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DAELIM VJF125, Service Manual

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STARTER MOTOR

REMOVAL

With the ignition switch turned to "OFF", remove the
negative cable at the battery before servicing the starter
motor.
Remove the rubber cap.
Remove the nut and starter motor cable from the starter
motor.

Remove the starter motor mounting bolts and ground
cable.

19-3

ELECTRIC STARTER

DISASSEMBLY

Remove the following.

- O-ring
- Starter motor case bolts / spring washers
- Front cover
- Seal ring
- Lock washer
- Washer
- Cir-clip
- Rear cover ass’y
- 2 pcs washer
- Amature

•

Always turn the ignition switch OFF before
servicing the starter motor. The motor could
suddenly start, causing serious injury.

INSPECTION

Check the bushing in the rear cover for wear or
damage.
Check the oil seal and bushing in the front cover for
wear or damage.

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

FLANGE BOLTS

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Summary of Contents for VJF125

Page 1: ......

Page 2: ......

Page 3: ...ble refer to Section 21 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be repr...

Page 4: ...on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must be performed in the place free of the open fire or electri...

Page 5: ...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 6: ...ing 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 compresse...

Page 7: ...the manufacturer marked surface directs outer surface direction not covered with oil Pay attention not to bend or damage the lip Apply the grease to the lip 20 Connect the tube until the tube fully i...

Page 8: ...tion 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 termi...

Page 9: ...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 10: ...he 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...

Page 11: ...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 12: ...R FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER ENGINE SERIAL NU...

Page 13: ...isk REAR BRAKE Hydraulic Disk FUEL CAPACITY 14 85 FUEL RESERVE CAPACITY 4 0 CASTER ANGLE 25 2 TRAIL 93 5mm FRONT FORK OIL CAPACITY 265 2 5cc TYPE Liquid 4 stroke DOHC 4 Valve CYLINDER NUMBER ARRANGEME...

Page 14: ...IGNITION TYPE Full Transisterized IGNITION TIMING F MARK 18 BTDC 1 600 rpm FULL ADVANCE 30 BTDC 8 500 rpm AC GENERATOR 12V 17A 5 000 rpm BATTERY CAPACITY 12V 10AH SPARK PLUG CR9EH 9 SPARK PLUG GAP 0 8...

Page 15: ...DER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARI...

Page 16: ...f m N m FRAME 2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5 M8 1 25 M6 1 0 M14 1 5 M8 1 25 M10 1 25 M8 1 25 M6 1 0 M22 1 0 M22 1 0 M8 1 25 M8 1 25 M8 1 25 M14 1 25 M10 1 25 6mmTapping M8 1 25 M8 1 25 M8 1 25 U...

Page 17: ...ates 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 1 1 Use m...

Page 18: ...ve Seat DESCRIPTION REFERENCE SECTION REMARK CLUTCH CENTER HOLDER 8 ACG ROTOR PULLER 9 VALVE GUIDE DRIVER 10 VALVE GUIDE REAMER 10 UNIVERSAL BEARING PULLER 12 BEARING REMOVER SET 12 THREAD ADAPTER 12...

Page 19: ...1 16 GENERAL INFORMATION WIRING DIAGRAM...

Page 20: ...1 17 GENERAL INFORMATION...

Page 21: ...1 18 GENERAL INFORMATION...

Page 22: ...1 19 GENERAL INFORMATION...

Page 23: ...MEMO...

Page 24: ...ON 2 13 BOLTS NUTS FASTENERS 2 13 WHEEL TIRE 2 14 STEERING STEM 2 14 COOLANT LEVEL INSPECTION 2 15 COOLANT REPLACEMENT 2 15 THROTTLE GRIP PLAY 2 6mm SPARK PLUG CR9EH 9 SPARK PLUG GAP 0 8 0 9mm IN 0 15...

Page 25: ...0 8 1 2kgf m AC GENERATOR CAP 0 4 0 8kgf m HOLE CAP 30mm 0 6 1 0kgf m AIR CLEANER CASE COVER SCREW 0 4 0 8kgf m REAR AXLE NUT 8 0 10 0kgf m DRIVE SPROCKET BOLT 1 0 1 4kgf m DRIVEN SPROCKET NUT 5 6 6 5...

Page 26: ...ervice at intervals indicated in the table 2 Service more frequently when riding in unusually wet or dusty areas 3 Replace every 2 years or at indicated odometer interval whichever comes first Replace...

Page 27: ...K NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUS...

Page 28: ...CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING COVER AIR CLEANER HOUSING C...

Page 29: ...MARK T MARK T MARK T MARK T MARK T MARK T MARK T MARK T MARK T MARK FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FE...

Page 30: ...82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 82 2 1 18 85 5 1 18...

Page 31: ...ING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT CHAIN SLACK 10 20mm CHAI...

Page 32: ...CATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR WEAR INDICATOR...

Page 33: ...BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE REAR BRAKE PEDAL REAR BRAKE PEDAL REAR BRAKE P...

Page 34: ...SWITCH REAR STOP SWITCH REAR STOP SWITCH REAR STOP SWITCH REAR STOP SWITCH REAR STOP SWITCH ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NUT ADJUST NU...

Page 35: ...OCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT SIDE STAND SIDE STAND SIDE STAND SIDE S...

Page 36: ...ed WHEEL INSPECTION Erect the motorcycle with the main stand Check a wear of the rear fork bush by moving the rear wheel aside If there is a free play replace the rear fork bush Tighten all nuts and b...

Page 37: ...lebar moves unevenly binds or has vertical movement inspect the steering stem STEERING STEM Check that the cables do not interfere with handlebar rotation 2 14 INSPECTIONS ADJUSTMENTS STANDARD PRESSUR...

Page 38: ...in stand prior to beginning work Check the coolant level and the reserve tank The level should be between the UPPER and LOWER level lines Fill the coolant to the reserve tank up to the F upper level R...

Page 39: ...MEMO...

Page 40: ...me ENGINE OIL TORQUE VALUES OIL DRAIN CAP 1 5 f m OIL FILTER COVER BOLT 1 1 f m 3 SERVICE INFORMATION 3 1 TROUBLESHOOTING 3 2 ENGINE OIL LEVEL INSPECTION 3 3 ENGINE OIL CHANGE 3 3 OIL FILTER ELEMENT C...

Page 41: ...on naturally External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed regularly Faulty head gasket Worn piston rin...

Page 42: ...plete and rapid draining OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE...

Page 43: ...R MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FILTER MAINTENANCE COVER OIL FI...

Page 44: ...R ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR...

Page 45: ...TABLENESSWIDTH SLIDING PART MITSUBISHIMULTIPURPOSENo 20orSUITABLENESSWIDTH EDGE PART GEAR COUPLING DAPHNEEPONEXEP2orSUITABLENESSWIDTH INSIDE ULTRACUSHOILNO 10SUITABLENESSWIDTH EDGE PART LIQUID O RING...

Page 46: ...MEMO...

Page 47: ...4 0 FUEL SYSTEM...

Page 48: ...ntilated area STANDARD OF MAINTENANCE Fuel tank capacity 14 85 Reserve fuel capacity 4 0 Fuel pump specification KGF38 Flow quantity Mimnim 20 hr Flow pressure 380kpa Injector specification Injector a...

Page 49: ...EL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK SERVE CORD FUEL TANK SERVE CORD FUEL TANK SERVE CORD FUEL TANK SERVE COR...

Page 50: ...NER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR CLEANER CASE AIR...

Page 51: ...MEMO...

Page 52: ...MAPAT 5 20 11 TPS Throttle Position Sensor 5 24 12 ETS Engine Temperature Sensor 5 27 13 ISA Idle Speed Actuator 5 30 14 O2 Oxgen Sensor 5 33 15 CHECKING OF ESS CIRCUIT 5 36 16 CHECKING OF MIL CIRCUIT...

Page 53: ...se 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 before assembly and disassembly of the ECU coupler Ot...

Page 54: ...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 55: ...gnal Engine Temperature Sensor Signal Third Gear Crank Position Signal B Communication LOW MIL Battery Power Intake pressure sensor power 5V Intake pressure sensor Signal Intake temperature sensor Sig...

Page 56: ...2 ECU 13 14 15 16 ECU 17 ECU 18 ECU 19 ECU 20 ECU 21 ECU 22 ECU 23 ECU 24 ECU 25 ECU 26 ECU 27 ECU 28 ECU 29 ECU 30 ECU 31 ECU 32 ECU 33 ECU 34 ECU 35 ECU 36 ECU 37 ECU 38 ECU 39 ECU 40 O O O O X O X...

Page 57: ...mally 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 EMS s fail safe fun...

Page 58: ...TAKE 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 The value of intake temperature is fixed as a temperature...

Page 59: ...utton of diagnostic tool Checks according to diagnostic procedure of diagnostic tool Measure the wire harness for checking by connecting the ECU with main wire harness to check the ECU It has two coup...

Page 60: ...fect 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 no...

Page 61: ...ectrical fuel 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 temperatur...

Page 62: ...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 fault code another fault cod...

Page 63: ...ER COVER CENTER COVER COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET COVER SETTING GROMMET CO...

Page 64: ...R AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSO...

Page 65: ...OR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR ID...

Page 66: ...PAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT S...

Page 67: ...efore the engine is starting THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTT...

Page 68: ...uld be damaged for the fire sparked on the spark plug Remove the injector Assemble Install in reverse order of removal 9 INJECTOR Be sure to check the engine is cooling because a little gasoline remai...

Page 69: ...5 18 CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit Coupler terminal is based on wire harness INJECTOR FUELPUMPRELAY ECU 40 INJECT...

Page 70: ...ey If the fuel pump operated for 3 seconds the power supply relay of injector is normal 6 Measure between the voltage of coupler Measuring terminal BLACK RED electric wire ground Measuring voltage bat...

Page 71: ...ve the MAPAT sensor coupler The key is off before disassembly CAUTION Assemble Install in reverse order of removal MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT S...

Page 72: ...y 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 of...

Page 73: ...0 1 V 4 8 V Remarks Measuring unit of voltage Voltage V The voltage of air pressure 20 kPa 0 719 0 859 V 107 kPa 4 154 4 294 V 5 If the measured voltage is not normal Check the P electric wire P G el...

Page 74: ...roblem ECU is broken Replace the ECU with the new one it rechecks 4 Turn on the ignition key Start the engine and idling 5 Measure the voltage of intake pressure sensor for ECU check Measuring the vol...

Page 75: ...in reverse order of removal MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MA...

Page 76: ...ge of TPS 3 Disassemble the 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 cou...

Page 77: ...If resistance and continuty are 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 volt...

Page 78: ...TAT THERMO STAT THERMO STAT ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SENSOR ENG TEMP SEN...

Page 79: ...he 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 Check to see if the ECU coupler is loose or bad conta...

Page 80: ...eck 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 tem...

Page 81: ...ISA IDLE SPEED ACTUATOR Remove the injector cap firstly for dismantling the ISA Remove the ISA screws 2EA Remove the ISA Assemble Install in reverse order of removal Remove Remove the ISA coupler The...

Page 82: ...le 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 about the level of elect...

Page 83: ...e measuring 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 contac...

Page 84: ...NSOR O2 SENSOR O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SE...

Page 85: ...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 86: ...AULT 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 87: ...oupler 6 Turn on the ignition key 7 Measure the voltage or tachometer of wire harness for ECU check Measuring terminal B electric wire G electric wire Output Voltage battery voltage Measuring terminal...

Page 88: ...ltage 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 electri...

Page 89: ...REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH CRANK CASE COVER LH CRANK CASE COVER LH CRANK CASE COVER LH CRANK CASE COVER LH CRANK C...

Page 90: ...UREMENT RESISTANCE Remove the LH side cover Disconnect the ACG coupler and L G connector Measure the resistance between G and L STANDARD 80 150 20 CHECKING OF CKP Crank Position Sensor Check the fly w...

Page 91: ...e ENGINE SINK ON change OFF to ON it s okay Check if ENGINE SINK ON is OFF while start up Remove the A C generator If there are over 10 spots on the flywheel protrusion replace it Check the CKP is wor...

Page 92: ...crank signal A Measure terminal No 30 pin of wire harness for inspection Red wire of coupler of CKP Measuring resistance 0 1 Check the wiring of crank signal B Measure terminal No 22 pin of wire harn...

Page 93: ...fuel pump coupler Loosen the 4 special screws and remove the fuel pump setting plate Remove the fuel pump It is located inside a fuel tank Remove the seat Loosen the washer bolt 2 flange bolts securin...

Page 94: ...EMS Engine Management System 5 43 The terminal arrangement of the fuel pump The following color chart is the internal color of the fuel pump 18 FUEL PUMP...

Page 95: ...asured resistance value is out of standard at float position replace the fuel unit The FLOAT position F 192 mm 1 2 138 mm E 74 mm Terminals resistance 30 5 300 5 566 3 CHECK THE BLOW PRESSURE OF FUEL...

Page 96: ...pler ofdiagnostictool Turn onthelgnitionkey Pressthepowerbuttonof the diagnostictool Presstheenter buttonintheinitialscreen Presstheenter inthevehiclediagnosisscreen Press theenterbuttonontheresetting...

Page 97: ...EMS Engine Management System 5 46 Presstheenter buttonwhenitisready Whenthe ECUwasinitialized turnoff thelgnition keyandthenturnontheignitionkey...

Page 98: ...ol Turnthe lgnitionkeyon Pressthepowerbuttonof the diagnosis tool Presstheenter buttononthe initialscreen Pressthebuttonatthevehiclediagnostic screen Press theenterbuttononthecurrentdata By looking th...

Page 99: ...onnectedtothecouplerof diagnostictool Turnthelgnitionkeyon Pressthepower buttonof thediagnosistool Presstheenter buttononthe initialscreen Press the enter button on the vehicle diagnosis screen Presst...

Page 100: ...nectedtothecoupler ofdiagnostictool Starttheengine Pressthepowerbuttonof the diagnosis tool Presstheenter buttononthe initialscreen Press the enter button on the vehicle diagnosis screen Presstheenter...

Page 101: ...6 0 COOLING SYSTEM...

Page 102: ...move the radiator cap if the coolant temperature is over 100 C It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding When the temp...

Page 103: ...d in radiator hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck Thermostat stuck...

Page 104: ...RE CHART ANTICORROSIVE AND ANTIFREEZE When the whole capacity of coolant is 2000cc Minimum temperature 9 C 16 C 25 C 37 C 44 5 C Mixture 20 30 40 50 60 Ratio 400 600 800 1 000 1 100 Distilledwater 1 6...

Page 105: ...ATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIA...

Page 106: ...ER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANG...

Page 107: ...FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH COOLING FAN SWITCH FLANGE BOLTS FLANGE BOLTS FLANGE BOL...

Page 108: ...center cowl CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKI...

Page 109: ...DRAIN BOLT DRAIN BOLT DRAIN BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...

Page 110: ...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 O RING CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HOLE CHECKING HO...

Page 111: ...ler INSPECTION Soak the engine coolant temperature gauge in the beaker fill the beaker with water Heats up the beaker Measure the resistance ENGINE COOLANT TEMPERATURE GAUGE TEMPERATURE Temperature Re...

Page 112: ...ermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room temperature Test the thermostat after it is opened for about 5 minutes and hold the temper...

Page 113: ...7 0 ENGINE REMOVAL INSTALLATION...

Page 114: ...ring the engine removal or installation The following works require engine removal for service Cylinder head valve Cylinder piston Transmission Crank shaft SPECIFICATION TORQUE VALUES ENGINE HANGER BO...

Page 115: ...CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP RADIATOR CAP LH DOWN TUBE COMP B LH DOWN TUBE COMP B LH DOWN TUBE COMP B LH DOWN TUBE COMP B LH DOWN TUBE COMP B LH DOWN TUBE COMP B LH DOWN TUB...

Page 116: ...gine Engine oil level Throttle grip operation and free play Clutch lever operation and free play Drive chain slack Carefully align mounting points with the jack to prevent damage from mounting bolt th...

Page 117: ...8 0 CLUTCH GEARSHIFT...

Page 118: ...REE LENGTH 35 5 34 2 CLUTCH DISK THICKNESS 2 9 3 0 2 6 CLUTCH PLATE WARPAGE 0 2 CLUTCH OUTER I D 28 000 28 013 28 030 CLUTCH OUTER GUIDE O D 28 0 020 0 033 28 5 0 1 TORQUE VALUES CLUTCH LOCK NUT 6 5kg...

Page 119: ...ee play Clutch plate warpage Clutch lock nut loose High fluid level or high fluid weight Clutch slippage Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play Diffic...

Page 120: ...UTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CLUTCH LEVER SPRING CABLE HOLDER CABLE HOL...

Page 121: ...ARING BEARING BEARING BEARING CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH PRIMARY DRIVE GE...

Page 122: ...NE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE W...

Page 123: ...UTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE FEELER CAUGE FEELER CAUGE FEELER...

Page 124: ...FT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE GEAR SHIFT SPINDLE...

Page 125: ...RM STOPPER ARM STOPPER ARM SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING GEAR SHIFT SPINDLE...

Page 126: ...COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER COMP CLUTCH OUTER CO...

Page 127: ...DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR PRIMARY DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIV...

Page 128: ...TER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR OUTER GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR PD GEAR...

Page 129: ...E GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE GEAR WATER PUMP DRIVE...

Page 130: ...MEMO...

Page 131: ...9 0 A C GENERATOR STARTER CLUTCH...

Page 132: ...done with the engine installed in the frame SPECIFICATIONS ITEM STANDARD VALUE SERVICE LIMIT O D 39 622 39 635 39 607 STARTER DRIVEN GEAR I D 22 010 22 022 22 100 STARTER IDLE GEAR I D 10 013 10 045 1...

Page 133: ...ON GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDUCTION GEAR COVER STARTER REDU...

Page 134: ...Y WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL GEAR SHAFT GEAR SHAFT GEAR SHAFT GEAR SHAF...

Page 135: ...OTOR PULLER ACG ROTOR PULLER STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER D...

Page 136: ...AR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GEAR STARTER DRIVEN GE...

Page 137: ...ATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR STATOR CRANK POSITION SENSOR CRANK POSITION SENSOR CRANK POSIT...

Page 138: ...Y WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL FLY WHEEL IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR IDLE GEAR ID...

Page 139: ...over the reduction gear cover and install the two bolts Install the LH crank cover bolt TORQUE 1 1kgf m LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVER LH REAR COVE...

Page 140: ...MEMO...

Page 141: ...10 0 CYLINDER HEAD VALVES...

Page 142: ...ORQUE VALUES CAM CHAIN TENSIONER PIVOT BOLT 1 0 kgf m 10N m SPARK PLUG 1 1 kgf m 11N m CYLINDER HEADSPECIAL SOCKET BOLT 4 0 kgf m 40N m CAM CHAIN TENSIONER LIFTER BOLT 1 2 kgf m 12N m CAM CHAIN TENSIO...

Page 143: ...ection 3 Valve springs damage Incorrect valve timing Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 10 11 Excessive white...

Page 144: ...PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG TENSIONER TENSIONER TENSIONER TENSIONER TENSIONER TENSIONER TE...

Page 145: ...CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARI...

Page 146: ...he valve springs more than necessary to remove the cotters Mark all parts during disassembly so they can be placed back in their original locations Avoid damaging the gasket surfaces NOTE Remove the v...

Page 147: ...IMIT IN 0 080 mm EX 0 100 mm Measure the inner diameter of the new valve guide If the clearance is not within the service limit replace the valve Rotate the reamer clockwise during the installation an...

Page 148: ...combustion chamber side of the cylinder head TOOL VALVE GUIDE DRIVER Install the new O ring to new valve guide Insert the valve guide from the upper part of cylinder head TOOL VALVE GUIDE DRIVER Afte...

Page 149: ...nd exhaust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to each valve face Tap the valve against the valve seat serveral times with the valve guide reamer without...

Page 150: ...SSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRESSOR VALV E SPRING COMPRE...

Page 151: ...the index mark of the LH crankcase cover Take precautions not to allow the cam chain to drop into the camshaft timing gear while turning the camshaft Apply engine oil to the camshaft then assemble th...

Page 152: ...the cylinder head cover grooves and accurately assemble the gasket to the cylinder head cover Install the cylinder head cover Tighten the cylinder head cover bolt TORQUE 1 0 kgf m CAM CHAIN GUIDE CAM...

Page 153: ...11 0 CYLINDER PISTON...

Page 154: ...ton ring Scored or scratched piston or cylinder Excessive carbon build up on top of piston SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 1 CYLINDER REMOVAL 11 2 PISTON PISTON RING 11 3 CYLINDER INSTALLA...

Page 155: ...easure the piston outer diameter Calculate the piston to cylinder clearance Take the maximum reading to determine the clearance SERVICE LIMIT 0 30 mm Calculate the cylinder for out of round at three l...

Page 156: ...L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D E R C Y L I N D...

Page 157: ...l end SERVICE LIMIT 17 010 17 028 mm Calculate the clearance between the inner diameter of the connecting rod small end and pisto pin SERVICE LIMIT 0 028 0 066 mm CYLINDER GAUGE Push the rings into th...

Page 158: ...t TOP RIDNG SECOND RING Insert the piston and piston into the conrod Install new piston pin clips IN MARK it does toward to intake side Take care not to drop the piston pin clip into the crankcase Do...

Page 159: ...ngs and install the cylinder Be careful not to damage the piston rings Be careful not to drop the cam chain into the crankcase Install the lower part of the cam chain guide to the part of the crankcas...

Page 160: ...MEMO...

Page 161: ...12 0 CRANKCASE TRANSMISSION CRANKSHAFT...

Page 162: ...TARTER MOTOR SECTION 19 ITEM STANDARD VALUE SERVICE LIMIT FORK I D 12 000 12 018 12 050 SHIFT FORK SHAFT CLAW THICKNESS 4 930 5 000 4 500 SHAFT O D 11 976 11 994 11 960 MAIN SHAFT O D M3 M5 19 967 19...

Page 163: ...indle claw bent Shift drum guide grooves damaged Shift fork guide spot damaged Transmission jumps out of gear Gear dogs worn Shift fork shaft bent Shift drum stopper damaged Shift drum guide grooves w...

Page 164: ...ANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK...

Page 165: ...CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR CRANK BALANCER GEAR...

Page 166: ...MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR MAIN GEAR COUNTER GEAR COUNTER...

Page 167: ...K CASE RH CRANK CASE RH CRANK CASE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GA...

Page 168: ...BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT B...

Page 169: ...angle 10 2 TOOLS MAIN SHAFT COUNTER SHAFT CRANK BALANCER SHAFT BEARING DRIVER ATTACHMENT PILOT Coat the socket bolt screw part with oil and install the main shaft bearing set plate TORQUE 1 2kgf m 12...

Page 170: ...GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALANCE DRIVE GEAR BALAN...

Page 171: ...K RIGHT FORK RIGHT FORK RIGHT FORK RIGHT FORK RIGHT FORK RIGHT FORK SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM...

Page 172: ...E RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE RH CRANK CASE LH CRANK CASE LH CRANK CASE LH CRANK CASE LH...

Page 173: ...ON CRANKSHAFT Install the below parts Clutch RH cover Cylinder Cylinder head Flywheel LH cover Install the engine on the frame Section 7 Pour the engine oil Pour the coolant Install of the cowl in the...

Page 174: ...MEMO...

Page 175: ...13 0 EXTERNAL PARTS...

Page 176: ...TION 13 1 SEAT SIDE COVER 13 2 REAR SEAT PILLION SEAT 13 2 REAR COWL 13 3 REAR FENDER 13 3 REAR WHEEL MUDGUARD 13 3 MUFFLER EXHAUST PIPE 13 4 FRONT FENDER 13 5 Beware of the muffler after driving or e...

Page 177: ...SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN SEAT MAIN...

Page 178: ...LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT WINKER RELAY WINKER RELAY WIN...

Page 179: ...FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUF...

Page 180: ...onto the exhaust ports of the cylinder head Install the new gasket onto the exhaust pipe When install the muffler temporarily install the flange bolt to the damper stay and the hex cap nut then tighen...

Page 181: ...14 0 FRONT WHEEL FRONT FORK STEERING...

Page 182: ...ngine to support the motorcycle SPECIFICATIONS TORQUE VALUES STEERING HANDLE PIPE BOLT 2 6kgf m 26N m FRONT BRAKE DISK BOLT 4 2kgf m 42N m FRONT AXLE NUT 5 9kgf m 59N m FORK TOP BRIDGE PINCH BOLT 2 6k...

Page 183: ...e Insufficient tire pressure Worn tire Steers to one side Damaged incorrectly tightened steering head bearing Unbalance of left right cushion Bent front fork Bent front axle shaft and inclind tire Wor...

Page 184: ...HT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STAR...

Page 185: ...RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE RH HANDLE PIPE HANDLE PIPE ASSEMBLY SOCKET BOLT HANDLE PIPE ASSE...

Page 186: ...RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK RH FRONT FORK LH H...

Page 187: ...LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH HANDLE PIPE LH H...

Page 188: ...HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE BRAKE HOSE FRONT BRAKE CALLIPER FRONT BRAKE CALLIPER FRONT BRAKE CALLIPER FRONT BRAKE CALLIPER FRONT BRAKE CALLIPER FRONT BRAKE CALLIPER FRONT BRAKE CA...

Page 189: ...SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPE...

Page 190: ...ASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GE...

Page 191: ...NER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER GEAR RETAINER...

Page 192: ...with the tangs of the left fork slider Insert the front axle into the speedometer gear box and the wheel hub Install the axle nut TORQUE 5 9 kgf m Install the speedometer cable and tighten it correct...

Page 193: ...E STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING HANDLE PIPE STEERING...

Page 194: ...ONT 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...

Page 195: ...PPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING DUST SEAL DUST SEAL D...

Page 196: ...IL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE...

Page 197: ...E SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK...

Page 198: ...bottom case with a piece of cloth and fix it to the vise Apply screw locking agent to the socket bolt thread and assemble the socket bolt to the seat pipe TORQUE 2 0 kgf m 20 N m When a vise is used...

Page 199: ...ARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD UP WARD DOWN WARD DOWN WARD DOWN WARD DOWN WARD DOWN...

Page 200: ...FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP...

Page 201: ...BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLA...

Page 202: ...STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STEM STEERING STE...

Page 203: ...el balls Retighten the steering head top thread to the specified torque TORQUE 0 3 kgf m FINAL TORQUE INSTALLATION TOP CONE RACE STEEL BALLS STEEL BALL RACE STEERING STEM STEEL BALL RACE STEEL BALLS W...

Page 204: ...tion valve and tighten the flange bolts Install the following Front wheel Front fender Front cowl Side cowls JUNCTION VALVE JUNCTION VALVE JUNCTION VALVE JUNCTION VALVE JUNCTION VALVE JUNCTION VALVE J...

Page 205: ...15 0 REAR WHEEL REAR SUSPENSION...

Page 206: ...NDER BOLT 4 0 f m SWINGARM PIVOT NUT 8 8 f m FINAL DRIVEN SPROCKET NUT 5 9 f m TOOLS ATTACHMENT PILOT DRIVER BEARING REMOVER SHAFT BEARING REMOVER HEAD 15 SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 2...

Page 207: ...r wheel bearing Damaged tire Axle not tightened properly Insufficient air in tire Worn rear fork bush Weak rear cushion Weak spring Incorrect rear damper Hard rear cushion Bent damper rod Rear cushion...

Page 208: ...L GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE...

Page 209: ...N SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN SPROCKET FINAL DRIVEN...

Page 210: ...eating with a hammer After removing the distance collar remove the other bearing TOOLS BEARING REMOVER SHAFT REMOVER HEAD Apply the grease to the bearing Insert the new bearing in parallel with the se...

Page 211: ...VE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE REAR WHEEL SLEEVE...

Page 212: ...R SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD...

Page 213: ...e bag from getting caught in the bit when you start 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 DUST SEAL DUST SEA...

Page 214: ...GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD MUD GUARD REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR C...

Page 215: ...s pivot distance center collar and bush Check the dust seal caps center collar and bush for wear or damage Apply grease to the center collar bearing and bushes Install the center collar bearings and b...

Page 216: ...hten the bolt to the specified torque TORQUE 4 0 kgf m Install the brake hose to swingarm clamp correctly Install the rear caliper bracket into the groove of the swingarm Install the rear wheel mudgua...

Page 217: ...16 0 HYDRAULIC BRAKE FRONT REAR...

Page 218: ...ecking if dust or dirt soils each part install them Always replace the specified parts Brake pad can be removed without disconnecting the hose Bleed the air in case of removing the brake hose 16 SERVI...

Page 219: ...g properly Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pad disk Misaligned wheel Clogged restri...

Page 220: ...voir Avoid spilling fluid on painted plastic or rubber parts DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM PLATE DIAPHRAGM P...

Page 221: ...pes of fluid There are not compatible If a brake bleeder is not available fill the master cylinder and operate the brake lever or pedal to fill the system BLEEDER RESERVOIR CAP RESERVOIR CAP RESERVOIR...

Page 222: ...T CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CALLIPER FRONT CAL...

Page 223: ...SE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP BRAKE HOSE CLAMP FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER FRONT CALIPER...

Page 224: ...et caliper PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PAD SPRING PA...

Page 225: ...ORQUE 1 8 kgf m Install the rear brake hose clamp Install the rear wheel mudguard BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PAD BRAKE PA...

Page 226: ...TER CYLINDER REMOVAL Drain the brake fluid 16 3 Disconnect the the front brake stop switch wire Remove the brake hose oil bolt and washers Brake fluid causes damage to the painted plastic or rubber pa...

Page 227: ...e the master piston and spring Clean the inside of the cylinder and reservoir with brake fluid STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWIT...

Page 228: ...DIAPHRAGM PLATE DIAPHRAGM MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLINDER PISTON MASTER CYLIND...

Page 229: ...SPRING SPRING PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON CIRCLIP CIRCLIP CIRCLIP CIRCLIP CIRCLIP CIRCLIP CIRCLIP CIRCLIP CIRCLIP C...

Page 230: ...m Connect the front brake switch wire Fill the reservoir to the upper level and bleed the brake system 16 5 REAR MASTER CYLINDER REMOVAL Drain the brake fluid 16 3 Remove the rear reservoir mounting...

Page 231: ...JOINT PIN JOINT PIN JOINT PIN JOINT PIN TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE...

Page 232: ...ING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING BRAKE ROD JOINT BRAKE ROD JOINT BRAKE ROD JOINT BRAKE ROD JOINT BRAKE ROD JOINT BRAKE ROD JOINT BRAKE ROD...

Page 233: ...JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT P...

Page 234: ...PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C JOINT PIN C FRONT LH BRAKE CALIPER FRONT LH BRAKE CALIPER FRONT LH BRAKE CALIPER FRONT LH BRAKE CALIPER FRONT...

Page 235: ...on with brake fluid Do not use high pressure air or bring the air gun too close Do not touch the inside of caliper Avoid spilling fluid on painted plastic or rubber parts Keep oil off the brake disk o...

Page 236: ...bracket to caliper Install the brake pad to brake caliper PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEA...

Page 237: ...N m Fill the brake fluid to upper level bleed the brake system 16 5 DISASSEMBLY Remove the spring slide pin caliper bracket and boot from the caliper body If there is any wear or damage in the boot r...

Page 238: ...SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL DUST SEAL DUST SEAL DUST S...

Page 239: ...CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT B...

Page 240: ...he washer and external cir clip Connect the brake pedal to the brake rod joint Install the joint pin C and secure it with a new cotter pin Hook the stop switch spring to the brake pedal spring Install...

Page 241: ...15A fi ECU BATTERY REGULATOR RECTIFIER REGULATOR RECTIFIER IGNITION COIL AC GENERATOR AC GENERATOR Y G R Y R W LOAD B CABLE FUSE 30A FUSE 15A Y ECU FUSE BOX B Black Y Yellow G Green R Red W White Lg...

Page 242: ...y 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 to note...

Page 243: ...BNORMAL OVERCHARGED 15V 14 15V NOT CHARGING 14V NORMAL NORMAL CORRECT No power Key turned on Dead battery Low fluid level Low specific gravity Charging system failure Disconnected battery cable Main f...

Page 244: ...egative cable Use a voltmeter that will accurately indicate 0 1V difference Never open the sealed filler cap When measuring the battery voltage after charging leave it for at least 30 minutes or the a...

Page 245: ...not turn the ignition on A sudden surge of current may blow out the fuse in the tester Be sure that the battery is fully charged before performing this test The amount of current flow may change abrup...

Page 246: ...RECTIFIER UNIT INSPECTION If all inspections on the wire harness side are normal and there are no loose connections at the regulator rectifier coupler inspect the regulator rectifier unit by measuring...

Page 247: ...ARGING COIL INSPECTION Remove the seat 13 2 Remove the LH side cover 13 2 Disconnect the A C generator cord coupler Measure the resistance between the yellow leads RESISTANCE VALUE 0 1 1 5 20 If the r...

Page 248: ...MEMO...

Page 249: ...18 0 IGNITION SYSTEM BATTERY ECU FUSE BOX AC GENERATOR REGULATOR RECTIFIER IGNITION COIL...

Page 250: ...orly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive peak voltage As inspections for coil resistance values are also included it...

Page 251: ...onnector 4 Open circuit or poor connection in ground cord of the ECU unit 5 Faulty peak voltage adaptor 6 Faulty ECUunit in case when above No 1 6 are normal 1 Faulty spark plug or leaking ignition co...

Page 252: ...k the resistance of coil between black yellow and green is within the specified range 0 73 0 08 23 5 Check continuity between ground and frame INSPECTION A C GENERATOR COUPLER A C GENERATOR COUPLER A...

Page 253: ...spark plugcapandmeasurethesecondarycoilresistance REFERENCE VALUE 15K K Since the resistance value of the primary coil is small it is too diffcult to judgment even if the problem happen from theshortc...

Page 254: ...the side stand switch couper connected with main wire harness Remove the side stand switch mounting screws and remove the cord clamp and side stand switch BLACK WHITE AND GREEN TERMINAL PUSH THE SHAFT...

Page 255: ...R G W G Y Y G B W B B B W B W W B Black Y Yellow G Green R Red W White Lg Light green Y R MAIN SWITCH FUSE FUSE NEUTRAL LAMP BATTERY 12A 10AH GEAR POSITION SIDE STAND SWITCH SWITCH STARTER MAGNETIC SW...

Page 256: ...be unable to turn the starter motor quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while the engine is not cranking over the st...

Page 257: ...netic switch coil ground wire 19 6 Connect the starter magnetic switch coupler Measure the starter magnetic voltage at the starter magnetic switch coupler 19 6 Check the starter magnetic switch operat...

Page 258: ...washer Washer Cir clip Rear cover ass y 2 pcs washer Amature Always turn the ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury INSPECTION Che...

Page 259: ...ontinuity Check for continuity between each commtator bar and armature shaft There should be no continuity Check for continuity between pairs of commutator bars There should be continuity Check the co...

Page 260: ...ligning the holder tab with the motor case groove Install the armature in the motor case while pushing in the brushes into the brush holder When installing the armature into the motor case hold the ar...

Page 261: ...c switch terrminal Disconnect the Yellow Red and Green Yellow connector from the wire harness Remove the starter magnetic switch from the bracket of the frame OPERATION INSPECTION Shift the transmissi...

Page 262: ...inal and ground If the battery voltage appears only when the starter switch is pushed with the ignition switch to ON it is normal CONTINUITY INSPECTION Disconnect the wire connector of the magnetic sw...

Page 263: ...LIGHTS METER SWITCHES 20 0 HEADLIGHT RELAY WINKER RELAY ECU FUSE BOX H HO OR RN N SPEEDOMETER HEADLIGHT BATTERY HORN...

Page 264: ...onnector corrosion an ohmmeter is required to check the circuit resistance value The following color codes are used throughout this section B Black Y Yellow L Blue G Green R Red W White Br Brown O Ora...

Page 265: ...T FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT HEAD LIGHT DUST COVER HEAD LIGHT DUST COVER HEAD LIGHT DUST COVER HEAD LIGHT DUST COVER HEAD LIGHT DUST COVER HEAD...

Page 266: ...NKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER...

Page 267: ...OMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COM...

Page 268: ...KER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER WINKER DIMMER SWITCH COUPLER...

Page 269: ...TER SWITCH COUPLER STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH S...

Page 270: ...IMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH DIMMER SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWITCH STOP SWIT...

Page 271: ...ome on Faulty winker relay Poor connection of the connector Broken wire harness GEAR CHANGE SWITCH Remove the seat 13 2 Remove the LH side cover 13 2 Disconnect the neutral switch connector from the s...

Page 272: ...cylinder compression Low compression Low speed of starter crank Incorrect valve clearance Faulty valve seat Worn cylinder and piston rings Seized valve Improper valve timing 4 Start by following norm...

Page 273: ...ly Engine speed increased Engine speed doesn t increase Closed carburetor choke Clogged fuel aisle Clogged air cleaner Clogged fuel tank breather Clogged muffler 4 Accelerate lightly Correct Incorrect...

Page 274: ...cation Not overheated Overheated Excessive carbon build up in combustion chamber Poor quality fuel being used Lean fuel mixture Clutch slipping 12 Check for engine overheating Correct Incorrect Incorr...

Page 275: ...EED 1 Check the ignition timing and Incorrect Faulty valve clearance adjustment valve clearance Faulty ECU unit Faulty pulse generator 2 Disconnect fuel tube at Fuel flows No fuel to fuel tank carbure...

Page 276: ...amaged Faulty float Balance coil damaged or shorted Terminal loose Faulty terminal connection Balance coil lead shorted or damaged GAUGE READING INACCURATE IGNITION SWTICH ON 1 Operate the turn signal...

Page 277: ...Balance coil lead shorted or damaged GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit 2 Remove the tank and operate the float 3 Move...

Page 278: ...MEMO...

Page 279: ...MEMO...

Page 280: ...MEMO...

Page 281: ...MEMO...

Page 282: ...22 WIRING DIAGRAM...

Page 283: ...22 1 WIRING DIAGRAM 22...

Page 284: ......

Page 285: ......

Page 286: ...22 WIRING DIAGRAM 2 1 09 01 25 17 16 08 32 24 37 36 34 33 39 38 35 40 1 2 1 2 2 1...

Page 287: ...SERVICEMANUAL 2009 10 PRINTED 2009 10 PUBLICATION C CO OP PY Y P PR RO OH HI IB BI IT T...

Page 288: ......

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