...

Page 100: ...DERHEAD CYLINDERHEAD CYLINDERHEAD CYLINDER HEAD VALVES CYLINDERHEADASSEMBLY Clean the gasket material from the cylinder mating surface Install the cam chain guide to the cylinder Install the dowel pin...

Page 101: ...d facing downward Assembly the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top pf the cylinder head Slowly rotate the crankshaft counterclockwise and al...

Page 102: ...ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM ROCKER ARM T...

Page 103: ...M E M O...

Page 104: ...CYLINDER PISTON...

Page 105: ...N 10 3 PISTON CYLINDER INSTALLATION 10 5 Unit mm Compression pressure too low Piston worn Piston ring worn or damaged Cylinder worn Emission of white gas from muffler Cylinder piston piston rings worn...

Page 106: ...CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CAKCHAIN CYLINDER REMOVAL Remove the engine from the engine Remove the cylinder head cover Remove th...

Page 107: ...N PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWORN SIDEWOR...

Page 108: ...ING PISTONRING PISTONRING PISTONRING PISTONRING PISTONRING PISTONRING PISTONRING PISTONRING PISTONRING Inset the piston ring into the inside of cylinder check the clearance of piston ring SERVICE LIMI...

Page 109: ...ISTON ASSEMBLY Clean the piston head ring lands and skirts NOTE Be careful not to damage the piston and rings during assembly Carefully install the piston rings onto the piston with the markings facin...

Page 110: ...ER CYLINDER CYLINDER Install the new gasket and dowel pins Coat the cylinder wall with clean the engine oil and lubricate the piston rings and install the cylinder NOTE Be careful not to damage the pi...

Page 111: ...M E M O...

Page 112: ...TRANSMISSION CRANKSHAFT CRANKCASE...

Page 113: ...following parts must be removed prior to removing the crank case Follow the removal procedure specified in each section Drain the engine oil Remove the carburetor Remove the engine Remove the cylinde...

Page 114: ...able to move out Transmission damage Transmission seized Noise during operation Gear worn overheated cracked Bearing worn Oil leaks Excessive oil level Oil seal worn damaged TROUBLESHOOTING TORQUE CRA...

Page 115: ...DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DRAIN BOLT DR...

Page 116: ...COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION...

Page 117: ...ase with special tool TOOL BEARING REMOVER SET ASSEMBLY Install the drive shaft on the transmission cover Install a new drive shaft oil seal TOOL CRANK ASSEMBLY SHAFT CRANK ASSEMBLY COLLAR Check wheth...

Page 118: ...semble drive shaft to LH Crank case Assemble the new drive shaft oil seal TOOL DRIVER HANDLE Assemble final shaft and counter shaft to crank case mission cover Assemble the new gasket and dowel pin In...

Page 119: ...SHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSH...

Page 120: ...NK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK TRANSMISSION CRANKSHAFT CRANKCASE Check RH Crank case Check LH Crank case CRANK SHA...

Page 121: ...GAUGE DIALGAUGE CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMCHAIN CAMC...

Page 122: ...T FLANGE BOLT TRANSMISSION CRANKSHAFT CRANKCASE CRANKCASEINSTALLATION Install the dowel pins and a new gasket Pulling the cam chain and check to see if the crankshaft installed correctly Install the R...

Page 123: ...M E M O...

Page 124: ...FRONT WHEEL FRONT BRAKE FRONT FORK STEERING STEM...

Page 125: ...12 4 FRONT WHEEL BEARING 12 5 SPEEDOMETER GEAR BOX 12 6 FRONT WHEEL ASSEMBLY 12 7 FRONT BRAKE 12 7 BRAKEFLUIDREPLACEMENT 12 10 FRONT CALIPER 12 12 FRONT FORK 12 15 STEERING STEM 12 20 TORQUE VALUES S...

Page 126: ...ster cylinder piston seal Worn brake pad Worn caliper piston seal Contamination inside of caliper Bad contact of the side of caliper slide Worn brake pad disk Insufficiency of brake fluid The channel...

Page 127: ...ECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER REARHANDLECOVER LH HANDLEBRACKET LH HANDLEBRACKET LH HANDLEBRACKET LH HANDLEBRACK...

Page 128: ...HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET RH HANDLEBRACKET...

Page 129: ...L ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL ROLL FRONT WHEEL FRONT BRAKE FRONT FORK STEERING STEM INSPECTION Check the front axle for deflecti...

Page 130: ...EEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETERGEAR SPEEDOMETE...

Page 131: ...eal and align the projection area of speedometer gear box retainer with the gear groove to assemble the speedometer gear box FRONT WHEEL INSTALLATION Insert the front wheel between the front forks Ins...

Page 132: ...disk FRONT BRAKE MASTER CYLINDER REMOVAL Remove the front handle cover Drain the brake fluid Remove the front stop switch coupler NOTE The brake fluid can damage the painted plastic or rubber parts Ke...

Page 133: ...ONDARYCAP SECONDARYCAP LEVER STOPSWITCH MASTERCYLINDERBODY FRONT WHEEL FRONT BRAKE FRONT FORK STEERING STEM Remove the cylinder spring from the master cylinder Clean the inside of master cylinder rese...

Page 134: ...ion of coil ends toward the piston Install the cir clip to the mater cylinder groove firmly TOOL SNAP RING PLIER Assemble boot to master cylinder INSTALLATION Install the front master cylinder to the...

Page 135: ...n the bleeder valve and pump the brake lever repeatedly When there is no more fluid flowing out of the bleeder valve Stop pumping the brake lever NOTE Check the fluid level often and replenish fluid i...

Page 136: ...ALIPER CALIPER CALIPER BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERSCREW BLEEDERS...

Page 137: ...ISTON PISTON PISTON PISTON PISTON PISTON MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICROMETER MICRO...

Page 138: ...DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE DIALGAUGE BRACKET CALIPERBODY PISTONSEAL DUSTSEAL PISTON PAD PADSPRING FRONT WH...

Page 139: ...T FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK BOLT FRONT FORK B...

Page 140: ...G OILSEALSTOPRING OILSEALSTOPRING OILSEALSTOPRING OILSEALSTOPRING OILSEALSTOPRING OILSEALSTOPRING OILSEALSTOPRING DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTSEAL DUSTS...

Page 141: ...DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE FORK SEAL DRIVE F...

Page 142: ...er pitch side facing downward Accurately assemble the stop ring to the bottom case Install the dust seal Fix bottom case by wrapping cloth fix to vice Assemble to fork piston by applying screw lock ge...

Page 143: ...2 3 times to discharge air Check the oil level the fork tube is completely compressed condition Install the fork pipe bolt toe the fork pipe INSTALLATION Align the part of groove with the setting bolt...

Page 144: ...NUT LOCK NUT LOCK NUT LOCK NUT BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL...

Page 145: ...VER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER BALL COVER STEERING STEM SOCKET...

Page 146: ...EBAR HANDLEBAR HANDLEBAR HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT FORK STEERING STEM Assemble the following parts Front fork Front wheel Handle bar Handle cover Front cover Check the followings after a...

Page 147: ...M E M O...

Page 148: ...REAR WHEEL REAR BRAKE REAR CUSHION...

Page 149: ...er designed to mininize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR CUSHION UPPER BOLT 3 5 4 5kgf m REAR CUSHION LOWER BOLT 3 5 4 5kgf m REAR CUSHION ROD LOCK NUT 3...

Page 150: ...ation Deformed wheel rim Bad tire Axle bad fastening Bad tire air pressure Improper wheel balancing Soft rear suspension Bad spring Bad rear damper oil leakage Hard suspension Twisted damper rod Bad t...

Page 151: ...UT LOCK NUT LOCK NUT LOCK NUT REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL REAR...

Page 152: ...BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING BRAKE LINING REAR WHEEL REAR BRAKE REAR CUSHION INSTALLATION Assemble...

Page 153: ...AKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE BRAKE SHOE REAR WHEEL REAR BRAKE REAR CUSHION REMOVAL Manually open the brake sho...

Page 154: ...MPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT COMPRESSORATTACHMENT UPPERMETAL UP...

Page 155: ...thread locking agent to the lock nut and install the rear cushion compressor attachment on damper rod Fix the upper metal and tighten the lock nut TORQUE 3 5 kgf m TOOL REAR CUSHION COMPRESSOR REAR CU...

Page 156: ...CDI UNIT WINKER RELAY REAR BRAKE CABLE SPEEDOMETER CABLE SIDE STAND AC GENERATOR W G G R R FUSE 7A BATTERY 12V 3AH REGURATOR RECTIFIER AUTO BY STARTER REGISTER 5W 6 7 Y Y Y Y Y HEADLIGHT 12V 35 35W SP...

Page 157: ...attery from the frame and do not open stopper There is the possibility of damaging the regulator rectifier etc if the terminal or coupler is separated connected when electricity is over flowing throug...

Page 158: ...g coil ABNORMAL NORMAL ABNORMAL ABNORMAL ABNORMAL OVER 15V 14 15V UNDER 14V NORMAL NORMAL CORRECT TROUBLE SHOOTING No power key turned on Dead battery Low fluid level Complete discharged Disconnected...

Page 159: ...reverse order of removal BATTERY OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover Measure the voltage between the battery terminals FULL CHARGED 12 6 13 0 V INSUFFICIENTLY CHARGED UNDER 12 3 V...

Page 160: ...t do not turn the ignition on A sudden surge of current may blow out the fuse in the tester CAUTION Be sure that the battery is fully charged before performing this test The amount of current flow may...

Page 161: ...H MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNETIC SWITCH MAGNET...

Page 162: ...SIDE STAND S W B W B R L Y PULSE GENERATOR AC GENERATOR CDI UNIT IGNITION COIL B Y SPARK PLUG IGNITION SYSTEM FUEL TANK CDI UNIT MAGNETIC SWITCH IGNITION COIL REGULATOR RECTIFIER ACG COUPLER SAI PIPE...

Page 163: ...rically controlled ignition timing system No adjustments can be made to the ignition timing Use spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine...

Page 164: ...CDI unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty CDI unit in case when above No 1 5 are normal 1 Cranking speed is too slow Battery is undercharged or opera...

Page 165: ...Follow the step described in the troubleshooting flow chart when servicing the ignition system Remove the front cover Disconnect the coupler from the CDI unit and check the ignition system circuits fr...

Page 166: ...esistance value is withtin the specified range the coil is good It resistance infinite replace the coil with a new one STANDARD VALUE 0 1 0 5 Remove spark plug cap from plug On condition that there is...

Page 167: ...MEMO...

Page 168: ...RTER MOTOR STARTER S W STARTER RELAY FUSE MAIN S W REAR STOP S W FRONT STOP S W BATTERY 12V3AH G G G M STARTING SYSTEM FUEL TANK FUEL COCK FUEL HOSE MAGNETIC SWITCH REGULATER RECTIFIER SAI PIPE CDI UN...

Page 169: ...ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury A weak battery mau be unable to turn the starter motor quickly enough or supply adequete ig...

Page 170: ...sconnection in starter switch wire Faulty brake stop switch Loose or poor contact at starter relay switch connector Faulty starter relay switch Remove the coupler from the starter replay and inspect t...

Page 171: ...T SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT SCREW BOLT...

Page 172: ...OR COMMUTATOR COMMUTATOR COMMUTATOR COMMUTATOR STARTING SYSTEM the brush spring and then remove the brush Measure the brush length Replace the brush if it is worn beyond the service limit SERVICE LIMI...

Page 173: ...ONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET REAR BRACKET REAR BRACKET REAR BRACKET REAR BRACKET REAR BRACKET REAR BRACKET REAR BRACKET REAR BRACKET...

Page 174: ...re harness and starter magnetic switch INSPECTION Check if the starter magnetic switch click when it is turened ON Click but the engine does not start Poorly connected battery terminal and motor termi...

Page 175: ...ocked 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 continuit...

Page 176: ...WINKER SOCKET FRONT WINKER SOCKET FRONT WINKER SOCKET FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER F...

Page 177: ...AIL LIGHT TAIL LIGHT REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER...

Page 178: ...IN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH TERMINAL MAIN SWITCH T...

Page 179: ...H 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 STA...

Page 180: ...LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER FUEL UNIT FUEL UNIT FUEL UNIT FU...

Page 181: ...usted 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 engine Open th...

Page 182: ...ulty 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 Insert the plug...

Page 183: ...an incorrect heat range Lean mixture Worn cylinder or piston Lean fuel mixture Poor quality fuel being used Excessive carbon built up on combustion chamber Incorrect ignition timing Damaged cooling f...

Page 184: ...ven 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 valance B...

Page 185: ...ak 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 FRONT REAR SUSP...

Page 186: ...MEMO...

Page 187: ...2010 03 PRINTED 2010 03 PUBLICATION C CO OP PY Y P PR RO OH HI IB BI IT T SERVICEMANUAL...

Page 188: ......

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