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HYOSUNG 2002 Comet 125, Service Manual, Page: 198 / 199

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HYOSUNG 2002 Comet 125 Service Manual Download Page 198

SHIM No.

T

APPET SHIM SELECTION CHART (EX.)

Specified clearance - Adjustment unnecessary

1.20

1.20

0.05-0.09

0.10-0.14

0.15-0.19

0.20-0.30

0.31-0.35

0.36-0.40

0.41-0.45

0.46-0.50

0.51-0.55

0.56-0.60

0.61-0.65

0.66-0.70

0.71-0.75

0.76-0.80

0.81-0.85

0.86-0.90

0.91-0.95

0.96-1.00

1.01-1.05

1.06-1.10

1.1

1-1.15

1.16-1.20

1.21-1.25

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

2.20

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.90

1.95

2.00

2.05

2.10

2.15

2.20

1.95

2.00

2.05

2.10

2.15

2.20

2.00

2.05

2.10

2.15

2.20

2.05

2.10

2.15

2.20

2.10

2.15

2.20

2.15

2.20

2.20

SHIM THICKNESS

AT PRESENT

(mm)

MEASURING

TAPPET

CLEARANCE (mm)

120

1.25

125

1.30

130

1.35

135

1.40

140

1.45

145

1.50

150

1.55

155

1.60

160

1.65

165

1.70

170

1.75

175

1.80

180

1.85

185

1.90

190

1.95

195

2.00

200

2.05

205

2.10

210

2.15

215

2.20

220

HOW T

O

 USE THE CHART

1. Measure the tappet clearance.(When cold)

2. Measure the shim thickness at present.

3. Look for meeting space in that horizontal line 

for thickness and vertical line for clearance.

(EXAMPLE)

When the tappet clearance is 0.33mm and the 

shim thickness at present is 1.70mm, the shim 

thickness should be used 1.80mm.

HYOSUNG MOT

ORS & MACHI

NER

Y INC.

Summary of Contents for 2002 Comet 125

Page 1: ...SERVICE MANUAL 99000 94710 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC ...

Page 2: ...FOREWORD This manual contains an introductory description on HYOSUNG and proce dures for its inspection service and overhaul of its main components Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspec tion and service This manual wil...

Page 3: ... sections are listed on the previous page as GROUP INDEX select the section where you are look ing for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Front wheel ...

Page 4: ...LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE A Apply SILICONE GREASE Apply MOLY PASTE Apply BOND 1215 DEFINITION SYMBOL DEFINITION SYMBOL Apply SUPER GREASE C ...

Page 5: ...NOTE Difference between photographs and actual motorcycles depends on the markets ...

Page 6: ...ION INFORMATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL AND OIL RECOMMENDATIONS 1 4 BREAK IN PROCEDURES 1 5 CYLINDER CLASSIFICATION 1 5 EXTERIOR ILLUSTRATION 1 6 SPECIFICATIONS 1 8 CONTENTS 1 ...

Page 7: ...t could result in vehicle damage WARNING Indicates a potential hazard that could result in death or injury NOTE Indicates special information to make maintenance easier or instructions cleaner WARNING Proper service and repair procedures are important for the safety of the service machanic and the safe ty and reliability of the vehicle When 2 or more persons work together pay attention to the safe...

Page 8: ...er head and case bolts and nuts beginning with larger diameter and ending with small er diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left ov...

Page 9: ...n Number is stamped on the steering head tube The engine seri al number is located on the left upside of crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FRAME SERIAL NUMBER ENGINE SERIAL NUMBER 1 3 GENERAL INFORMATION ...

Page 10: ...L SPECIFICATION WARNING Don t mix the unrecommended oil It could damage the engine When refilling the oil tank don t allow the dust to get inside Mop the oil spilt Don t put the patch on the cap It could disturb the oil to be provided and damage the engine WARNING Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different typ...

Page 11: ...e position BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rule...

Page 12: ...395 315 760 890 895 1 120 1 045 180 1 455 2 080 325 795 960 795 635 795 800 890 EXTERIOR ILLUSTRATION GENERAL INFORMATION 1 6 ...

Page 13: ...EXTERIOR ILLUSTRATION 1 7 GENERAL INFORMATION ...

Page 14: ...troke 48 8 mm 1 92 in 41 0 mm 1 61 in Piston displacement 249 15 2 in3 124 7 7 6 in3 Carburetor BDS 26TYPE DOUBLE Starter system Electric starter Lubrication system Wet sump Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Final reduction 3 286 3 714 Gear ratio 1st 2 462 2 750 2nd 1 556 1 786 3rd 1 190 1 350 4th 0 957 1 091 5th 0 840 0 913 Drive chain 52...

Page 15: ...T D C at 6 000 rpm Spark plug CR8E Battery 12V 12Ah Fuse 15 A Head lamp HI 60 W HI 35 W LO 55 W LO 35 W Turn signal lamp 10 W Brake Tail lamp 21 5 W Speedometer lamp 1 7 W 3 High beam indicator lamp 1 7 W Turn signal indicator lamp right left 1 7 W 2 License plate lamp 5 W Neutral indicator lamp 1 7 W Fuel tank 17 0 Engine oil oil change 1 450 with filter change 1 500 overhaul 1 800 1 650 Front fo...

Page 16: ...2 5 EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2 5 AIR CLEANER 2 6 CARBURETOR 2 7 FUEL HOSE 2 8 CLUTCH 2 8 ENGINE OIL 2 9 ENGINE OIL FILTER 2 10 DRIVE CHAIN 2 11 BRAKE SYSTEM 2 13 STEERING 2 17 FRONT FORK 2 17 REAR SUSPENSION 2 17 TIRE 2 18 CHASSIS BOLTS AND NUTS 2 18 COMPRESSION PRESSURE 2 19 OIL PRESSURE 2 20 CONTENTS 2 2 PERIODIC MAINTENANCE ...

Page 17: ...Inspect Inspect Inspect Tighten Inspect Inspect Inspect Inspect Inspect Inspect Inspect Tighten Clean and lubricate every 1 000km Replace every 4 years Replace every 2 years CHASSIS 2 11 2 13 2 13 2 13 2 18 2 17 2 17 2 17 2 18 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak p...

Page 18: ...lder Drive chain Side stand pivot and spring hook Speedometer gear box Front brake lever holder Throttle cable Rear brake pedal pivot O Motor oil G Grease NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the motor cycle has been operated under wet or rainy...

Page 19: ...efer to page 4 1 Remove the cylinder head cover and Remove the magneto cover plug and the timing inspection plug 0 1 0 2 mm 0 004 0 008 in 0 2 0 3 mm 0 008 0 012 in IN EX Valve clearance when cold Thickness gauge 09900 20806 Rotate the magneto rotor to set the front cylinder s piston at TDC Top Dead Center of the compression stroke Rotate the rotor until F line on the rotor is aligned with the cen...

Page 20: ...he tappet shim selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim which 170 1 70 mm of the shim add up the excess clearance 0 25 mm when adjust with the standard 0 15 as the intake standard clearance 0 1 0 2 mm CAUTION Valve clearance should be checked when the engine is cold If you d...

Page 21: ...t to specified torque CR7E CR8E CR9E Hot type Standard type Cold type 0 7 0 8 mm 0 028 0 032 in Spark plug gap Thickness gauge 09900 20806 Spark plug 20 25 N m 2 0 2 5 kg m SPARK PLUG Disconnect the spark plug caps Remove the spark plugs Inspect Interval Clean Initial 1 000 km and Every 4 000 km Replace Every 8 000 km EXHAUSE PIPE NUTS AND MUFFLER MOUNTING BOLTS Tighten the exhaust pipe nuts and m...

Page 22: ... located under the fuel tank Remove the fuel tank Remove the four screw Pull up the air cleaner cover and the air cleaner ele ment Rear Cylinder Inspect Interval Clean Every 3 000 km Replace Every 12 000 km PERIODIC MAINTENANCE 2 6 ...

Page 23: ...vent damage of the engine Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere 1 450 and 1 550 rpm by turning throttle stop screw THROTTLE CABLE PLAY There should be 0 5 1 0 mm play on the throttle cable To adjust the throttle cable play Tug on the throttle cable to check the amount of play Loosen the lock nut and turn the adjuster in or out until...

Page 24: ...begins to disengage If the play in the clutch is incorrect adjust it in the following way Loosen the lock nut and screw the adjuster on the clutch lever holder all the way in Loosen clutch cable adjuster lock nut Turn the clutch cable adjuster in or out to acquire the specified play Tighten lock nut while holding the adjuster in position The clutch cable should be lubricated with a light weight oi...

Page 25: ...with the engine oil change Keep the motorcycle upright Place an oil pan below the engine and drain the oil by removing the filler cap and drain plug Tighten the drain plug to the specified torque and pour fresh oil through the oil filler Use an API classi fication of Over SG oil with SAE 10W 30 or 10W 40 viscosity Start up the engine and allow it to run for several minutes at idling speed Turn off...

Page 26: ...firm and clean the oil strainer when replace the engine oil specially when first replacement CAUTION More frequent servicing may be performed on mo torcycles that are used under severe conditions ENGINE OIL FILTER Drain the engine oil as described in the engine oil replacement procedure Remove the oil filter cap Remove the oil filter Install the new O ring Install the new oil filter Install the ne...

Page 27: ...y the jack or block turn the rear wheel slowly by hand with the trans mission shifted to Neutral Loose pins Excessive wear Damaged rollers Improper chain adjustment Dry or rusted links Kinked or binding links If any defects are found the drive chain must be replaced Add new engine oil and check the oil level as described in the engine oil replacement procedure CAUTION Use HYOSUNG MOTORCYCLE GENUIN...

Page 28: ...nce exceeds the service limit the chain must be replaced 256 5 mm 10 10 in Service limit Drive chain 20pitch length 319 4 mm 12 58 in Loosen or tighten both chain adjusters until the chain has 20 30 mm of slack in the middle between the engine and rear sprockets The marks on both chain adjusters must be at the same position on the scale to ensure that the front and rear wheels are correctly aligne...

Page 29: ...ry 4 000 km Replace the brake hoses Every 4 years Replace the brake fluid Every 2 years Wash the drive chain with kerosine If the drive chain tends to rust quickly the intervals must be shortened After washing and drying the chain oil it with a engine oil or chain lubricating oil CAUTION The drive chain for this motorcycle is made of the special material The chain should be replaced with a 520HO f...

Page 30: ...containers Never re use brake fluid left over from the last servicing or stored for a long period CAUTION Brake fluid if it leaks will interfere with safe run ning and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding Front Brake BRAKE PAD WEAR The extend of brake pad wear can be checked by observing the grooved limit on the pad Wh...

Page 31: ...er end of the hose into a receptacle Specification and Classification DOT 3 or DOT 4 Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper line Replace the rear brake s fluid with the same manner of the front brake Front brake caliper air bleeder valve 6 9 N m 0 6 0 9 kg m Rear brake caliper air bleeder valve 6 9 N m 0 6 0 9 kg m Loosen the ...

Page 32: ...nd release the brake lever several times in rapid succession and sqeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip Then close the air bleeder valve pump and squeeze the brake lever and open the valve Repeat this...

Page 33: ...outer surface of the inner tubes Replace any defective parts if necessary REAR SUSPENSION Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage Replace any defective parts if neces sary Refer to page 6 36 Inspect Interval Inspect Initial 1 000 km and Every 4 000 km Inspect Interval Inspect Every 4 000 km Inspect Interval Inspect Every 4 ...

Page 34: ...nd nuts are tightened to their specified torque Refer to page 7 12 COLD INFLATION TIRE PRESSURE Front Rear SOLD RIDING KPa 196 221 2 00 2 25 29 0 32 0 196 245 2 00 2 50 29 0 36 0 kgf cm2 psi DUAL RIDING KPa kgf cm2 psi TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear increased Therefore maintain the correct tire pressure for good roadabili...

Page 35: ... cylinder COMPRESSION TEST PROCEDURE Compression gauge 09915 64510 COMPRESSION PRESSURE The compression of a cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compres sion reading for each maintenance service Standard Service limit 14 16...

Page 36: ...ncrease the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Oil pressure gauge 09915 74510 Engine tachometer 09900 26006 LOW OIL PRESSURE Oil leakage from the oil passage Damaged O ring Defective oil pump Combination of above items OIL PRESSURE Check the oil pressure periodically This will give a good indication of the condition of the moving parts If the oil p...

Page 37: ...of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring Oil the rotating or sliding parts before assembly Make sure to use the correct type of lubricant where specified Check that each rotating or sliding part moves or operates smoothly after assembly Make sure to follow ...

Page 38: ...Refer to page 6 1 Remove the fuel tank Refer to page 4 1 Drain the engine oil Refer to page 2 9 Disconnect the battery lead wire NOTE If the engine is dirtied wash the machine with a suitable cleaner before removing the engine CARBURETOR Remove the carburetor after removed the intake pipes Refer to page 4 5 Disconnect the vacuum hoses CAUTION First disconnect the lead wire ...

Page 39: ...TCH CABLE Disconnect the clutch cable end out of clutch lever Disconnect the clutch cable end out of clutch release arm EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts and muffler mounting bolts removed remove the exhaust pipes and muf flers ...

Page 40: ...t Cylinder Rear Cylinder 3 3 ENGINE ELECTRIC PARTS With take out the spark plug caps remove the spark plug Remove the starter motor lead wire Remove the engine ground lead wire Disconnect the magneto coupler ...

Page 41: ...link rod Flatten the lock washer Remove the engine sprocket nut and washer Remove the engine sprocket NOTE When loosening the engine sprocket nut depress the brake pedal NOTE If it is difficult to remove the engine sprocket loosen the rear axle nut chain adjusters to provide additional chain slack Refer to page 2 11 ...

Page 42: ...ine mounting bolts and nuts to the specified torque Support the engine using an engine jack Remove the engine mounting nuts and bolts Remove the engine from the frame CAUTION Remove the carburetor when removing or installing the engine necessarily When removing the carburetor loosen the intake pipe mounting bolts at the same time Engine mounting bolt 40 60 N m 4 0 6 0 kg m ...

Page 43: ...dal Install the gearshift arm and adjust the gearshift lever height Refer to page 2 9 Connect each electric part and its couplers Refer to page 7 23 30 Install the exhaust pipes and mufflers Install the carburetor and air cleaner After remounting the engine the following adjust ments are necessary Engine idling speed Refer to page 2 7 Throttle cable play Refer to page 2 7 Clutch cable play Refer t...

Page 44: ...3 7 ENGINE ENGINE DISASSEMBLY STARTER MOTOR Remove the starter motor Remove the gear position switch Remove the contacts and springs Remove the three union bolts ...

Page 45: ...LINDER HEAD COVER Remove the cylinder head cover CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as turn the crankshaft counter clockwise To set piston at TDC Top Dead Center of the compression stroke as align the F mark for front cylinder and the R mark for rear cylin der ...

Page 46: ...3 9 ENGINE With the three bolts removed remove the cam chain guide NO 2 Remove the camshaft housing Remove the camshaft IN EX Remove the C ring ...

Page 47: ...ENGINE 3 10 Loosen the four cylinder head stud bolts Remove the chain guide NO 1 and cylinder head Loosen the three cylinder head base nuts Loosen the two cylinder head base cover nuts ...

Page 48: ...H5100 Compress the valve spring by using the special tool Take out the valve cotter from the valve stem Remove the valve spring retainer Pull out valve from the other side CAUTION Draw out the tappet and shim with the strong magnet not to be scratched CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly ...

Page 49: ... Piston pin puller 09910 34510 Remove the piston pin by using the special tool Remove the two cylinder base nuts and cylinder Remove the rear cylinder head and cylinder with the same manner of the front cylinder head and cylinder removal CAUTION If tapping with the plastic hammer is necessary pay attention to break the fins NOTE Make an identification on each piston head so that confirmed the cyli...

Page 50: ...idle gear Conrod holder 09910 20115 Rotor remover 09930 30164 Rotor remover 09930 30162 Rotor remove sliding shaft 09930 30102 MAGNETO ROTOR With the magneto rotor held immovable using the special tool loosen the rotor nut Remove the magneto rotor by using the special tool 3 13 ENGINE ...

Page 51: ...ENGINE 3 14 CLUTCH COVER Remove the clutch release arm Remove the clutch cover bolts Remove the clutch cover Remove the key Remove the starter driven gear Remove the cam chain tensioner and cam chain ...

Page 52: ...ve the clutch spring mounting bolts diagonally Remove the disk pressure Remove the clutch drive and driven plates Flatten the lock washer Clutch sleeve hub holder 09920 53710 With the clutch sleeve hub held immovable using special tool remove the clutch sleeve hub nut ...

Page 53: ...e clutch sleeve hub and primary driven gear assembly Conrod holder 09910 20115 PRIMARY DRIVE GEAR With the magneto rotor held immovable using special tool remove the primary drive gear nut CAUTION This bolt has left hand thread If turning it counter clockwise it may cause damage Pay attention at the primary drive gear with two washer ...

Page 54: ... Draw out the gearshift shaft With the cam guide screws loosened draw out the guide and lifter Remove the cam driven gear With the neutral cam stopper plug loosened remove the washer spring stopper CAUTION Pay attention to not lost the gearshift pawl pin spring with the cam driven gear removal ...

Page 55: ...Remove the crankcase securing bolts Separate the crankcase into 2 parts right and left with a special tool Crankcase separator 09920 13120 CAUTION When separating the crankcase necessarily remove it after installed the special tool Crankcase separator on the side of clutch In case separate oppositely the gearshift cam stop per will be damaged in the side of magneto NOTE Fit the crankcase separater...

Page 56: ... with a new one VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend Place the valve on V blocks and measure runout If the service limit is exceeded or abnormal condition exists replace the valve Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 CYLINDER HEAD DISTORTION Decarbonate in combustion chamber Check the gasketed surface of the cylinder head for dis tortion...

Page 57: ...on or scratch is present replace the tap pet The shim has various size Replace the thin shim to valve clearance is narrow or the thick shim to valve clearance is wide as that shim thickness was installed with standard at present Refer to page 7 33 34 SHIM KIND There are 41 kinds of shim which thickness is increased by each 0 025 mm from 1 20 mm to 2 20 mm CAMSHAFT WEAR Worn down cams are often the...

Page 58: ...ter measured exceeds the standard replace the valve VALVE GUIDE VALVE STEM CLEAR ANCE Measure the clearance in the valve guide valve stem by rigging up the dial gauge as shown If the clearance is measured exceeds the limit specified below then determine whether the valve or the guide should be replaced to reduce the clearance to within the standard range VALVE SPRING The force of the coil spring k...

Page 59: ...ck that the push rod slides smoothly with the lock shaft handle clockwise If it does not slide smoothly replace the cam chain ten sion adjuster with a new one Thickness gauge 09900 20806 Cylinder gauge set 09900 20508 CYLINDER BORE Measure the cylinder bore diameter at six place If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replac...

Page 60: ...der clearance calculate the difference between the cylinder bore and outside diameter of the piston CAM CHAIN AND CAM CHAIN GUIDE Check the cam chain for wear damage and kinked or bind ing links If any defects are found replace it with a new one Check the cam chain guide for wear and damage If it is found to be damaged replace it with a new one Micrometer 50 75 mm 09900 20203 Micrometer 25 50 mm 0...

Page 61: ...ce the pin Piston pin hole bore Service limit 15 030mm 0 5917in 13 030mm 0 513in Piston pin diameter Service limit 14 980 mm 0 5898 in 13 980 mm 0 550 in Piston ring free end gap Standard 7 2mm 0 284in 5 8mm 0 228in 5 0mm 0 197in 6 0mm 0 236in 1st 2nd Piston ring free end gap Service limit 5 7mm 0 224in 4 6mm 0 181in 4 0mm 0 158in 4 8mm 0 189in 1st 2nd Dial calipers 09900 20605 PISTON PIN HOLE BOR...

Page 62: ...g The following two types of oversize oil ring are used They bear the following identification marks Color classification Painted red Painted yellow Oversize oil ring 0 5 mm 1 0 mm 2nd 05 10 1st 05 10 Oversize piston ring 0 5 mm 1 0 mm OVERSIZE RINGS Oversize piston ring The following two types of oversize piston ring are used They bear the following identification numbers Standard 0 970 0 990 mm ...

Page 63: ... check the extent of wear on the parts of the conrod s big end CONROD BIG END SIDE CLEARANCE INSPECTION Using a thickness gauge measure the side clearance at the conrod big end If the measurement is out of stan dard value measure the conrod big end and the crank pin widths individually to determine which one is to be replaced Standard 0 40 0 85 mm 0 016 0 034 in Service limit 1 0 mm 0 040 in Conro...

Page 64: ...e starter driven gear should turn smoothly If excessive resistance is felt while turn ing the starter driven gear inspect the starter clutch Also inspect the surface of the starter driven gear which contacts the starter clutch for wear or dam age If any wear or damage is found replace the defective parts DISASSEMBLY Hold the magneto rotor with the rotor holder and remove the starter clutch bolts R...

Page 65: ...the starter driven gear bushing and gear onto the crankshaft and turn the starter driven gear by hand Inspect the starter driven gear bushing for smooth rotation and any abnormal noise If the bushing does not turn smoothly or there is any abnor mal noise replace it Bearing remover 20 35 mm 09923 74510 DISASSEMBLY Remove the bushing using the special tool Oil seal remover 09913 50121 CLUTCH COVER O...

Page 66: ...rvice limit replace the clutch plates as a set Standard 11 8 12 0 mm 0 465 0 472 in Clutch drive plate claw width Service limit 11 0 mm 0 433 in Clutch drive plate claw width Standard 2 9 3 1 mm 0 114 0 122 in Clutch drive plate thickness Service limit 2 6 mm 0 102 in Clutch drive plate thickness Vernier calipers 09900 20101 CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch dr...

Page 67: ...the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing PRIMARY DRIVEN GEAR Inspect the primary driven gear bearing for any damage If any abnormal condition are found replace the primary driven gear OIL PUMP Turn the oil pump shaft and check that rotation is smooth If any abnormal condition is...

Page 68: ...ting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 5 mm 0 020 in Standard 0 10 0 30 mm 0 004 0 012 in Thickness gauge 09900 20806 Vernier calipers 09900 20101 Shift fork groove clearance Shift fork groove width Standard 5 0 5 1 mm 0 197 0 201 in 5 5 5 6 mm 0 217 0 221 in Shift fork thickness Standard 4 8 4 9 mm 0 189 0 1...

Page 69: ...acers 1 0mm 1 0mm 1 2mm 1 0mm 0 5mm CAUTION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely f...

Page 70: ...er to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing in the following procedure if there is anything unusual play play Thickness for washers circlips and spacers 1 2mm 6 0mm 0 5mm 1 0mm 1 0mm 3 33 ENGINE ...

Page 71: ...r 17 mm 09923 73210 Bearing remover 20 35 mm 09923 74510 Bearing installer 09913 76010 Remove the bearing Remove the bearings and Oil seal remover 09913 50121 LEFT CRANKCASE BEARING Remove the oil seals and CAUTION The removed bearing should be replace with a new one ENGINE 3 34 ...

Page 72: ...35 mm 09923 74510 Remove the bearings and Bearing installer 09913 70122 Bearing installer 09913 76010 REASSEMBLY RIGHT CRANKCASE BEARING Drive in the bearings and Bearing installer 09913 70122 Bearing installer 09913 76010 LEFT CRANKCASE BEARING Drive in the bearings and 3 35 ENGINE ...

Page 73: ...ine reassembly can be performed in the reverse order of disassembly procedures However the follow ing points must be observed in the reassembly opera tion TRANSMISSION Install the transmission CAUTION Make sure to coat the rotating and sliding sec tions with engine oil CAUTION Never fit the crankshaft into crankcase by strik ing it with a plastic hammer Always use the special tool otherwise cranks...

Page 74: ... pins Before assembling the crankcase apply the engine oil to each gear and bearing BOND 1215 Apply BOND 1215 to the right crankcase Install the crankcase Install the crankcase bolts Crankcase bolt 8 12 N m 0 8 1 2 kg m CAUTION Application of BOND 1215 must be per formed within a short period of time Take extreme care not to let BOND 1215 enter into the oil hole or bearing 3 37 ENGINE ...

Page 75: ...shift into the cam driven gear the big shoulder face toward outside as shown in figure Install the cam guide and pawl lifter When installed apply the THREAD LOCK 1324 to the securing screw NOTE After the crankcase bolts have been tight ened make sure that the crankshaft counter shaft and driveshaft rotate smoothly If these shafts do not rotate smoothly try to free it by tapping with a plastic hamm...

Page 76: ...324 to the oil pump securing screws Tighten the oil pump securing screws Install the oil pump pin THREAD LOCK 1324 Put in the oil pump driven gear and install the circlip CAUTION After the cam driven gear cam guide gear shift shaft and neutral cam stopper have been fitted confirm that gear change is normal while turning the countshaft and driveshaft If gear change is not obtained it means that ass...

Page 77: ...stall the primary drive gear and NO 2 gear to the crankshaft put in the key to the key groove Align the key groove and mark No 2 Gear CAUTION When installing the oil pump to the crankcase turn the pump gear and check that rotation is smooth by the hand CAUTION When installing the NO 2 gear install so that the mark on the gear align the key groove as shown in figure ENGINE 3 40 ...

Page 78: ... gear nut 40 60 N m 4 0 6 0 kg m CLUTCH Install the clutch sleeve hub lock washer CAUTION Pay attention to the two washer to lower end of the primary drive gear nut in times of assemblage NOTE Valve clearance should be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke 3 41 ENGINE ...

Page 79: ... nut and tighten it to the specified torque using the special tool Install the clutch drive plates and driven plates Clutch sleeve hub holder 09920 53710 Clutch sleeve hub nut 30 50 N m 3 0 5 0 kg m Install the clutch release rack bearing and washer ENGINE 3 42 ...

Page 80: ...en the clutch cover bolts securely Install the clutch release arm as following Turn the clutch release shaft toward This time mark on the shaft align outside contact line the stopper screw the right Install that the cable connecting center line of the clutch release arm align matching mark rightside of the case as shown in the right figure Crankcase matching mark Clutch release arm Clutch release ...

Page 81: ... installing the starter clutch and rotor apply the THREAD LOCK 1324 to the bolts and tighten to the specified torque Engine oil drain plug 18 20 N m 1 8 2 0 kg m OIL DRAIN PLUG Tighten the oil drain plug to the specified torque Starter clutch bolt 15 20 N m 1 5 2 0 kg m THREAD LOCK 1324 MAGNETO ROTOR Fit the key in the key slot on the crankshaft With the magneto rotor install the starter clutch on...

Page 82: ...EAR AND MOTOR Install the starter idle gear shaft and spacer Install the starter motor Conrod holder 09910 20115 Magneto rotor nut 50 60 N m 5 0 6 0 kg m MAGNETO COVER Install the new gasket and dowel pin Apply oil to the each gear bearing and starter clutch 3 45 ENGINE ...

Page 83: ...n the mark on the piston head to exhaust side After the piston pin has been inserted through the conrod install the circlip MOLY PASTE Front tire side Exhaust pipe installation side Rear tire side Exhaust pipe installation side Front piston Rear piston CAUTION Be careful not to cause scratch on the piston when inserting the piston ring to the piston Also do not expand the piston ring more than nec...

Page 84: ...n and the piston rings Coat the cylinder wall with oil Install the cylinder This cylinder is different from the front and rear With the cam chain groove of cylinder face the left side it is the front cylinder when the cam chain tension adjuster be existed at the back Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 Valve spring compressor attachment 09916H5100 Hea...

Page 85: ...1 5 2 0 kg m Install the tappet and shim Fit the chain guide Fit the C ring Tappet Shim Front Cylinder Rear Cylinder CAUTION With fit the tappet it should be replaced if turn not smoothly by the hand CAUTION The tappet and shim should be installed at the original position when removed If otherwise it is difficult to adjust the valve clear ance ENGINE 3 48 ...

Page 86: ...rings With pull up the camshaft drive chain align the F mark of magneto rotor into the punching mark of mag neto cover to turn the crankshaft Front cylinder The front cylinder head install first the exhaust camshaft following the intake camshaft The rear cylinder head install first the intake as the cam chain tension adjuster exist exhaust side CAUTION If turn the crankshaft without pulling up the...

Page 87: ... Exhaust Notch mark Notch mark Intake The notch mark of exhaust camshaft should be aligned with the plane of cylinder head At that time the 2 arrow of exhaust camshaft sprock et should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into camchain The notch mark of intake camshaft should be toward the outside and aligned with the plane of cylinder h...

Page 88: ...ont cylinder CAUTION The cam chain is installed to the all of three sprocket Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely NOTE The camshaft housing should be installed in the same manner with the front engine 3 51 ENGINE ...

Page 89: ... is punched also to the cylinder head upper surface Fix the four camshaft bearing holder and cam chain guide by tightening of the bolt in order Install each bolt diagonally by using the wrench pulling the shaft down Tighten the bolt of each camshaft bearing holder with the same torque CAUTION If get damaged the head or surface of camshaft bearing housing thrust produce an result that the bearing h...

Page 90: ...bout 10 times counter clock wise on the basis of the magneto rotor If the valve clearance is within standard after measured the valve clearance begin the next operation If it is out of stanadard adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim Adjust the valve clearance of rear cylinder with the same manner of the front cylinder Refer to...

Page 91: ...nder head and cylinder with the same manner which installed the front cylinder head and cylinder SUPER GREASE A GEAR POSITION SWITCH Install the spring and contact Apply SUPER GREASE A to the O ring and install the gear postion switch Front Cylinder Rear Cylinder ENGINE 3 54 ...

Page 92: ...CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks FUEL SYSTEM FUEL TANK FUEL COCK 4 1 FUEL PUMP 4 2 CARBURETOR 4 4 CONTENTS 4 ...

Page 93: ...he front seat Refer to page 6 1 Remove the fuel tank mounting bolt and take off the hooks Disconnect the fuel hose and remove the fuel tank Remove the fuel cock WARNING Gasoline is very explosive Extreme care must be taken 4 1 FUEL SYSTEM ...

Page 94: ...r Tighten the fuel pump mounting bolts Connect the fuel hoses securely FUEL HOSE ROUTING Fuel hose To fuel cock Fuel hose To carburetor FUEL PUMP RELAY Remove the fuel pump relay mounting bolts and cou pler Disconnect the fuel hose and check the fuel flow when starting the engine for few seconds by pressing the starter switch If the fuel pump are not fault check the fuel pump relay Refer to page 5...

Page 95: ... replace the fuel pump INSPECTION REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly Tighten the fuel pump mounting bolts Connect the fuel hoses and vacuum hose securely FUEL HOSE ROUTING Fuel hose To fuel cock Fuel hose To carburetor Vacuum hose To intake pipe FUEL PUMP REMOVAL Remove the front seat and fuel tank Turn the fuel cock to OFF Disconnect the fuel hoses and...

Page 96: ...CARBURETOR FUEL SYSTEM 4 4 ...

Page 97: ...s shown in the right photo REMOVAL Remove the fuel tank Refer to page 4 1 Remove the fuel hose Remove the throttle cables and choke cable Loosen the clamp screw and remove the carburetor DISASSEMBLY Remove the diaphragm cover Remove the spring and piston valve along with diaphragm 4 5 FUEL SYSTEM ...

Page 98: ... cap spring retainer and jet needle Remove the float chamber body Remove the float assembly along with the needle valve by removing the pin Remove the valve seat Remove the main jet jet holder and pilot jet FUEL SYSTEM 4 6 ...

Page 99: ...t outlet and bypass Needle jet holder Float Needle valve Jet needle Valve seat If any abnormal condition is found wash the part clean If damage or clogging is found replace the part with a new one Needle valve Check for stopped wear Foreign substance CLEANING Clean all jets by using compressed air After cleaning reassemble the carburetor with new seals and gaskets NOTE Record the number of turn fo...

Page 100: ... and install the float chamber to the carburetor body Install the eight screw Bend the float arm as necessary to bring the height to the specified level After adjustment check the float height and the fuel level again REASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly When reassembling carefully observe the following instructions After cleaning reinstall the pilo...

Page 101: ... 2 7 Install the jet needle with the pin on the spacer securely engaged with the hole on the piston valve Align the hole of the diaphragm with passage way on the carburetor body Install the eight screw CAUTION Never adjust CO adjust screw of the carbure tor If adjust at discretion have a bad influence upon output of the engine as the two carburetor is disharmonious 4 9 FUEL SYSTEM ...

Page 102: ...F ELECTRICAL COMPONENTS 5 1 IGNITION SYSTEM 5 3 CHARGING SYSTEM 5 7 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 5 11 SWITCHES 5 15 LAMP 5 16 BATTERY 5 18 FUEL SYSTEM 5 21 ELECTRICAL SYSTEM 5 CONTENTS ...

Page 103: ...Front brake lamp switch Rear brake lamp switch Side stand switch Starter motor Battery Turn signal relay Head lamp relay C D I Unit LOCATION OF ELECTRICAL COMPONENTS 5 1 ELECTRICAL SYSTEM ...

Page 104: ...Regulator Rectifier Ignition coil NO 1 NO 2 Magneto Gear position switch Fuse Fuel pump relay ELECTRICAL SYSTEM 5 2 ...

Page 105: ... tion system is composed a rotor with five rotor tip the D C CDI the ignition coil and battery This system ignites after get signal from ignition timing of pick up with the electric energy of this battery and occur the 1st electric current Therefore a high voltage current is induced in the secondary winding of the ignition coil and results in strong spark between spark plug gap Ignition coil Spark...

Page 106: ...pocket tester R 1 range measure the resistance between the terminal in the following table CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws ELECTRICAL SYSTEM 5 4 WIRE COLOR L Blue G Green BY Black with Yellow tracer OB Orange with Black tracer Br Brown BW Black with White tracer WL White with Blue tracer YG Yellow with...

Page 107: ...the spark plug Place it on the cylinder head after installing it at the plug cap to obtain ground Push in the electric starter switch to rotate the starter motor to have the test of sparking performance If not emited spark or the spark bring out the orange color replace the ignition coil CAUTION Numberical value may differ a little according to the tester Please remind that there may be a defect w...

Page 108: ... brush and pin Use the pin to remove carbon taking care not to damage the porce lain Check the gap with a thickness gauge Thickness gauge 09900 20806 Spark plug gap 0 7 0 8 mm 0 028 0 032 in 0 7 0 8 mm 0 028 0 032 in ELECTRICAL SYSTEM 5 6 ...

Page 109: ...r than the adjusted voltage of the regulator the regulator does not function incidentally the generated current charges the battery directly CHARGING SYSTEM The circuit of the charging system is indicated in figure which is composed of the AC generator regulator rec tifier unit and battery The AC current generated from the AC generator is converted by the rectifier and is turned into the DC curren...

Page 110: ...omes conductive to the direction from point to point Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again At the end of this state since the AC current generated from the AC generator flows into the point reverse current tends to flow to SCR then the circuit of SCR turns to OFF mode and begins to...

Page 111: ... the three lead wires from the magneto terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the tester reads under 67 V or over 99 V the magneto is faulty 14 0 15 0 V at 5 000 rpm Standard charge Regulator Rectifier DCV Battery IG switch Pocket tester 09900 25002 CAUTION When making this test be sure that the batt...

Page 112: ...lti tester 1 range measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the regu lator rectifier 0 8 2 0 8 2 0 8 2 30 55 0 8 2 0 8 2 0 8 2 0 8 2 0 8 2 0 8 2 30 55 0 8 2 0 8 2 0 8 2 Probe of tester Probe of tester Unit ...

Page 113: ...ts the motorcycle from being started with side stand down The system is operated by an electric circuit provided between the battery and ignition coil The circuit consists of the C D I unit neutral indicator light and switches The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whe ther the side stand is either up or down The gear position and ...

Page 114: ... you can only start the engine with pulling in clutch lever and side stand up 1 2 3 4 Possible Possible Impossible Impossible NOTE On or Up Off or Down ELECTRICAL SYSTEM 5 12 BATTERY CDI Unit IGNITION COIL IGNITION SWITCH ON IGNITION SWITCH ON NEUTRAL INDICATOR LIGHT NEUTRAL INDICATOR LIGHT GEAR POSITION SWITCH ON GEAR POSITION SWITCH OFF SIDE STAND SWITCH DOWN POSITION BATTERY CDI Unit IGNITION C...

Page 115: ...he armature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 25002 Segment STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire With loosen the bolt remove the starter motor Disassemble the starter motor STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brus...

Page 116: ...g end SUPER GREASE A Apply SUPER GREASE A to the O ring and remount the starter motor STARTER MOTOR REASSEMBLY Reassemble the starter motor Pay attention to the following points Reassembly the starter motor as shown in the illustration ELECTRICAL SYSTEM 5 14 ...

Page 117: ... replace the respective switch assemblies with new ones 5 15 ELECTRICAL SYSTEM R O BW BR ON OFF LOCK IGNITION SWITCH G BW ON OFF HORN SWITCH O WB ON OFF FRONT REAR BRAKE LAMP SWITCH OB YG ON OFF STARTER SWITCH O Gr LIGHT SWITCH YW HI LO Y W DIMMER SWITCH Lg L PUSH R Sb B TURN SIGNAL SWITCH O OB ENGINE STOP SWITCH ...

Page 118: ...LAMP HEADLAMP TURN SIGNAL LAMP TAIL BRAKE LAMP Front Rear ELECTRICAL SYSTEM 5 16 ...

Page 119: ...tion INSPECTION Using the pocket tester check the continuity between lead wires in the following illustration If the continuity measured incorrect replace the respec tive part Pocket tester 09900 25002 CAUTION When making this test it is not necessary to remove the combination meter 5 17 ELECTRICAL SYSTEM ...

Page 120: ...of water When it be stained clothes should come into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was dropped to the surface of land wash a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the battery electrolyte filler hole untill use as...

Page 121: ...t it does not fall Take precaution not to allow any fluid to spill Confirmation of pour Make sure that air bubbles are coming up each electrolyte container and keep this position for more than about 20 minutes CAUTION The pouring of electrolyte may not be done if the electrolyte container is pushed slopely CAUTION If no air bubbles are coming up from a filler port tap the buttom of the two or thre...

Page 122: ... coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper RECHARGING OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than the 12 0V DC recharge the battery with a battery charger How to charge Standard Fast 1 4 A 10 hours 6 A 30 minutes After recharging wait for more than 30 minutes and check the battery voltage w...

Page 123: ...resistance checked is incorrect replace the fuel pump FUEL PUMP RELAY Remove the fuel pump relay coupler Using the pocket tester X 1 range measure the resistance between the terminals in the following table If the resistance checked is incorrect replace the fuel pump relay Fuel pump resistance 4 5 10 0 BW BL Probe of tester 1 1 2 3 4 2 700 950 3 700 950 4 Pocket tester 09900 25002 Pocket tester 09...

Page 124: ...HASSIS EXTERIOR PARTS 6 1 FRONT WHEEL 6 2 FRONT BRAKE 6 6 HANDLEBARS 6 12 FRONT FORK 6 14 FRONT FORK 6 20 STEERING 6 27 REAR WHEEL 6 30 REAR BRAKE 6 34 REAR SHOCK ABSORBER 6 36 SWING ARM 6 37 CONTENTS 6 ...

Page 125: ... PARTS FRONT FENDER With the bolts removed remove the front fender REAR SEAT Remove the rear seat with the ignition key FRONT SEAT To remove the front seat pull the knob located under the rear seat 6 1 CHASSIS ...

Page 126: ...nch bolt right and left Loosen the front axle Raise the front wheel off the ground with a block or jack Remove the front wheel by removing the front axle CAUTION When using a jack take care not to cause scratches on the chassis CHASSIS 6 2 ...

Page 127: ... due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the wheel WHEEL BEARING Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnormal noise and smooth rotation Replace the bearing in the following procedure if there is anything unusual Dial gauge 09900 2...

Page 128: ...CK 1324 to the disc mounting bolts and tighten them to the specified torque Wheel bearing remover 09941 50111 SUPER GREASE A Steering race installer 09941 34513 Install the wheel bearings as follows by using the special tools Brake disc bolt 18 28 N m 1 8 2 8 kg m WHEEL BEARING Apply SUPER GREASE A to the wheel bearings THREAD LOCK 1324 CAUTION The removed bearing should be replaced with new ones ...

Page 129: ...Tighten the front axle bolt and axle pinch bolt to the specified torque Front axle bolt 50 80 N m 5 0 8 0 kg m Front axle pinch bolt 15 25 N m 1 5 2 5 kg m 6 5 CHASSIS ...

Page 130: ...f time To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the system To wash the brake system parts use brake fluid and not any other material Do not allow dirt and fluid to contact the brake disc or pad CHASSIS 6 6 ...

Page 131: ...pad Refer to page 2 14 Remove the brake caliper holder CAUTION Do not allow brake fluid to contact the paint surface plastic or rubber parts or its chemical reaction can cause discoloration or crack CAUTION To prevent brake fluid from splashing on the parts nearby cover the parts with cloth WARNING Place a rag over the piston to prevent it from popping out and flying and keeping hand off the pisto...

Page 132: ...bly procedures and observe the following points Install the brake pad spring Brake fluid specification and classification DOT 3 or DOT 4 CAUTION Care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have been removed CAUTION Wash the caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid after washing the components Replace ...

Page 133: ...s 20 25 N m 2 0 2 5 kg m Measure the runout using the dial gauge Replace the brake disc if the runout exceeds the service limit If either measurement exceeds the service limit replace the brake disc Refer to page 6 3 Dial gauge 09900 20606 Magnetic stand 09900 20701 Brake disc thickness Service limit 3 0 mm 0 12 in Brake disc runout Service limit 0 3 mm 0 012 in Micrometer 0 25 mm 09900 20201 BRAK...

Page 134: ...he union bolt Remove the two clamp bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts Detach the dust seal boot and remove the circlip Pull out the piston cup set and spring CHASSIS 6 10 ...

Page 135: ...ter cylinder in the reverse order of disassembly Pay attention to the following points CAUTION Wash the master cylider components with new brake fluid before reassembly When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc NOTE When installing the circlip make sure that the sharp edge of the circlip faces ou...

Page 136: ...tches Remove the handlebar balancer and grip Remove the clutch lever holder Remove the clamp bolts and detach the handlebar holders Remove the handlebar REMOUNTING Perform the remounting work in the reverse order of the removal procedures while observing the following instructions Install the handlebars with the punch mark aligned with the handlebar clamp as shown Tighten the handlebar clamp bolts...

Page 137: ...e respective punch marks and tighten the bolt Install the brake master cylinder Refer to page 6 11 Apply SUPER GREASE A to the throttle cables and assemble them SUPER GREASE A NOTE The gap between the handlebar clamp and holder should be even 6 13 CHASSIS ...

Page 138: ...FRONT FORK CHASSIS 6 14 ...

Page 139: ...wheel See page 6 2 Remove the front fork cap O ring and seat lever Straighten the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes CAUTION To remove the O ring it will be necessary to push the seat lever inwards to remove the spring pressure from the O ring The removed O ring should be replaced with a new one 6 15 CHASSIS ...

Page 140: ...ench 6mm 09914 25811 Separate the inner tube from outer tube Remove oil lock piece and damper rod with rebound spring Remove the snap ring by using the snap ring plier Remove the oil seal by using the special tool CAUTION The oil seal removed should be replaced with a new one Oil seal remover 09913 50121 CHASSIS 6 16 ...

Page 141: ...sliding surfaces for any scuffing or flaws FORK SPRING Measure the fork spring free length If it is shorter than the service limit replace it Standard 433 3 mm 17 1 in Fork spring free length REASSEMBLY Reassemble and remount the front fork in the reverse order of disassembly and removal and also carry out the following steps 6 17 CHASSIS ...

Page 142: ...er tube by using the special tool as shown FORK OIL For the fork oil be sure to use a front fork oil whose viscosity rating meets specifications below Hold the front fork vertical and adjust the fork oil level with the special tool Front fork level gauge 09943 74111 Standard 146 mm 5 8 in Front fork oil level Each leg 400 2 5cc Fornt fork oil capacity CAUTION When adjusting oil level remove the fo...

Page 143: ...ecessary to push the spring seat inward REMOUNTING Tighten the upper and lower clamp bolts Up side CAUTION Always use a new stopper ring After installing a stopper ring always insure that it is completely seated in its groove and securely fitted Front fork upper clamp bolts 22 35 N m 2 2 3 5 kg m Front fork lower clamp bolts 22 35 N m 2 2 3 5 kg m 6 19 CHASSIS ...

Page 144: ...FRONT FORK CHASSIS 6 20 ...

Page 145: ...spacer and spring guide Invert the front fork and stroke it several times to drain out the fork oil Hold the front fork in the inverted position for a few minutes to allow the fork oil to fully drain CAUTION Secure the brake caliper to the frame with a string etc taking care not to bend the brake hose NOTE Slightly loosen the front fork upper bolt to facilitate later disassembly Remove the front f...

Page 146: ... and rebound spring from the inner tube Remove the dust seal and oil seal stopper ring Separate the inner tube from the outer tube Remove the following parts Oil seal Slide metal Oil lock piece CAUTION The removed oil seal and slide metal should be replaced with new ones CHASSIS 6 22 ...

Page 147: ...ONT FORK SPRING Measure the free length of the front fork spring If the length is found shorter than the service limit replace the spring Fork spring free length Service limit 354 mm 13 9 in CAUTION Thoroughly wash all the component parts being assembled Insufficient washing can result in oil leakage or premature wear of the parts When reassembling the front fork use new fork oil Use the specified...

Page 148: ...ork oil seal installer With the oil lock piece fitted to the inner tube assem ble the inner tube to the outer tube CAUTION Wash and clean the front fork oil seal installer before using If dirt is on the installer the inner tube may possibly be damaged during press fit ting work CAUTION Make sure that the stopper ring is securely fitted into the groove on the outer tube Fit the rebound spring on th...

Page 149: ...ition compress the inner tube all the way Front fork oil specification TELLUS 22 Front fork oil level gauge 09943 74111 Wait until the fluid level stabilizes measure and adjust the level to specification using the special tool Install the front fork spring Install the spring guide front fork inner spacer and O ring Front fork oil capacity Each leg 262 cc Front fork oil level Standard 155 mm 6 1 in...

Page 150: ... A Install the front fork to the motocycle Align the upper surface of the inner tube with the upper surface of the steering stem upper bracket Front fork upper clamp bolt 22 35 N m 2 2 3 5 kg m Front fork lower clamp bolt 22 35 N m 2 2 3 5 kg m Front fork upper bolt 22 30 N m 2 2 3 0 kg m Tighten the front fork lower clamp bolts and front fork upper bolts to the specified torque Tighten the front ...

Page 151: ...REMOVAL AND DISASSEMBLY Take off the front wheel See page 6 2 Remove the four bolts and front fender Take off the front fork See page 6 15 6 21 STEERING 6 27 CHASSIS ...

Page 152: ... nut and draw out the steering stem Take off the steering stem lower bracket Remove the upper and lower bearing CAUTION Hold the steering stem lower bracket by hand to prevent from falling Remove the outer race fitted on the steering stem This can be done with a chisel Draw out the two inner races fitted to the top and bot tem ends of the head pipe CHASSIS 6 28 ...

Page 153: ... adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly If play is noticeable re adjust the steering stem nut INSPECTION Inspect and check the removed parts for the following abnormalities Handlebar distortion Handlebar clamp wear Abnormality operation of bearing ...

Page 154: ...REAR WHEEL REMOVAL Raise the rear wheel off the ground with a jack or block Loosen the drive chain adjuster right and left Disengage the drive chain from the rear sprocket CHASSIS 6 30 ...

Page 155: ...RING REMOVAL Remove the bearing by using the special tool Remove the rear wheel shock absorber Remove the rear sprocket from the rear sprock et mounting drum NOTE Before separating the rear sprocket and mounting drum slightly loosen the rear sprocket bolts CAUTION The removed bearing should be replaced with new one Wheel bearing remover 09941 50111 6 31 CHASSIS ...

Page 156: ...llowing points Tighten the rear sprocket nuts to the specified torque Normal wear Excessive wear INSPECTION WHEEL AXLE Refer to page 6 3 WHEEL Refer to page 6 3 WHEEL BEARING Refer to page 6 3 TIRE Refer to page 2 18 REAR WHEEL SHOCK ABSORBER Inspect the rear wheel shock absorber for wear and damage Replace the rear wheel shock absorber if there is any thing unusual Rear sprocket nut 20 30 N m 2 0...

Page 157: ... nut to the specified torque Install the rear wheel After installing the drive chain to the rear sprocket adjust the drive chain Tighten both chain adjusting nuts securely Rear axle nut 90 140 N m 9 0 14 0 kg m 6 33 CHASSIS ...

Page 158: ... time To store brake fluid make sure to seal the container and keep it in a safe place to be out of reach of children When filling brake fluid take care not to allow water or dirt to enter the system To wash the brake system parts use brake fluid and not any other material Do not allow dirt and fluid to contact the brake disc or pad CHASSIS 6 34 ...

Page 159: ... to page 2 15 Brake pad replacement Refer to page 2 14 Disassembly of caliper Refer to page 6 7 Inspection of caliper Refer to page 6 8 Reassembly of caliper Refer to page 6 8 Inspection of brake disc Refer to page 6 9 6 35 CHASSIS ...

Page 160: ...place the rear shock absorber with a new one Shock absorber mounting nut upper 40 60 N m 4 0 6 0 kg m Shock absorber mounting nut lower 40 60 N m 4 0 6 0 kg m REMOUNTING Install the rear shock absorber and tighten the nuts to the specified torque REAR SHOCK ABSORBER CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable CHASSIS 6 36 ...

Page 161: ...SASSEMBLY Remove the rear wheel See page 6 30 Remove the rear shock absorber fitting nut and bolt See page 6 36 Remove the swing arm pivot nut Draw out the pivot shaft and take off the swing arm SWINGARM 6 37 CHASSIS ...

Page 162: ...he pivot shaft exceeds the service limit replace it with a new one Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 Swingarm pivot shaft runout Service limit 0 6 mm 0 024 in INSPECTION SWINGARM Inspect the swingarm for damage If any defects are found replace the swingarm with a new one CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace t...

Page 163: ...Pay attention to the following points Press the needle bearings into the swingarm pivot using the special tool Swingarm pivot nut 45 70 N m 4 5 7 0 kg m Install the rear wheel Refer to page 6 32 Install the rear shock absorber Refer to page 6 36 Adjust the following points Drive chain slack Refer to page 2 13 Install the swingarm and tighten the swingarm pivot nut to the specified torque 6 39 CHAS...

Page 164: ...VICING INFORMATION TROUBLESHOOTING 7 1 SPECIAL TOOLS 7 8 TIGHTENING TORQUE 7 11 SERVICE DATA 7 13 WIRE AND CABLE ROUTING 7 23 WIRE AND CABLE ROUTING 7 27 WIRING DIAGRAM 7 31 WIRING DIAGRAM 7 32 CONTENTS 7 ...

Page 165: ...ce Clean Clean or replace Replace Clean or replace Noisy engine Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down piston pin or piston pin bore 4 Piston rings or ring groove worn Noise seems to come from timing chain 1 Stretched c...

Page 166: ...ountershaft 2 Distorted or worn gearshift forks 3 Weakened stopper pawl spring on gearshift cam 4 Worn gearshift pawl Replace Replace Replace Replace Engine idles poorly 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Defective pick up coil 5 Spark plug gap too wide 6 Defective ignition coil resulting in weak sparking 7 Float chamber fuel level out of adjust...

Page 167: ... 2 Weakened valve springs 3 Valve timing out of adjustment 4 Worn piston ring or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Worn camshaft 8 Spark plug gap incorrect 9 Clogged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe Adjust Replace Adjust Replace Repair or replace Clean or replace...

Page 168: ... 3 Defective regulator rectifier 4 Not enough electrolyte in the battery 5 Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between the level lines Replace the battery Generator overcharges 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier poorly grounded Replace the battery R...

Page 169: ...trolyte 6 Battery is too old Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte specific gravity Replace the electrolyte recharge the battery and then adjust specific gravity Replace the battery ...

Page 170: ...ion too soft 1 Weakened springs 2 Not enough fork oil Replace Refill Front suspension too stiff 1 Fork oil too viscous 2 Too much fork oil Replace Drain excess oil Noisy front suspension 1 Not enough fork oil 2 Loosen nuts on suspension Refill Retighten Rear suspension too soft 1 Weakened springs 2 Rear suspension adjuster improperly set Replace Adjust Rear suspension too stiff 1 Rear suspension a...

Page 171: ...ueaking 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Loosen front wheel axle or rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return port of master cylinder Repair surface with sandpaper Modify pad fitting Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Leakage of brake fluid 1 Insufficient t...

Page 172: ...g end 09900 20606 Dial gauge Meassure oscillation of wheel with using magnetic stand 09900 20701 Magnetic stand With using dial gauge 09900 20806 Thickness gauge Measure clearance of piston ring 09900 21304 V block 09900 21109 Torque wrench With using magnetic stand Measure torque of tightening 09900 22301 Plastigauge Measure clearance of crankshaft thrust 09900 22401 Small bore gauge Measure insi...

Page 173: ... Bearing installer Used to install rear axle shaft oil seal 09913 76010 Bearing installer Used to drive crankshaft bearing in 09915 63310 Compression gauge adapter 09913 80112 Bearing installer Used with compression gauge Used to drive bearing in 09915 64510 Compression gauge Measure cylinder compression 09915 74510 Oil pressure gauge Measure oil pressure of 4 stroke engine Separate to crankcase U...

Page 174: ...to drive small bearing in 09923 74510 Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 09940 34561 Front fork assembling tool attachment D Used with T handle Used to with bearing remover or rotor remover 09930 30162 Rotor remover 09930 30164 Rotor remover Attached to the top of sliding shaft when removing rotor 09930 30102 Rotor remove sliding shaft Attached to th...

Page 175: ...ter bolt Camshaft sprocket bolt Crankcase bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Oil cooler union bolt M10 Oil cooler union bolt M12 Spark plug Neutral cam stopper plug 5 0 6 0 0 8 1 2 2 0 3 0 1 8 2 8 1 5 2 0 0 7 1 1 1 2 1 6 2 1 2 5 0 7 1 1 1 5 2 0 8 0 10 0 1 8 2 0 4 0 6 0 1 0 1 3 0 6 0 8 0 8 1 2 1 0 1 2 0 8 1 2 3 0 5 0 4 0 6 0 0 8 1 2 2 0 2 5 2 0 2 5 2 0 2 5 2 0 2...

Page 176: ... and Rear brake caliper mounting bolt Front and Rear brake hose union bolt Front axle bolt Front axle pinch bolt Front fork damper rod bolt Front fork upper clamp bolt Front fork upper bolt Front fork lower clamp bolt Front footrest bolt Handlebar clamp bolt 4 0 6 0 4 0 6 0 2 0 3 0 9 0 14 0 4 5 7 0 8 0 10 0 8 0 10 0 1 8 2 8 0 5 0 8 1 8 2 8 0 6 0 9 1 8 2 8 2 0 2 5 5 0 8 0 1 5 2 5 3 0 4 0 2 2 3 5 2 ...

Page 177: ... 12 1 13 9kgf 26 7 30 6 lbs at length 33 7mm 1 33 in 0 9 1 1 0 035 0 043 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 37 80 1 488 37 80 1 488 VALVE GUIDE Unit mm in Valve diam Valve clearance When cold Valve guide to valve stem clearance Valve stem deflection Valve guide I D Valve stem O D Valve stem runout Valve head thickness...

Page 178: ...12 0 0022 4 000 4 012 0 1575 0 1580 3 975 3 990 0 1565 0 1571 3 955 3 970 0 1557 0 1563 45 30 kgf 66 1 lbs at length 27 95mm 1 10 in 30 kgf 66 1 lbs at length 27 95mm 1 10 in 0 9 1 1 0 035 0 043 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX 0 35 0 014 0 05 0 002 0 50 0 02 0 03 0 0012 37 64 1 482 37 64 1 482 VALVE GUIDE Unit mm in Valve diam Valve clearance When cold Valve...

Page 179: ...2 0 284 5 8 0 228 0 20 0 32 0 008 0 013 0 20 0 32 0 008 0 013 1 01 1 03 0 040 0 041 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 0 970 0 990 0 0382 0 0390 0 970 0 990 0 0382 0 0390 1st 2nd 1st 2nd 1st 2nd 1st 2nd Oil 1st 2nd CYLINDER PISTON PISTON RING Unit mm in Compression pressure Piston to cylinder clearance Cylinder bore Piston diam Cylinder or cylinder head distortion Piston ring free end gap...

Page 180: ... 0 03 0 04 0 0012 0 0016 44 000 44 015 1 7323 1 7329 43 965 43 980 1 7309 1 7315 Measure at 11mm 0 4 in from the skirt end 8 9 9 1 0 350 0 358 10 kg cm2 0 1 0 0040 44 080 1 7354 43 890 1 7280 0 05 0 002 4 0 0 158 4 8 0 189 0 5 0 020 0 5 0 020 0 180 0 007 0 150 0 006 13 030 0 513 13 980 0 550 5 0 0 197 6 0 0 236 0 10 0 25 0 004 0 010 0 25 0 40 0 010 0 016 1 01 1 03 0 040 0 041 1 01 1 03 0 040 0 041...

Page 181: ... 65 3 000 rpm 70 20 14 20 2 45 ITEM STANDARD NOTE OIL PUMP ITEM STANDARD LIMIT Clutch cable play Drive plate thickness Drive plate claw width Driven plate distortion Clutch spring free length Clutch spring free length 2 6 0 102 11 0 0 433 0 1 0 004 36 2 1 43 29 5 1 16 CLUTCH Unit mm in 4 0 16 2 9 3 1 0 114 0 122 11 8 12 0 0 465 0 472 38 2 1 50 7 17 SERVICING INFORMATION ...

Page 182: ... 4th 5th Type Links 20 pitch length NO 1 NO 2 NO 3 NO 1 NO 2 NO 3 0 10 0 30 0 004 0 012 Primary reduction ratio Secondary reduction ratio Gear ratio Shift fork to groove clearance Shift fork groove width Shift fork thickness Drive chain Drive chain slack 3 000 70 20 3 714 52 14 5 0 5 1 0 197 0 201 5 5 5 6 0 217 0 221 4 8 4 9 0 189 0 193 5 3 5 4 0 209 0 213 20 30 0 79 1 18 0 5 0 020 256 5 10 10 ITE...

Page 183: ... ITEM SPECIFICATION CARBURETOR Unit mm in 1 0 9 2 0 9 3 0 8 4 0 8 1 0 9 2 0 9 3 0 8 4 0 8 Carburetor type Bore size Idle r p m Float height Throttle cable play Main jet M J Main air jet M A J Jet needle J N Needle jet N J Pilot jet P J Throttle valve TH V By pass B P Valve seat V S Starter jet G S Pilot outlet P O PV Stroke P V MIKUNI BDS26 TYPE DOUBLE 26 1 450 1 550 r p m 17 0 67 0 5 1 0 0 02 0 0...

Page 184: ...oil Charging coil G L Y Y Type Gap Hot type Standard type Cold type ITEM STANDARD 15 2 000rpm 30 6 000rpm 15A 67 99V 5 000 rpm 14 15V 5 000 rpm NOTE ELECTRICAL Unit mm in Head lamp Head lamp License lamp Brake Tail lamp Turn signal lamp Speedometer lamp Neutral indicator lamp Turn signal indicator lamp Right left High beam indicator lamp 5W 21 5W 10W 1 7W 3 1 7W 1 7W 2 1 7W 60W 55W 35W 35W ITEM SP...

Page 185: ... in Front fork stroke Front fork spring free length Front fork oil type Front fork oil level Front fork oil capacity each leg Rear wheel travel Swingarm pivot shaft runout Rear shock absorber pre load position Rear shock absorber spring length 354 13 9 0 6 0 024 175 6 89 120 4 72 361 14 2 TELLUS 22 155 6 1 262cc 110 4 33 2 5 position 179 2 7 07 ITEM STANDARD LIMIT SUSPENSION Unit mm in 7 21 SERVIC...

Page 186: ...ound 3 0 0 12 3 0 0 12 0 3 0 012 2 0 0 08 2 0 0 08 0 25 0 01 0 25 0 01 1 6 0 06 1 6 0 06 Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Axial Radial Front Rear Front Rear Front Rear ITEM STANDARD LIMIT BRAKE WHEEL Unit mm in NOTE Fuel type Fuel tank capacity Engine oil type Engine oil capacity Engine oil capacity 17 3 Gasoline used should be graded 85 95 octane or higher An unle...

Page 187: ... LAMP RELAY TURN SIGLAL RELAY 09407 22402 HARNESS 45280 35000 CABLE COMP SEAT LOCK C D I UNIT REGULATOR BATTERY MINUS ASSEMBLY POINT DIODE 09407 22402 HARNESS 09407 14408 HARNESS HANDLE S W R L HANDLE S W LH CLUTCH LEVER S W 58410HM8102 CABLE COMP STARTER 58200HM8101 CABLE ASS Y CLUTCH 09407 22402 HARNESS FUSE BOX 09407 22402 HARNESS HANDLE S W RH WIRE AND CABLE ROUTING 7 23 SERVICING INFORMATION ...

Page 188: ...OX 09407 14408 HARNESS 09407 14408 HARNESS HEAD LAMP RELAY TURNSIGNAL RELAY C D I UNTT ASSEMBLY POINT L WIRE FUEL GAUGE DIODE 09407 14408 HARNESS Ft IGNITION HANDLE SWITCH LH OIL COOLER HOSE LH 09407 14403 HANDLE SWITCH RH SWITCH CLUTCH LEVER LH 09407 14408 HARNESS HANDLE SWITCH R L CLUTCH LEVER SWITCH 34910HM8101 CABLE SPEED WELDING CLAMP HORN COVER HORN 5948HM8102 HOSE FRONT BRAKE L WIRE STEERIN...

Page 189: ...RH HARNESS 59266HM8100 CLAMP BRAKE HOSE SPEEDOMETER CABLE 59480HM8102 HOSE COMP FRONT BRAKE 58410HM 8102 CABLE COMP SPEEDOMETER HANDLE S W LH CLUTCH LEVER S W FRONT IGNITION COIL VIEW A 7 25 SERVICING INFORMATION ...

Page 190: ...4 CLUTCH CABLE 58200HM8101 CABLE ASS Y CLUTCH 58410HM8102 CABLE COMP STARTER 58300HM8102 CABLE ASS Y THROTTLE REAR BRAKE REAR BRAKE S W 09404 06401 L WIRE STARTER MOTOR 09404 06401 L WIRE STARTER MOTOR 09404 06401 L WIRE STARTER MOTOR WELDING CLAMP OIL COOLER HOSE RH STARTER MOTOR SERVICING INFORMATION 7 26 ...

Page 191: ...ER RELAY TURN SIGLAL REALY 09407 14408 HARNESS 45280 35000 CABLE COMP SEAT LOCK C D I UNIT REGULATOR BATTERY MINUS ASSEMBLY POINT DIODE 09407 14408 HARNESS 09407 14408 HARNESS HANDLE S W R L HANDLE S W LH CLUTCH LEVER S W 58410HM8102 CABLE COMP STARTER 58200HM8101 CABLE ASS Y CLUTCH 09407 14408 HARNESS FUSE BOX 09407 14408 HARNESS HANDLE S W RH WIRE AND CABLE ROUTING 7 27 SERVICING INFORMATION ...

Page 192: ...408 HARNESS FUSE BOX 09407 14408 HARESS 09407 14408 HARNESS TURNSIGNAL RELAY C D I UNTT ASSEMBLY POINT L WIRE FUEL GAUGE DIODE 09407 14408 HARNESS Ft IGNITION HANDLE SWITCH LH 09407 14403 HANDLE SWITCH RH SWITCH CLUTCH LEVER LH 09407 14408 HARNESS HANDLE SWITCH R L CLUTCH LEVER SWITCH 34910HM8101 CABLE SPEED WELDING CLAMP HORN COVER HORN 5948HM8102 HOSE FRONT BRAKE L WIRE STEERING LOCK WELDING CLA...

Page 193: ...RH HARNESS 59266HM8100 CLAMP BRAKE HOSE SPEEDOMTTER CABLE 59480HM8102 HOSE COMP FRONT BRAKE 58410HM 8102 CABLE COMP SPEEDOMETER HANDLE S W LH CLUTCH LEVER S W FRONT IGNITION COIL VIEW B 7 29 SERVICING INFORMATION ...

Page 194: ...4 CLUTCH CABLE 58200HM8101 CABLE ASS Y CLUTCH 58410HM8102 CABLE COMP STARTER 58300HM8102 CABLE ASS Y THROTTLE REAR BRAKE REAR BRAKE S W 09404 06401 L WIRE STARTER MOTOR 09404 06401 L WIRE STARTER MOTOR 09404 06401 L WIRE STARTER MOTOR WELDING CLAMP OIL COOLER HOSE RH STARTER MOTOR SERVICING INFORMATION 7 30 ...

Page 195: ...E STAND S W DIODE NEUTRAL S W MAGNETO IGNITION S W HANDLE SWITCH LH Rr TURN LH Ft POSITION HEAD LAMP Ft TURN RH WIRE COLOR B Black Lg Light green Y Yellow RB Red with Black tracer Br Brown O Orange BG Black with Green tracer RW Red with White tracer G Green R Red BW Black with White tracer WB White with Black tracer Gr Gray Sb Light blue BR Black with Red tracer WR White with Red tracer L Blue W W...

Page 196: ...ODE NEUTRAL S W MAGNETO IGNITION S W HANDLE SWITCH LH Rr TURN LH HEAD LAMP POSITION LAMP Ft TURN RH WIRE COLOR B Black Lg Light green Y Yellow RB Red with Black tracer Br Brown O Orange BG Black with Green tracer RW Red with White tracer G Green R Red BW Black with White tracer WB White with Black tracer Gr Gray Sb Light blue BR Black with Red tracer WR White with Red tracer L Blue W White LW Blue...

Page 197: ...0 1 35 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 40 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 45 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 50 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 2...

Page 198: ... 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 55 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 60 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 65 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 70 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 75 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20 1 80 1 85 1 90 1 95 2 00 2 05 2 10 2 15 2 20...

Page 199: ...Prepared by HYOSUNG MOTORS MACHINERY INC Overseas Technical Department 1st Ed NOV 2002 Manual No 99000 94710 Printed in Korea ...

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