HYOSUNG TE450 - Service Manual Download | Manualshive

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1-3 GENERAL INFORMATION

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the frame pipe.
The engine serial number is stamped on the left downside of the crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.

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FRAME SERIAL NUMBER

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ENGINE SERIAL NUMBER

COPYRIGHTED

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Summary of Contents for TE450 -

Page 1: ...SERVICE MANUAL SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC 99000HP8910 ...

Page 2: ...l will help you know the vehicle better so that you can assure your customers of your optimum and quick service WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer This man...

Page 3: ...is listed on the previous page as GROUP INDEX select the section where you are looking 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 C O P Y R I G H T E D ...

Page 4: ...e fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Use engine coolant 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 Use fork oil DEFINITION SYMBOL DEFINITION SYMBOL Apply SUPER GREASE C C O P Y R I G ...

Page 5: ...NOTE Difference between photographs and actual vehicles depends on the markets C O P Y R I G H T E D ...

Page 6: ...NFORMATION LABELS 1 1 GENERAL PRECAUTIONS 1 2 SERIAL NUMBER LOCATION 1 3 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS 1 4 BREAK IN PROCEDURES 1 6 EXTERIOR ILLUSTRATION 1 7 SPECIFICATIONS 1 8 CONTENTS 1 C O P Y R I G H T E D ...

Page 7: ...ervice operation ask a more experienced mechanic for advice WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words CAUTION Indicates a potential hazard that could result in vehicle damage WARNING...

Page 8: ...the battery disconnect the battery lead wire first and then the battery lead wire When reconnecting the battery connect the battery lead wire first and then the battery lead wire Finally cover the battery terminal with the terminal cover When performing service to electrical parts if the service procedures do not require use of battery power diconnect the battery lead wire at the battery Tighten c...

Page 9: ...cation Number is stamped on the right side of the frame pipe The engine serial number is stamped on the left downside of the crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FRAME SERIAL NUMBER ENGINE SERIAL NUMBER C O P Y R I G H T E D ...

Page 10: ...NING Since the brake system of this vehicle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never re use brake fluid left over from a previous servicing which ...

Page 11: ...your area does not go down to freezing point Hyosung recommends the use of HYOSUNG COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AMOUNT OF WATER ENGINE COOLANT For engine coolant mixture information refer to cooling system section page 5 1 CAUTION Mixture of anti freeze engine coolant should be limited to 60 Mixin...

Page 12: ...anufacture 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 rules are as follows Keep to these break in...

Page 13: ...1 7 GENERAL INFORMATION 1 165mm HEIGHT 1 160mm WIDTH 1 810mm LENGTH 1 265mm WHEEL BASE 290mm EXTERIOR ILLUSTRATION C O P Y R I G H T E D ...

Page 14: ...4 in3 BDS42 TYPE Electric starter Wet sump Type Number of cylinder Bore Stroke Piston displacement Carburetor Starter system Lubrication system Wet multi plate type 5 forward and 1 reverse 1 down 4 up foot operated Foot hand operated 3 143 2 538 1 684 1 261 1 040 0 885 2 231 RK 520EXW 102 Links SPECIFICATIONS DIMENSIONS AND DRY MASS ENGINE TRANSMISSION Clutch Transmission Gearshift pattern Forward...

Page 15: ...ont brake Rear brake Front tire size Rear tire size I T E M I T E M I T E M Igniter type 6 B T D C at 1 500 rpm CR8E 12V 8Ah MF 15A HI 55W LO 55W POSITION 5W LED type 10W 4 LCD type 5W Ignition type Ignition timing Spark plug Battery Fuse Head lamp Brake Tail lamp Turn signal lamp Speedometer lamp License plate lamp Fuel tank Engine oil Oil change With filter change Overhaul Coolant 8 ℓ 2 500 2 60...

Page 16: ... HOSE 2 9 THROTTLE CABLE PLAY 2 9 ENGINE IDLE SPEED 2 9 ENGINE OIL AND OIL FILTER 2 10 ENGINE OIL HOSES 2 11 ENGINE COOLANT 2 12 RADIATOR HOSES 2 13 SPARK ARRESTER 2 13 CLUTCH 2 13 BRAKES 2 14 BRAKE FLUID 2 16 BRAKE HOSES 2 18 TIRES 2 18 STEERING 2 19 DRIVE CHAIN 2 20 SUSPENSIONS 2 23 CHASSIS BOLTS AND NUTS 2 23 COMPRESSION PRESSURE 2 24 OIL PRESSURE 2 25 CONTENTS 2 PERIODIC MAINTENANCE C O P Y R ...

Page 17: ... 2 years Tighten every time before riding CHASSIS 2 20 2 14 2 18 2 16 2 18 2 19 2 23 7 12 7 72 2 23 2 2 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy Clean Tighten Inspect Inspect Inspect Inspect CAUTION Using poor quality replacement parts can cause yo...

Page 18: ...ing shaft holder Throttle lever Front brake lever holder Rear brake pedal and rod link Drive shaft joint spline 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 vehicle has been operated under wet or rainy condition G G O G G G C O...

Page 19: ...r to page 7 3 Remove the air cleaner case cover Remove the air cleaner element Separate the polyurethane foam element ele ment frame and element trap stopper Fill a wash pan of a proper size with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Press the air cleaner element between the palms of both hands to remove the excess solvent do not twist...

Page 20: ...d If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or with torn ele ment Make sure that the air cleaner element is in good condition at all times Life of the engine depends largely on this component Inspect Interval Tighten Initially at 1 month and Every 3 months thereafter Exhaust ...

Page 21: ...arance results in valve damage and reduced power Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification if necessary VALVE CLEARANCE Remove the fuel tank Remove the spark plug Disconnect the oil tank overflow hose and breather hose Inspect Interval Inspect Initially at 1 month and Every 6 months thereafter C O P Y R I G H T E...

Page 22: ... insert a thickness gauge between the tappet and the camshaft 0 10 0 20 mm 0 004 0 008 in 0 20 0 30 mm 0 008 0 012 in IN EX Standard When cold Valve clearance NOTE The piston must be at top dead center TDC on the compression stroke in order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold Cap plug wrench 09910 36000 Thickness gauge 09900 208...

Page 23: ...0 mm of the shim add up the excess clearance 0 25 mm when adjust with the standard 0 15 as the intake standard clear ance 0 1 0 2 mm CAUTION If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning of valve clearance B D A C If the clearance is out of specification first remove the cam chain tension adjuster camshaft housing camshaft To install the...

Page 24: ...Hot type Standard type Cold type SPARK PLUG SPECIFICATION TYPE Inspect Interval Inspect Every 6 months Replace Every 18 months SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If the spark plug gap is out of specification adjust the gap ELECTRODE Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the spark plug with a new one And al...

Page 25: ... play as follows Loosen the lock nut of the throttle cable Turn the adjuster in or out to obtain the correct play ENGINE IDLE SPEED CAUTION To avoid damaging the cylinder head threads first finger tighten the spark plug and then tight en it to the specified torque using the spark plug wrench Inspect Interval Inspect Every 3 months Replace Every 4 years Inspect Interval Inspect Initially at 1 month...

Page 26: ... engine oil that meets the API ser vice classifications of over SL and that has a vis cosity rating of SAE 10W 40 Install the oil lever gauge Install the outer cover oil filler cap Start the engine and allow it to run for a few min utes at idling speed Turn off the engine and wait about three minutes and then check the oil level on the dipstick Remove the oil level gauge Wipe the oil from the oil ...

Page 27: ...filter with a new one Add new engine oil and check the oil level as described in the engine oil replacement proce dure ENGINE OIL HOSES CAUTION When reassembling the oil filter make sure that the oil filter is installed If the filter is installed improperly serious engine damage may result CAUTION Necessarily confirm and clean the oil strainer when replace the engine oil specially when first repla...

Page 28: ...m as follows 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 4 minutes to bleed air from the system 3 Stop the engine and add the engine coolant up to the radiator cap inlet neck 4 Repeat the above procedure until no air bleed from the radiator cap inlet Inspect Interval Replace Every 2 years NOTE For engine coolant information refer to ...

Page 29: ... tighten the lock nut and cover the rubber boot SPARK ARRESTER Inspect the radiator hoses for damage and engine coolant leakage If any damages are found replace the radiator hoses with new ones CAUTION Repeat the above procedure several times and make sure the radiator is filled with the engine coolant to the upper line of the engine coolant reservoir tank Engine coolant capacity including reserve...

Page 30: ...ock nut Turn the clutch cable adjuster in or out to pro vide the specified play After adjustment tighten the lock nut The clutch cable should be lubricated with a light weight oil whenever it is adjusted REAR BRAKE PEDAL The procedure for adjusting the rear brake pedal is as follows BRAKES 10 15 mm 0 4 0 6 in Clutch cable play Inspect Interval Inspect Initially at 1 month and Every 3 months therea...

Page 31: ...brake adjustment may be required if the parking brake does not work properly Every time the brake pads are replaced adjust the parking brake Park the ATV on level ground Check the front wheels Lift the rear end of the ATV and place a block under swingarm Loosen the parking brake adjuster lock nut Loosen the parking brake adjuster Loosen the parking brake cable adjuster lock nut Turn the adjuster s...

Page 32: ...ragging when turning the rear wheel with the wheel off the ground Inspect Interval Inspect Every 3 months Replace Every 2 years Specification and classification DOT 4 WARNING The brake system of this vehicle is filled with a glycol based brake fluid Do not use or mix dif ferent types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unseal...

Page 33: ...e Squeeze and release the brake lever or the brake pedal several times in rapid succession and squeeze the lever or push down the pedal fully without releasing it Loosen the air 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 or the brake pedal reaching bottom of ...

Page 34: ...ONT 0 3 kgf cm2 30 kPa 4 4 psi 0 35 kgf cm2 35 kPa 4 9 psi 0 35 kgf cm2 35 kPa 4 9 psi 0 3 kgf cm2 30 kPa 4 4 psi REAR ONE PERSON TWO PERSONS Inspect Interval Inspect Every 3 months BRAKE HOSES Check the brake hoses for leakage crack wear and damage If any damages are found replace the brake hoses with new ones Inspect Interval Inspect Every 6 months Replace Every 4 years CAUTION To minimize the p...

Page 35: ...pressure for right and left tires is the same and set to the proper specification Set the front wheels in the straight position Place a load of 75 kg 165 lbs on the seat Measure the distance and of the front wheels with a toe in gauge as shown and calcu late the difference between and If the toe in is out of specification bring it into the specified range Refer to page 7 40 Inspect Interval Inspec...

Page 36: ...G Place the vehicle on a level ground Loosen the two rear axle housing nuts and two rear axle housing wrench bolts Tense the drive chain fully by turning chain adjuster DRIVE CHAIN If any defects are found the drive chain must be replaced Damage to the drive chain means that the sprocket may also be damaged If any defects are found the sprocket must be replaced Inspect Interval Inspect drive chain...

Page 37: ...of slack at the middle of the chain between the engine and rear sprockets as shown After adjusting the drive chain tighten the rear axle housing nuts and wrench bolts in the described order to the specified torque Standard 30 40 mm 1 2 1 6 in Drive chain slack Service limit 319 4 mm 12 58 in Drive chain 20 pitch length Rear axle housing nut 70 100 N m 7 0 10 0 kgf m Rear axle housing wrench bolt 4...

Page 38: ... Use Hyosung chain lube or an equivalent that is specifically intended for use with O ring chains CAUTION Do not use trichloroethylene gasoline or any sim ilar solvent These fluids have too great a dissolv ing power for this chain and they can damage the O rings Use only kerosine to clean the drive chain CAUTION The drive chain for this vehicle is made of the special material The standard drive ch...

Page 39: ...t the suspension arm bearing and bushing for scratches wear or damage If any damages are found replace the suspension arm bearing or bushing with a new one Refer to page 7 24 25 Inspect the swingarm rear axle and bearing for scratches wear or damage If any damages are found replace them with a new one Refer to page 7 63 and 7 69 Inspect the front and rear shock absorbers for oil leakage or damage ...

Page 40: ... 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 mainte nance records kept at your dealership should include compression pressure reading for each maintenance service Standard Service limit 16 kg cm2 at 500 rpm 14 kg cm2 at 500 rpm Compression pressure NOTE Before testing the engine for comp...

Page 41: ...e as follows Summer 10 min at 2 000 rpm Winter 20 min at 2 000 rpm After warming up the engine increase the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge OIL PRESSURE Check the engine oil pressure periodically This will give a good indication of the condition of the moving parts If the oil pressure is lower or higher than the specification the following cause...

Page 42: ...ark an identification 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 assembl...

Page 43: ...e engine using a suitable cleaner Engine removal is sequentially explained in the fol lowing steps Drain engine coolant Refer to page 2 12 Remove the engine under cover CAUTION Do not lose the spacer with O ring behind the out let oil hose Drain engine oil Refer to page 2 10 Remove the gearshift lever Remove the engine oil outlet hose and inlet hose C O P Y R I G H T E D ...

Page 44: ... page 4 1 Disconnect the spark plug cap oil tank over flow hose and breather hose Remove the engine coolant inlet hose and dis connect the outlet hose Disconnect the breather hose and remove the oil return tank with hose C O P Y R I G H T E D ...

Page 45: ...3 3 ENGINE Remove the engine sprocket cover Disconnect the starter motor lead wire and ground lead wire Remove the carburetor with throttle cable C O P Y R I G H T E D ...

Page 46: ...ket with drive chain Remove the clutch cable bracket Disconnect the clutch cable end out of the clutch lever Disconnect the clutch cable end out of the clutch release arm Remove the clutch release arm Disconnect the magneto lead wire couplers and gear position switch lead wire coupler C O P Y R I G H T E D ...

Page 47: ...bolt Remove the muffler mounting bolts Remove the exhaust pipe nuts Remove the muffler Remove the radiator Remove the engine mounting bolts and nut Remove the engine mounting brackets Remove the engine from the left side C O P Y R I G H T E D ...

Page 48: ...haust pipe and muffler ENGINE REMOUNTING Remount the engine in the reverse order of engine removal Pay attention to the following points 66 N m 6 6 kgf m 66 N m 6 6 kgf m 66 N m 6 6 kgf m 66 N m 6 6 kgf m C O P Y R I G H T E D ...

Page 49: ...tall the O ring to the engine oil outlet hose Tighten the engine oil outlet hose bolt securely Tighten the engine oil inlet hose union bolts to the specified torque Tighten the engine sprocket bolts to the specified torque THREAD LOCK 1324 Exhaust pipe nut 23 N m 2 3 kgf m Muffler mounting bolt 23 N m 2 3 kgf m Muffler connecting bolt 23 N m 2 3 kgf m Engine sprocket bolt 11 13 N m 1 1 1 3 kgf m E...

Page 50: ...Engine oil Refer to page 2 1 Oil change Oil and filter change Engine overhaul Engine oil type 2 500 2 600 2 700 SAE 10W 40 API Over SL Necessary amount of engine oil Adjust the drive chain slack Refer to page 2 21 Throttle cable play Refer to page 2 9 Engine idle speed Refer to page 2 9 Clutch cable play Refer to page 2 13 C O P Y R I G H T E D ...

Page 51: ...3 9 ENGINE ENGINE DISASSEMBLY Remove the starter motor Remove the spark plug Remove the thermostat cover and 2nd pipe Remove the thermostat C O P Y R I G H T E D ...

Page 52: ... cam chain tension adjuster Remove the cylinder head cover bolts in diagonal stages and then remove the cylinder head cover Remove the valve timing inspection plug Remove the magneto cover cap using the spe cial tool Cap plug wrench 09910 36000 C O P Y R I G H T E D ...

Page 53: ...he triangle mark on the crankcase NOTE Before removing the camshaft housing the piston must be at TDC of the compression stroke Remove the dowel pins intake camshaft and exhaust camshaft Remove the four cylinder head bolts in diagonal stages NOTE Do not drop the dowel pins and camshaft drive chain into the crankcase C O P Y R I G H T E D ...

Page 54: ...ead NOTE If the cylinder head does not come off easily lightly tap it using a plastic hammer Remove the cylinder gasket and dowel pins Remove the cam chain guide Remove the cylinder base nuts and then remove the cylinder NOTE If the cylinder does not come off easily lightly tap it using a plastic hammer C O P Y R I G H T E D ...

Page 55: ...ase to pre vent the piston pin circlip from dropping into the crankcase Remove the piston pin circlip Draw out the piston pin and remove the piston Remove the dowel pins and gasket Remove the magneto cover Remove the clutch cover C O P Y R I G H T E D ...

Page 56: ...move the dowel pins and gasket Remove the clutch drive plates No 1 and driven plates Remove the spring washer and spring washer seat Remove the clutch drive plate No 2 Loosen the clutch spring mounting bolts working in diagonal stages Remove the bolts and springs Remove the clutch pressure disk C O P Y R I G H T E D ...

Page 57: ...the clutch sleeve hub washer Hold the clutch sleeve hub using the special tool and then remove the clutch sleeve hub nut Remove the clutch sleeve hub Remove the primary driven gear assembly and washer Clutch sleeve hub holder 09920 53710 C O P Y R I G H T E D ...

Page 58: ...ENGINE 3 16 Remove the coller Remove the oil pipe Remove the oil pin and oil pump assembly Remove the oil pump driven gear by removing the circlip C O P Y R I G H T E D ...

Page 59: ...e crankshaft held immovable using the special tool remove the primary drive gear nut washer and water pump drive gear CAUTION The primary drive gear nut has left hand threads If turning it counter clockwise it may cause damage Pay attention at the primary drive gear nut with a washer and water pump drive gear with a washer Conrod holder 09910 20115 C O P Y R I G H T E D ...

Page 60: ...n gear With the magneto rotor held immovable using the special tool loosen the rotor nut Remove the magneto rotor using the special tool CAUTION Do not hit the magneto rotor with a hammer oth erwise the rotor may be damaged Conrod holder 09910 20115 Rotor remover 09930 30164 C O P Y R I G H T E D ...

Page 61: ...Remove the O ring switch contact and spring Remove the cam chain and cam chain ten sioner Remove the starter idle shaft and starter idle gear Remove the left crankcase securing bolts Remove the right crankcase securing bolts C O P Y R I G H T E D ...

Page 62: ...e the crankcase using the special tool NOTE Fit the crankcase separator so that the tool arms parallel the side of the crankcase Remove the countershaft assembly and drive shaft assembly Remove the reverse idle gear with its shaft Remove the crank balancer Crankcase separator 09920 13120 C O P Y R I G H T E D ...

Page 63: ...ntify the position of each removed part Organize the parts in their respective group for example exhaust or intake so that they can be installed in their original positions Compress the valve springs and then remove the valve cotters from the valve stem using the special tools Crankcase separator 09920 13120 Valve spring compressor 09916 14510 Valve spring compressor attachment 09916 14520 C O P Y...

Page 64: ...ring seat Apply MOLY PASTE to each oil seal and press fit them into position Apply MOLY PASTE to the valve as shown and then insert them into the valve guides Install the valve spring with the smaller pitch facing the cylinder head CAUTION Do not reuse the oil seals CAUTION When inserting each valve into the valve guides make sure not to damage the lip of the oil seal MOLY PASTE Head direction MOL...

Page 65: ...s gauge Take clearance reading at several places as indicat ed If any clearance reading exceeds the service limit replace the cylinder head with a new one Install the valve spring retainer by pressing down the spring using the valve spring compressor Fit the cotter halves to the stem end and release the lifter to allow the cotter to wedge between the retainer and the valve stem Make sure that the ...

Page 66: ...ET SHIM WEAR When measuring the valve clearance the clearance should be within the standard range Exhaust valve Intake valve Inspect the tappet for wear and scratch If modification or scratch is present replace the tappet When you checked the valve clearance if the valve clearance is wide please replace the present shim into thick one if the valve clearance is nar row please replace the present sh...

Page 67: ...ns X and Y perpendicular to each other Position the dial gauge as shown If the deflection exceeds the service limit determine whether the valve or the guide should be replaced with a new one EX IN VALVE HEAD RADIAL RUNOUT Support the valve using a v block and measure the valve head radial runout using the dial gauge as shown If the runout exceeds the service limit replace the valve with a new one ...

Page 68: ...imit or if the force required to compress the valve spring is not within specification replace both the inner and outer springs as a set Valve spring free length Inner Outer Service limit 36 9 mm 1 45 in 39 9 mm 1 57 in Valve spring tension Inner Outer Standard 6 5 7 1 kgf 14 3 15 7 lbs at length 32 0 mm 1 26 in 12 0 14 0 kgf 26 5 30 9 lbs at length 35 5 mm 1 40 in Cam height Intake cam Exhaust ca...

Page 69: ... the widest portion which is specified as follows If the camshaft journal oil clearance exceeds the ser vice limit measure the inside diameter of the camshaft housing and outside diameter of the camshaft journal Replace the camshaft or the cylin der head and camshaft housing depending upon which one exceeds the specification CAMSHAFT RUNOUT Support the valve using a V blocks and measure the camsha...

Page 70: ...dge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straight edge exceeds the limit replace the cylinder CAM CHAIN TENSION ADJUS TER AND TENSIONER CAM CHAIN TENSION ADJUSTER Check that the push rod slides smoothly with the lock shaft handle clockwise If it does not slide smoothly replace the cam chain tension adjuster with...

Page 71: ...n using a micrometer If the measurement is found less than the service limit replace the piston PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calcu late the difference between the cylinder bore and out side diameter of the piston Piston pin hole bore Service limit 19 030 mm 0 7492 in PISTON PIN HOLE BORE Using a dial calipers measure the piston pin hole bore both the v...

Page 72: ... limit 18 980 mm 0 7472 in Piston ring free end gap Standard Approx11mm 0 433in Approx10mm 0 394in 1st 2nd PISTON RING END GAP INSPECTION Assembly condition Insert the piston ring squarely into the cylinder using the piston head Measure the end gap with a thickness gauge If the gap exceeds the service limit replace the pis ton ring with a new one Piston ring end gap Assembly condition Standard 0 2...

Page 73: ...170 1 190 mm 0 0461 0 0469 in Piston ring thickness Standard Piston ring groove width Oil 2nd 1st 2 01 2 03 mm 0 079 0 080 in 1 01 1 03 mm 0 040 0 041 in 1 21 1 23 mm 0 0476 0 0484 in 2nd 1st 0 970 0 990 mm 0 0382 0 0390 in CONROD CONROD SMALL END INSIDE DIAME TER INSPECTION Using a dial calipers measure the conrod small end inside diameter both in vertical and horizontal direc tions If any of the...

Page 74: ...w one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod big end bearing crankshaft crank pin etc with new ones Standard 0 10 0 65 mm 0 004 0 026 in Service limit 1 0 mm 0 040 in Conrod big end side clearance CRANKSHAFT CRANKSHAFT RUNOUT INSPECTION With the right and left crank journals supported using a V block turn the crankshaft slowly At ...

Page 75: ...ANCER DRIVE GEAR DISASSEMBLY Disassemble the crank balancer and balancer drive gear as shown in the illustration REASSEMBLY Reassemble the crank balancer and balancer drive gear in the reverse order of disassembly C O P Y R I G H T E D ...

Page 76: ... clutch Also inspect the surface of the starter driven gear which contacts the starter clutch for wear or damage If any wear or damage is found replace the defective parts DISASSEMBLY With the magneto rotor held immovable remove the starter clutch bolts REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tighten them to the specified torque with the magneto rotor ...

Page 77: ...plate is not within the service limit replace the clutch plates as a set CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using a vernier calipers If any spring is not within the service limit replace all of the spring with new ones Clutch spring free length Service limit 51 6 mm 2 032 in Service limit 2 62 mm 0 103 in 3 12 mm 0 123 in NO 1 NO 2 Clutch drive plate thickness ...

Page 78: ...oil pump inner rotor outer rotor and shaft When installing the inner rotor align the pin with the groove When installing the outer rotor face the punched mark on the outer rotor to the outside CAUTION The oil pump case securing screw is applied with THREAD LOCK 1324 If an attempt is made to overhaul the oil pump assembly the screw may be damaged Only the oil pump unit is avail able as a replacemen...

Page 79: ...3 37 ENGINE TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown C O P Y R I G H T E D ...

Page 80: ... clearance checked is noted to exceed the limit specified replace the fork or its gear or both Service limit 0 50 mm 0 020 in Standard 0 10 0 30 mm 0 004 0 012 in Shift fork to groove clearance Shift fork groove width Standard NO 3 NO 1 NO 2 4 85 5 00 mm 0 191 0 197 in 4 85 5 00 mm 0 191 0 197 in Shift fork thickness Standard NO 3 NO 1 NO 2 5 3 5 4 mm 0 209 0 213 in 5 3 5 4 mm 0 209 0 213 in Verni...

Page 81: ...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 fitted Thrust Sharp edge REASSEMBLY Reassemble the transmission in the reve...

Page 82: ...ENGINE 3 40 TRANSMISSION GEARS AND RELATED PARTS CRANKCASE OIL STRAINER CAP Remove the oil strainer cap C O P Y R I G H T E D ...

Page 83: ...tor oil before inspection Rotate the inner race and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormalities the bearing is defective and must be replaced with a new one as follows play play Remove the oil strainer screw Clean the oil strainer using compressed air C O P Y R I G H T E D ...

Page 84: ...replace the oil seal with a new one OIL SEAL REMOVAL Remove the oil seal retainer Remove the oil seal OIL SEAL INSTALLATION Install the oil seals into the crankcase Pay atten tion to the following points Apply SUPER GREASE A to the lip of the oil seals Install the new oil seals CAUTION Replace the removed oil seals with new ones SUPER GREASE A GREASE C O P Y R I G H T E D ...

Page 85: ...ENGINE CLUTCH RELEASE CAMSHAFT Remove the clutch release camshaft Install the clutch release camshaft correctly CLUTCH COVER OIL FILTER Refer to page 2 11 WATER PUMP Refer to page 5 11 C O P Y R I G H T E D ...

Page 86: ...kcase it is necessary to pull its left end into the crankcase by using the special tools Width between webs Standard 71 0 0 1 mm 2 795 0 004 in NOTE Apply engine oil to each running and sliding part before reassembling the engine CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the accu racy of the crankshaft alignment w...

Page 87: ...position and direction Gearshift fork No 1 Gearshift fork No 2 Gearshift fork No 3 Install the gearshift cam Install the gearshift fork shaft NOTE After the gearshift fork shaft and gearshift forks have been fitted make sure that the gears engage normally Set the transmission gears to the neutral posi tion C O P Y R I G H T E D ...

Page 88: ... to the transmission gears Apply BOND 1215 to the mating surface of the crankcase Tighten the crankcase bolts to the specified torque After the crankcase bolts have been tightened check if the crankshaft countershaft and drive shaft rotate smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic hammer BOND 1215 Crankcase bolt 11 N m 1 1 kgf m C O P ...

Page 89: ... 12 0 kgf m Conrod holder 09910 20115 GEAR POSITION SWITCH Install the springs contacts and new O ring Install the gear position switch and tighten the bolts to the specified torque CAM CHAIN Install the cam chain onto the sprocket Tighten the cam chain tensioner mounting bolt to the specified torque Install the starter idle shaft and starter idle gear Gear position switch bolt 6 5 N m 0 65 kgf m ...

Page 90: ... Install the primary drive gear to the crankshaft Install the water pump drive gear Apply engine oil to the thread and inside surface of the nut With the crankshaft held immovable using the special tool and then tighten the primary drive gear nut to the specified torque NOTE This nut has left hand thread CAUTION Apply engine oil to the primary drive gear nut Primary drive gear nut 140 N m 14 0 kgf...

Page 91: ...unting screws and then tighten them securely OIL PIPE Apply engine oil to the O rings Tighten the oil pipe bolt securely THREAD LOCK 1324 Install the gearshift shaft Install the circlip OIL PUMP Before mounting the oil pump apply engine oil to the sliding surfaces of the oil pump case outer rotor inner rotor and crankcase C O P Y R I G H T E D ...

Page 92: ...b using the special tool and then tighten the clutch sleeve hub nut to the specified torque Install the clutch sleeve hub lock washer Clutch sleeve hub nut 90 N m 9 0 kgf m Clutch sleeve hub holder 09920 53710 CLUTCH C O P Y R I G H T E D ...

Page 93: ... the tongue of the washer securely Install the push rod clutch push piece Install the clutch drive plate NO 2 Install the spring washer seat and spring wash er onto the clutch sleeve hub correctly Install the clutch driven plates and drive plates NO 1 one by one into the clutch sleeve hub in the prescribed order C O P Y R I G H T E D ...

Page 94: ...and new gasket Tighten the magneto rotor cover bolts securely CAUTION Use a new gasket to prevent oil leakage Install the dowel pins and new gasket CAUTION Use a new gasket to prevent oil leakage Tighten the clutch cover bolts securely C O P Y R I G H T E D ...

Page 95: ...hen install the two side rails The spacer and side rails do not have a designated top and bottom They can be installed in any position CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove INCORRECT CORRECT Position the piston ring gaps as shown Before inserting the piston into its cylinder check that the gaps are properly positioned 2nd ring and lower si...

Page 96: ... cylinder Make sure that the piston rings are caught by the cylinder skirt CAUTION Use a new piston pin circlip to prevent circlip fail ure with a bent one CAUTION Use a new gasket to prevent oil leakage NOTE When mounting the cylinder after attaching the cam chain keep the cam chain taut The cam chain must not be caught between the cam chain sprocket and crankcase when the crankshaft is rotated P...

Page 97: ...bolts to specifi cation tighten the cylinder head base bolts and cylinder base nuts to the specified torque CAMSHAFT ASSEMBLY Turn the magneto rotor until the T line on the magneto rotor is aligned with the triangle mark on the crankcase NOTE Apply engine oil to the threaded parts of the cylinder head bolts and its washers Be sure to install the washer with rounded side facing up CAUTION If the cr...

Page 98: ...d lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft sprocket The exhaust camshaft sprocket has an arrow marked 1 Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head Engage the cam chain with the exhaust camshaft sprocket The other arrow marked 2 should now be pointing straight up Starting from the r...

Page 99: ...3 57 ENGINE 15th pin 1st pin C O P Y R I G H T E D ...

Page 100: ...over gasket as shown Apply engine oil to both sides of the washer Lightly tighten the cylinder head cover bolts in diagonal stages and then tighten them to the specified torque NOTE NOTE When tightening the camshaft housing bolts the piston position must be at TDC on the compres sion stroke BOND 1215 CAUTION Use a new washers Camshaft housing bolt 10 N m 1 0 kgf m Cylinder head cover bolt 14 N m 1...

Page 101: ... gasket and cam chain tension adjuster to the cylinder Tighten the cam chain tension adjuster mounting bolts to the specified torque Tighten the cam chain tension adjuster bolt to the specified torque Install the thermostat Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m Cam chain tension adjuster bolt 20 N m 2 0 kgf m C O P Y R I G H T E D ...

Page 102: ...ENGINE 3 60 Install the thermostat cover and 2nd pipe Install the spark plug Install the starter motor C O P Y R I G H T E D ...

Page 103: ...CAUTION Gasoline must be handled carefully in an area well ventilated and away from fire or sparks FUEL SYSTEM FUEL TANK 4 1 FUEL COCK 4 1 FUEL PUMP 4 2 CARBURETOR 4 3 CONTENTS 4 C O P Y R I G H T E D ...

Page 104: ...everse order of removal INSPECTION If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss of engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks FUEL COCK REMOVAL Remove the fuel tank Drain fuel completely Remove the fuel cock WARNING Gasoline is highly flammable and explosive Keep heat sparks and flames away from ga...

Page 105: ...el cock Refer to page 4 1 If the fuel cock and hoses are not fault 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 carburetor Fuel hose To fuel cock Vacuum hose To intake pipe FUEL PUMP REMOVAL Remove the seat and fuel ...

Page 106: ...4 3 FUEL SYSTEM CARBURETOR CONSTRUCTION C O P Y R I G H T E D ...

Page 107: ... Refer to page 7 4 Disconnect the fuel hose LOCATION OF CARBURETOR I D NO The carburetor I D is stamped on the location on the carburetor as shown in the right photo Loosen the carburetor clamp screw Remove the carburetor side cap C O P Y R I G H T E D ...

Page 108: ...ISASSEMBLY Remove the fuel hose and air vent hoses Remove the throttle stop screw Remove the choke lever Remove the carburetor top cap CAUTION Do not use compressed air on the carburetor body removing the diaphragm this may damage the diaphragm C O P Y R I G H T E D ...

Page 109: ...FUEL SYSTEM 4 6 Remove the spring along with the diaphragm assembly Remove the jet needle holder spring E ring ring and jet needle Remove the diaphragm cover Remove the diaphragm C O P Y R I G H T E D ...

Page 110: ...EM Remove the O ring Remove the float chamber body Remove the float pin float and needle valve Remove the valve seat CAUTION Replace the removed O ring with a new one to prevent leakage of fuel C O P Y R I G H T E D ...

Page 111: ...damage or clogging is found replace the part with a new one CLEANING Clean all jets by using compressed air After cleaning reassemble the carburetor with new seals and gaskets Needle valve Check for stopped wear Foreign substance NOTE Before removing the pilot air jet its setting must be determined Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated Make ...

Page 112: ...vel 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 pilot air jet to the origi nal setting by turning the screw in until it lightly seat and then backing it out the same number of turns counted during disa...

Page 113: ... carburetor hoses properly After the carburetor assembly has been remount ed onto the engine perform the following adjust ment Throttle cable adjustment Refer to page 2 9 Idle speed adjustment Refer to page 2 9 Apply SUPER GREASE A to thread part of the throttle stop screw then install the throttle stop screw to the carburetor SUPER GREASE A NOTE When installing the diaphram make sure the diaphram...

Page 114: ... 5 1 COOLING CIRCUIT 5 2 RADIATOR 5 2 COOLING FAN 5 5 COOLING FAN THERMO SWITCH 5 6 WATER TEMPERATURE SWITCH 5 8 THERMOSTAT 5 9 WATER PUMP 5 11 OIL TANK AND HOSES 5 16 COOLING SYSTEM 5 CONTENTS C O P Y R I G H T E D ...

Page 115: ...Right figure Do not use a radiator anti leak additive 50 Engine coolant including reserve tank capacity Anti freeze Water 0 7 ℓ 0 7 ℓ WARNING You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot After the engine cools wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap...

Page 116: ... coolant by removing the drain bolt Disconnect the cooling fan thermo switch lead wire coupler and water temperature switch lead wire coupler Disconnect the radiator inlet hose and outlet hose Impeller Radiator cap Radiator Thermostat Cooling fan thermo switch Water temperature switch C O P Y R I G H T E D ...

Page 117: ... dirt or trash stuck to the fins must be removed Use of compressed air is recommended for this cleaning Remove the radiator by the mounting bolts Disconnect reserve tank hose Disconnect the cooling fan motor lead wire cou pler C O P Y R I G H T E D ...

Page 118: ...nstall the reservoir tank in the reverse order of removal Fill the reservoir tank to the upper level line Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Fins bent down or dented can be repaired by straightening them with the blade of a small screw driver INSPECTION OF WATER HOSE Remove the front fender Refer to page 7 3 Any water hose found in a cracke...

Page 119: ... radiator Route the radiator hoses properly Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Install the front fender INSTALLATION Install the cooling fan to the radiator COOLING FAN INSPECTION Remove the front fender Refer to page 7 3 Disconnect the cooling fan motor lead wire cou pler and its thermo switch lead wire coupler Test the cooling fan motor f...

Page 120: ...an thermo switch INSPECTION Check the thermo switch closing or opening tem peratures by testing it at the bench as shown in the figure Connect the thermo switch to a circuit tester and place it in the OIL contained in a pan which is placed on a stove Heat the oil to raise its temperature slowly and read the column thermometer when the switch closes of opens Cooling fan thermo switch operating temp...

Page 121: ...e front fender INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Install a new O ring and apply engine coolant to the O ring Tighten the cooling fan thermo switch to the speci fied torque Cooling fan thermo switch 13 N m 1 3 kgf m C O P Y R I G H T E D ...

Page 122: ...switch INSPECTION Check the engine coolant temperature by testing it at the bench as shown in the figure Connect the water temperature switch to a circuit tester and place it in the WATER contained in a pan which is placed on a stove Heat the water to raise its temperature slowly and read the column thermometer and the ohmmeter If the resistance noted to show infinity or too much different resista...

Page 123: ... flange as shown in the photograph Immerse the thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermostat is in suspen sion Heat the water by placing the beaker on a stove and observe the rising temperature on a ther mometer Read the thermometer just when opening the ther mostat This reading which is the temperature level at which the thermostat va...

Page 124: ... one INSTALLATION Install the thermostat in the reverse order of removal Pay attention to the following points Apply engine coolant to the rubber seal on the thermostat Install the thermostat Install the thermostat case cap Tighten the thermostat case bolts to the specified torque Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Install the front fender ...

Page 125: ...ngine oil and coolant leakage between the water pump and clutch cover If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the O ring WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor The engine must be harmful if swallowed or if it comes in contact with the skin or eyes If en...

Page 126: ...COOLING SYSTEM 5 12 Remove the circlip and water pump driven gear Remove the pin and washer Remove the water pump case from the clutch cover Remove the O rings C O P Y R I G H T E D ...

Page 127: ...earing INSPECTION BEARING Inspect the play of the bearing by hand while it is in the water pump case Rotate the inner race by hand to inspect abnormal noise and smooth rotation Replace the bearing if there is anything unusual NOTE If there is no abnormal noise bearing removal is not necessary C O P Y R I G H T E D ...

Page 128: ...LLER Visually inspect the impeller and its shaft for damage REASSEMBLY AND INSTAL LATION Install the water pump in the reverse order of removal Pay attention to the following points Install the bearing Install the impeller to the water pump body Apply SUPER GREASE A to the impeller shaft SUPER GREASE A C O P Y R I G H T E D ...

Page 129: ...ke master cylinder mounting bolts Connect the rear brake switch spring and rear brake pedal spring as to lower side Fix the impeller shaft with the E ring Fill the bearing with engine oil until engine oil comes out from the hole of the bearing housing CAUTION Use a new O ring to prevent engine coolant leakge Rear brake master cylinder mounting bolt 8 12 N m 0 8 1 2 kgf m C O P Y R I G H T E D ...

Page 130: ...COOLING SYSTEM 5 16 OIL TANK AND HOSES CONSTRUCTION C O P Y R I G H T E D ...

Page 131: ... Remove the front fender Refer to page 7 3 Drain engine coolant Refer to page 2 12 Remove the radiator Refer to page 5 2 Drain engine oil Refer to page 2 10 Remove the engine under cover Remove the oil hoses C O P Y R I G H T E D ...

Page 132: ...TING Remount the oil tank and hoses in the reverse order of removal Pay attention to the following points Tighten the engine oil inlet hose union bolts to the specified torque Engine oil inlet hose union bolt 23 N m 2 3 kgf m C O P Y R I G H T E D ...

Page 133: ...askets Apply engine oil to the O ring and gaskets Pour engine oil Refer to page 2 11 Install the radiator Refer to page 5 4 Pour engine coolant Refer to page 2 12 Install the front fender CAUTION Use the new O rings to prevent engine coolant leakage C O P Y R I G H T E D ...

Page 134: ...LOCATION OF ELECTRICAL COMPONENTS 6 1 IGNITION SYSTEM 6 3 CHARGING SYSTEM 6 7 STARTER SYSTEM 6 9 SWITCHES 6 12 LAMPS 6 14 BATTERY 6 16 ELECTRICAL SYSTEM 6 CONTENTS C O P Y R I G H T E D ...

Page 135: ...OCATION OF ELECTRICAL COMPONENTS Left handlebar switch Ignition coil Cooling fan motor relay Head lamp relay Horn Magneto Gear position switch Igniter Regulator Rectifier Turn signal relay Starter relay C O P Y R I G H T E D ...

Page 136: ...ELECTRICAL SYSTEM 6 2 Battery Front brake lamp switch Cooling fan motor Cooling fan thermo switch Water temperature switch Main fuse Rear brake lamp switch Starter motor C O P Y R I G H T E D ...

Page 137: ...d pin Use the pin to remove carbon taking care not to damage the porcelain Check the gap with a thickness gauge Spark plug gap 0 7 0 8 mm 0 028 0 032 in 0 7 0 8 mm 0 028 0 032 in Thickness gauge 09900 20806 IGNITION COIL IGNITER IG S W FUSE REG REC BATTERY 12V 8Ah G L Y Y Y C O P Y R I G H T E D ...

Page 138: ...thin the specified value replace the stator coil with a new one CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws WIRE COLOR L Blue G Green Y Yellow Br Brown BY Black with Yellow tracer OB Orange with Black tracer BW Black with White tracer WL White with Blue tracer YG Yellow with Green tracer THREAD LOCK 1324 Pocket Te...

Page 139: ...s close to the specified values the wind ings are in sound condition IGNITION COIL Remove the front fender side cover fuel tank Refer to page 7 3 and 4 1 Pull out the spark plug Place it on the cylinder head after installing it at the plug cap to obtain ground Push the electric starter switch to rotate the starter motor to have the test of sparking performance If spark doesn t emit or the spark br...

Page 140: ... using the tester indicates a low volt age The range of measurement adjust a X 1 unit IGNITER Using the pocket tester R 1 range measure the resistance between the terminal in the following table Pocket tester 09900 25002 Unit kΪ TESTER PROBE 7965 10775 7959 10764 16116 21804 4463 6037 4437 6003 9894 13386 2 6 3 6 3120 4220 2 6 3 6 3145 4255 T E S T E R P R O B E C O P Y R I G H T E D ...

Page 141: ...n the specified value check the magneto no load performance and regulator rectifier 6 7 ELECTRICAL SYSTEM CHARGING SYSTEM 13 5 15 0V at 5 000 rpm Standard charge CAUTION When making this test be sure that the battery is full charged condition Regulator Rectifier DCV Battery IG switch Pocket tester 09900 25002 A C generator IG switch IC Battery LOAD Regulator Rectifier C O P Y R I G H T E D ...

Page 142: ...ver 70 V at 5 000 rpm Standard NO load per for mance of magneto REGULATOR RECTIFIER Remove the rear fender Refer to page 7 5 Remove the regulator rectifier Using the pocket tester 1 MΪ range measure the resistance between the terminals in the follow ing table If the resistance checked is incorrect replace the regulator rectifier 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2 3 4 3 4 1 2 1 2 1 2 1 2 1 2 32 1 2 1 ...

Page 143: ... SYSTEM STARTER SYSTEM DESCRIPTION This ATV can only start the engine with pulling the clutch lever Clutch lever position switch Starter switch Ignition switch Fuse Battery Starter relay Starter motor Igniter C O P Y R I G H T E D ...

Page 144: ... and the 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 Segment STARTER MOTOR INSPEC TION CARBON BRUSH Inspect the carbon brush for abnormal wear crack or smoothness in the brush holder If any damage are found replace the brush assembly with a new one Pocket tester 09900 25002 STARTER MOTOR...

Page 145: ...e on the housing end 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 SUPER GREASE A C O P Y R I G H T E D ...

Page 146: ...pective switch assemblies with new ones R O ON OFF IGNITION SWITCH O WB ON OFF FRONT REAR BRAKE LAMP SWITCH R N O YR PUSH OFF STARTER SWITCH G O PUSH OFF HORN SWITCH YW Y W LIGHT DIMMER SWITCH Sb Gr HAZARD WARNING SWITCH Pocket tester 09900 25002 Lg Sb B TURN SIGNAL SWITCH GR L EARTH GEAR POSITION SWITCH C O P Y R I G H T E D ...

Page 147: ...to remove the head lamp bulb Remove the dust cover and socket spring After removing the bulb at socket replace the new bulb To install the head lamp reverse the above sequence CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure C O P Y R I G H T E D ...

Page 148: ...N SIGNAL LAMP BULB REPLACEMENT Remove the lens by removing the screw Push the bulb turn it to the counter clockwise and pull it out After stick in the new lamp assemble the lens TURN SIGNAL LAMP CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure CAUTION Overtightening the screws may cause the lens t...

Page 149: ...tration INSPECTION Using the pocket tester check the continuity between lead wires Blue color coupler in the following illus tration If the continuity measured incorrect replace the respective part CAUTION When making this test it is not necessary to remove the combination meter Pocket tester 09900 25002 C O P Y R I G H T E D ...

Page 150: ...ere stained clothes will come into being a hole or painting will take off Consult a doctor When the battery electrolyte was dropped to the surface of land wash it with a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on FILLING ELECTROLYTE Put the battery on even land and remove the alu minum tape sealing Remove the cap at the electrolyte container Aluminum tape Filler h...

Page 151: ...s not fall Take precaution not to allow any fluid to spill Confirmation of pour Make sure that air bubbles are coming up each elec trolyte 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 bottom two or three times C O P ...

Page 152: ... Using the pocket tester check the battery voltage If the voltage reading is less than the 12 0 V DC recharge the battery with a battery charger CAUTION Draw the empty receptacle out slowly because there may be a chance remaining electrolyte vaporize How to charge Standard Fast 0 8 A 5 10 hours 4 A 30 minutes After recharging wait for more than 30 minutes and check the battery voltage with a pocke...

Page 153: ... EXTERIOR PARTS 7 1 FRONT AND REAR WHEELS 7 7 FRONT BRAKE 7 13 FRONT SUSPENSION 7 21 STEERING 7 30 REAR BRAKE 7 41 REAR SHOCK ABSORBER 7 54 REAR SUSPENSION 7 59 REAR AXLE 7 66 CONTENTS 7 C O P Y R I G H T E D ...

Page 154: ...7 1 CHASSIS EXTERIOR PARTS CONSTRUCTION C O P Y R I G H T E D ...

Page 155: ...CHASSIS 7 2 C O P Y R I G H T E D ...

Page 156: ...hind the rear fender FRONT FENDER Disconnect the head lamp coupler Remove the seat Refer to above Remove the center front fender mounting bolts Remove the center front fender Remove the fuel tank cap Remove the center rear fender mounting bolts Remove the center rear fender C O P Y R I G H T E D ...

Page 157: ... Remove the four steering head cover bracket bolts Remove the side covers left and right FOOTREST MUDGUARD Remove the mudguards Remove the front fender mounting bolts Remove the front fender C O P Y R I G H T E D ...

Page 158: ...rds Refer to page 7 4 Remove the footrests REAR FENDER Remove the seat Refer to page 7 3 Remove the battery plate Disconnect the battery lead wires Remove the battery Remove the rear fender mounting bolts Remove the rear fender C O P Y R I G H T E D ...

Page 159: ...ttention to the following points FOOTREST Apply THREAD LOCK 1324 to the bolts and tighten bolts to the specified torque MUDGUARD BRACE Apply THREAD LOCK 1324 to the mudguard brace bolts THREAD LOCK 1324 THREAD LOCK 1324 Footrest mounting bolt 40 60 N m 4 0 6 0 kgf m C O P Y R I G H T E D ...

Page 160: ...7 7 CHASSIS FRONT AND REAR WHEELS CONSTRUCTION C O P Y R I G H T E D ...

Page 161: ...UB Remove the front wheel Refer to above Remove the front hub plate Remove the cotter pin then loosen the wheel hub nut Remove the wheel hub nut and washer Remove the front brake caliper Refer to page 7 15 Remove the disk Refer to page 7 18 Remove the front wheel hub CAUTION Do not operate the brake lever while removing the caliper C O P Y R I G H T E D ...

Page 162: ... any damages are found replace the dust seal with a new one Remove the spacer Remove the dust seal with the special tool HUB BEARINGS Inspect the inner race play of the hub bearing by hand while it is in the wheel hub Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusu al replace the bearing with a new one CAUTION Replace the removed dust seal...

Page 163: ...spacer into the front wheel hub Install the dust seal into the front wheel hub with fabric portion facing to outside Apply SUPER GREASE A to the dust seal s lip CAUTION Do not reuse the removed bearings SUPER GREASE A SUPER GREASE A NOTE Install the inner bearing first and then install the spacer and the outer bearing GREASE C O P Y R I G H T E D ...

Page 164: ...l the cotter pin into the front axle Install the front wheel REAR WHEEL HUB Apply small amount of SUPER GREASE A to the wheel hub s spline CAUTION Replace the removed cotter pin with a new one Front wheel hub nut 55 N m 5 5 kgf m Install the cotter pin into the rear axle Install the rear wheel Install the rear wheel hub washer and nut Tighten the rear wheel hub nut to the specified torque CAUTION ...

Page 165: ...que TIRE Refer to page 2 18 NOTE When installing the front wheel make sure that the arrow on the tire points in the direction of rotation NOTE When installing the rear wheel make sure that the arrow on the tire points in the direction of rotation Wheel set nut 39 2 58 8 N m 3 92 5 88 kgf m Wheel set nut 39 2 58 8 N m 3 92 5 88 kgf m ON ROAD type ON ROAD type C O P Y R I G H T E D ...

Page 166: ...y brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long periods When storing brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disk...

Page 167: ...e pad removal Replace the brake pads as a set otherwise braking performance will be adversely affected NOTE Before installing the new pads inspect the pad mounting pins for wear If excessive wear is found replace them with new ones The E ring must be installed to the caliper NOTE After replacing the brake pads pump the brake lever several times to check for proper brake operation and then check th...

Page 168: ...spection window BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 7 8 Disconnect the brake hose from the brake caliper by removing the brake hose union bolt and allow the brake fluid to drain into a suitable recep tacle Remove the brake caliper by removing the brake caliper mounting bolts Remove the brake pads Refer to page 7 14 Specification and classification DOT 4 CAUTI...

Page 169: ... corrosion or other damages If any abnormal condition is noted replace the caliper WARNING Place a rag over the piston to prevent it from popping out and flying and keeping hand off the piston Be careful of brake fluid which can possibly splash Do not use high pressure air but increase the pressure gradually CAUTION Care not to cause scratch on the cylinder bore Do not reuse the piston seal and du...

Page 170: ...id and bleed air Refer to page 2 17 Inspection after reassembly Refer to page 2 16 CAUTION Wash the brake caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid with a rag after washing the compo nents Replace the piston seal and dust seal into new ones with brake fluid applied Brake fluid specification and classification DOT 4 SILICONE GREASE NOTE Before remountin...

Page 171: ...eds the ser vice limit Apply THREAD LOCK 1324 to the brake disk bolts and tighten them to the specified torque If either measurement exceeds the service limit replace the brake disk Refer to above Brake disk thickness Service limit 3 0 mm 0 12 in Brake disk runout Service limit 0 3 mm 0 012 in NOTE Make sure that the disk is clean and free of any greasy matter Micrometer 0 25 mm 09900 20201 Dial g...

Page 172: ...ove the union bolt Remove the two mounting bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm Detach the dust seal boot and remove the cir clip Pull out the piston cup set and spring CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts C O P Y R I G H T E D ...

Page 173: ...ylinder 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 Brake fluid specification and classification DOT 4 NOTE When installing the circlip make sure that the sharp edge of the circlip faces outside WARNING Bleed air from the brake fluid circuit after a...

Page 174: ...7 21 CHASSIS FRONT SUSPENSION CONSTRUCTION C O P Y R I G H T E D ...

Page 175: ...7 8 Remove the front wheel hub Refer to page 7 8 Remove the brake caliper Refer to page 7 15 Remove the front disk cover Remove the cotter pin and tie rod end nut Remove the front grip CAUTION Replace the removed cotter pin with a new one C O P Y R I G H T E D ...

Page 176: ...the shock absorber upper mounting bolt Remove the shock absorber Remove the cotter pins and nuts Remove the steering knuckle Remove the spacers dust seals and bear ings from the suspension arm Remove the dust caps dust seals bearings and spacers from the suspension arm UPPER LOWER C O P Y R I G H T E D ...

Page 177: ...le for damage If any damages are found replace the knuckle with a new one KNUCKLE END Inspect the knuckle end boot for wear or damage If any damages are found replace the knuckle end with a new one Inspect the knuckle end for smooth movement If there are any abnormalities replace the knuckle end with a new one SUSPENSION ARM Inspect the suspension arm for wear or damage If any damages are found re...

Page 178: ... heat High gas pres sure caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Remove the valve cap Press the valve with a screwdriver to bleed out the nitrogen gas WARNING Releasing high pressure gas from the front shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the front shock absor...

Page 179: ...m Install the spacers bearings dust seals and dust caps into the suspension arm Degrease the tapered portion of knuckle and also knuckle end with nonflammable cleaning solvent SUPER GREASE A NOTE Stamped mark on the dust seal must face out side Install the suspension arms to the steering knuck le and tighten the knuckle end nuts to the speci fied torque Install the cotter pins CAUTION Replace the ...

Page 180: ...ON Replace the removed cotter pin with a new one Shock absorber mounting nut Upper and Lower 40 60 N m 4 0 6 0 kgf m THREAD LOCK 1324 Tie rod end nut 22 35 N m 2 2 3 5 kgf m Apply THREAD LOCK 1324 to the front shock absorber mounting bolts THREAD LOCK 1324 Tighten the suspension arm pivot nuts to the specified torque Install the front grip and the front shock absorber Suspension arm pivot nut 40 6...

Page 181: ...he front shock absorber Refer to page 7 23 Loosen the lock nut Adjust the spring set length by turning the adjuster Tighten the lock nut NOTE When installing the tie rod end install the washer between the nut and steering knuckle 270 mm 10 6 in 280 mm 11 0 in 258 mm 10 2 in STANDARD MAXIMUM SOFTEST MINIMUM STIFFEST FRONT SUSPENSION SPRING SET LENGTH CAUTION Do not set the spring length out of the ...

Page 182: ...hock absorber compression damping force adjuster Standard 1 turn from end of S direction counter clockwise Front shock absorber tension damping force adjuster Standard End of S direction counter clockwise STANDARD FRONT SHOCK ABSORBER DAMPING FORCE Compression Tension Softer Standard Stiffer Turn to S direction counter clockwise 1 turn from end of S direction counter clockwise Turn to H direction ...

Page 183: ...CHASSIS 7 30 STEERING CONSTRUCTION C O P Y R I G H T E D ...

Page 184: ... from the handlebar Refer to page 7 19 Remove the throttle lever case Disconnect the parking brake cable and the clutch cable Remove the clutch switch Remove the handlebar switch box Remove the speedometer Remove the harness clamps Remove the steering head cover bracket and the handlebar C O P Y R I G H T E D ...

Page 185: ...2 10 and 2 12 Remove the radiator assembly Refer to page 5 2 Remove the oil tank Refer to page 5 17 18 Disconnect the oil hoses and overflow hose Remove the cotter pins and tie rod end nuts Remove the tie rods CAUTION Replace the removed cotter pins with new ones C O P Y R I G H T E D ...

Page 186: ...33 CHASSIS Remove the cotter pin and steering shaft nut and washer Remove the O ring Remove the steering shaft holder cotter pin CAUTION Replace the removed cotter pins with new ones C O P Y R I G H T E D ...

Page 187: ...ring shaft holder half INSPECTION Inspect the removed parts for the following abnormal ities Handlebar distortion Handlebar clamp wear DUST SEALS AND O RING Inspect the dust seal and O ring for wear or damage If any damages are found replace the dust seal or O ring with new ones TIE ROD Inspect the tie rod for distortion or damage If any damages are found replace the tie rod with a new one C O P Y...

Page 188: ...found replace the tie rod end with a new one STEERING SHAFT Inspect the steering shaft for distortion or bends If any damages are found replace the steering shaft with a new one STEERING SHAFT BUSHING Inspect the steering shaft bushing for wear and damage If any damages are found replace it with a new one STEERING SHAFT HOLDER Inspect the steering shaft holders for wear or dam age If any damages a...

Page 189: ...ing shaft Install the dust seal and bushing to the steering shaft Install the new O ring and washer to the steering shaft SUPER GREASE A Tighten the steering shaft nut to the specified torque Install the cotter pin Apply SUPER GREASE A to the dust seals and sliding surface of the steering shaft holders before remounting the steering shaft holders CAUTION Replace the removed cotter pin with a new o...

Page 190: ...t the wiring harness cables and brake hose routing are properly Refer to page 8 26 to 8 31 TIE ROD Tighten the tie rod end nuts to the specified torque Install the cotter pins CAUTION Replace the removed cotter pins with new ones Steering shaft holder bolt 18 28 N m 1 8 2 8 kgf m Tie rod end nut 22 35 N m 2 2 3 5 kgf m C O P Y R I G H T E D ...

Page 191: ...h have left hand threads HANDLEBAR Assemble the handlebar handlebar clamp and steering head cover bracket Align the punch mark on the handlebar with the mating surface of handlebar clamp First tighten the bolt to the specified torque and then tighten the bolt to the specified torque NOTE The higher portion of handlebar clamp must face forward so that the clearance of holder is in back of the handl...

Page 192: ...embly to the handlebar with the mating surface of clutch lever holder aligned with punch mark on the handlebar Connect the clutch cable rear brake cable and clutch switch Adjust each cable play Refer to page 2 9 2 13 and 2 15 Install the throttle case to the handlebar with the mating surface of throttle case aligned with the punch mark Tighten the throttle case bolts to the specified torque Instal...

Page 193: ... is within the specified range Temporarily tighten the four lock nuts Check that the distances and are equal as shown If the distances are not equal adjust the tie rod to the right or left until the toe in is within specifica tion Check the toe in again by measuring distances and If the toe in is not within specification repeat the adjustment as above until the proper toe in is obtained and distan...

Page 194: ...g periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When cleaning brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disk or brake pad reduces braking performance Discard contaminated pads and clean the disk with high quality brake cleaner or neutral d...

Page 195: ...the lock washer CAUTION Do not operate the brake pedal while dis mounting the pads Replace the brake pads as a set otherwise braking performance will be adversely affected NOTE Before installing the new pads inspect the pad mounting pins for wear If excessive wear is found replace them with new ones Be sure to loosen the parking brake adjuster before installing the pads NOTE After replacing the br...

Page 196: ...ther end of the hose into a receptacle Loosen the air bleeder valve and pump the brake pedal until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper level Specification and classification DOT 4 Brake caliper mounting bolt 18 28 N m 1 8 2 8 kgf m Brake air bleeder valve 9 14 N m 0 ...

Page 197: ... to drain into a suitable receptacle Remove the parking brake housing Remove the brake caliper by removing the caliper mounting bolts WARNING Brake fluid if it leaks will interfere with safe run ning and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Remove the pad Refer to page 7 42 Remove the pad spring C O P Y R I G H T E D ...

Page 198: ...he piston by pushing the piston hanger pin Remove the dust seal and piston seal CAUTION Do not reuse the dust seal and piston seal to pre vent leakage of brake fluid BRAKE CALIPER INSPECTION Refer to page 7 16 PARKING BRAKE Inspect the parking brake for any damages and smooth rotation by turning the axle If there is any thing unusual replace the parking brake with a new one C O P Y R I G H T E D ...

Page 199: ...ston seal and dust seal Tighten the brake caliper pin bolt to the speci fied torque Apply SILICONE GREASE to the brake caliper holder pin and caliper pin bolt BRAKE CALIPER HOLDER Tighten the holder pin to the caliper holder to the specified torque SILICONE GREASE Rear brake caliper pin bolt 23 N m 2 3 kgf m Rear brake caliper holder pin 18 N m 1 8 kgf m Install the pad spring and pads Refer to pa...

Page 200: ...ers in completely so that the cable play is max imum NOTE Before remounting the brake caliper push the brake caliper piston all the way into the caliper CAUTION The removed brake hose washers should be replaced with new ones in order to prevent leakage of brake fluid Bleed air from the system after after reassem bling the brake caliper Refer to page 2 17 SILICONE GREASE Brake caliper mounting bolt...

Page 201: ...to page 7 67 Remove the brake disk Install the brake disk to the rear axle Apply THREAD LOCK 1324 to the brake disk bolts and tighten them to the specified torque Install the rear axle Refer to page 7 70 Install the rear wheel Refer to page 7 12 BRAKE DISK INSPECTION Refer to page 7 18 NOTE Make sure that the disk is free of any greasey matter THREAD LOCK 1324 Brake disk bolt 18 28 N m 1 8 2 8 kgf...

Page 202: ...master cylinder rod Disconnect the reservoir tank hose CAUTION Immediately wipe off any brake fluid contacting any part of the vehicle The brake fluid reacts chemically with paint plastics rubber materials etc and will damage them severely MASTER CYLINDER INSPECTION Refer to page 7 20 PRESSURE CONTROL VALVE REMOVAL Drain the brake fluid Place a rag underneath the brake hose union bolt on the press...

Page 203: ... master cylinder pin Tighten the master cylinder rod lock nut mas ter cylinder mounting bolts and brake hose union bolt to the specified torque CAUTION The removed brake hose washers should be replaced with new ones Bleed air from the system after reassembling the brake master cylinder Refer to page 2 17 MOLY PASTE Rear brake master cylinder rod lock nut 10 20 N m 1 0 2 0 kgf m Rear brake master c...

Page 204: ...7 51 CHASSIS REVERSE CABLE REMOVAL Remove the reverse lever assembly from the bracket Remove the reverse cable mounting screw Remove the cap Remove the screw C O P Y R I G H T E D ...

Page 205: ...he cable mounting screw REMOUNTING Remount the reverse cable in the reverse order removal Pay attention to the following points Install the spring with the spring end matched the groove on the housing Install the O ring to the reverse cable Connect the cable to the spool through the hole of the housing Apply SUPER GREASE A to the O ring SUPER GREASE A C O P Y R I G H T E D ...

Page 206: ...Loosen the lock nut Turn the adjuster in or out until the cable play should be 1 2 mm 0 04 0 08 in at the reverse lever Tighten the lock nut securely After adjustment be sure to check for reverse function NOTE When installing the spool hook the spring end on the concave portion of the spool Make sure that the reverse cable is routed cor rectly C O P Y R I G H T E D ...

Page 207: ...CHASSIS 7 54 REAR SHOCK ABSORBER CONSTRUCTION REMOVAL Raise the rear wheel off the ground and support the vehicle with jack or wooden block Remove the cushion lever cover C O P Y R I G H T E D ...

Page 208: ...ear shock absorber by lifting up the swingarm INSPECTION Inspect the shock absorber body bearing seals and spacers for damage and leakage of oil If any defects are found replace the shock absorber with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable C O P Y R I G H T E D ...

Page 209: ...lease gas pressure before disposing WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screw driver to press the valve Do not use your fin ger to depress the gas valve ...

Page 210: ...ar shock absorber Refer to page 7 54 Loosen the lock nut Adjust the spring set length by turning the adjuster Tighten the lock nut Remount the rear shock absorber Refer to page 7 56 REAR SUSPENSION SPRING SET LENGTH STANDARD MAXIMUM SOFTEST MINIMUM STIFFEST 228 mm 8 98 in 235 mm 9 25 in 213 mm 8 39 in CAUTION Do not set the spring length out of the specified range C O P Y R I G H T E D ...

Page 211: ...H direction clockwise DAMPING FORCE ADJUSTMENT The compression and tension damping force are adjustable for rider s preference rider s weight and field condition 1 Compression damping force To adjust the compression damping force turn in the adjuster fully for S or H direction counter clockwise or clockwise Count the number of turns from the fully turned in position Fully turned in H direction or ...

Page 212: ...7 59 CHASSIS REAR SUSPENSION CONSTRUCTION C O P Y R I G H T E D ...

Page 213: ...ooden block Remove the cushion lever cover Remove the cushion rod Remove the cushion lever REAR SWINGARM Remove the cushion rod and cushion lever Refer to above Remove the rear shock absorber Refer to page 7 54 Remove the rear wheels Refer to page 7 8 Remove the rear axle and axle housing Refer to page 7 67 C O P Y R I G H T E D ...

Page 214: ...7 61 CHASSIS Remove the brake hose guide Loosen the swingarm pivot nut and remove the swingarm pivot shaft Remove the swingarm assembly Remove the chain buffer C O P Y R I G H T E D ...

Page 215: ...m Remove the spacers from the cushion lever and cushion rod Inspect the spacers for any flaws or other dam age If any defects are found replace the spacers with new ones DUST SEAL Inspect the dust seals for wear or damage If any defect are found replace them with new ones C O P Y R I G H T E D ...

Page 216: ...BEARING Insert the spacer into the bearing and then check the play when moving the spacer up and down If excessive play is neted replace the bearing with a new one SWINGARM PIVOT SHAFT Using a dial gauge check the pivot shaft runout If the runout exceeds service limit replace the pivot shaft with a new one Swingarm pivot shaft runout Service limit 0 6 mm 0 024 in Dial gauge 09900 20606 Magnetic st...

Page 217: ...t the cushion lever and rod bolts for damage or bend If any defect are noted replace them with new ones CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace the chain buffer with a new one C O P Y R I G H T E D ...

Page 218: ...he rear shock absorber and cushion lever Tighten the rear shock absorber mounting nuts to the specified torque Tighten the cushion rod nut and cushion lever nut to the specified torque Swingarm pivot nut 50 80 N m 5 0 8 0 kgf m Rear shock absorber nut Upper 40 60 N m 4 0 6 0 kgf m Rear shock absorber nut Lower 40 60 N m 4 0 6 0 kgf m Cushion lever nut 70 100 N m 7 0 10 0 kgf m Cushion rod nut 70 1...

Page 219: ...CHASSIS 7 66 REAR AXLE CONSTRUCTION C O P Y R I G H T E D ...

Page 220: ...e the rear caliper Loosen the chain adjuster rear axle housing nuts and wrench bolts Loosen the sprocket mounting bolts and remove the sproket REAR AXLE SHAFT Remove the rear wheel Refer to page 7 8 Remove the rear wheel hub Refer to page 7 9 Loosen the axle nuts by applying the rear brake Remove the axle nuts Remove the sprocket flange Remove the caliper Draw out the rear axle shaft to the right ...

Page 221: ...he axle housing from the swingarm s right side INSPECTION AND DISASSEMBLY SPROCKET Inspect the sprocket teeth for wear If they are worn as shown replace the engine sprocket rear sprocket and drive chain as a set CAUTION Do not attempt to remove the brake disk flange from the rear axle shaft The rear axle shaft is available only as an assem bly Normal wear Excessive wear C O P Y R I G H T E D ...

Page 222: ...re in the axle housing Rotate the inner race by finger to inspect for abnor mal noise and smooth rotation Replace the bearing with a new one if there is any thing unusual Rear axle shaft runout Service limit 6 mm 0 24 in NOTE When measuring the runout support the rear axle shaft at 34 mm 1 34 in diameter of the rear axle shaft as shown in illustration Measure the runout at 40 mm 1 57 in diameter o...

Page 223: ...ints REAR SPROKET Install the rear sprocket to the sprocket flange Apply THREAD LOCK 1324 to the sprocket mounting bolts Tighten the sprocket mounting bolts to the speci fied torque AXLE HOUSING Apply SUPER GREASE A to the bearings and dust seals before installing SUPER GREASE A THREAD LOCK 1324 Rear sprocket mounting bolt 18 28 N m 1 8 2 8 kgf m GREASE C O P Y R I G H T E D ...

Page 224: ...s replaced with a new one install the right axle nut onto the new axle shaft Apply THREAD LOCK 1324 to the axle shaft THREAD LOCK 1324 Install the brake disk to the rear axle shaft Apply THREAD LOCK 1324 to the disk bolts and tighten them to the specified torque Install the rear axle shaft into the axle shaft housing NOTE Make sure that the brake disk is clean and free of any grease matter THREAD ...

Page 225: ...n of the rear axle shaft Tighten the inner axle shaft inner nut to the specified torque SUPER GREASE A BOND 1215 THREAD LOCK 1324 Axle shaft nut inner 120 150 N m 12 0 15 0 kgf m Apply THREAD LOCK 1324 to the thread portion of the rear axle shaft Tighten the rear axle outer nut to the specified torque THREAD LOCK 1324 Axle shaft nut outer 120 150 N m 12 0 15 0 kgf m C O P Y R I G H T E D ...

Page 226: ...axle housing nuts and wrench bolts to the specified torque in the described order Refer to page 2 21 Install the rear caliper and tighten the caliper mounting bolts to the specified torque Rear axle housing nut 70 100 N m 7 0 10 0 kgf m Rear axle housing wrench bolt 40 60 N m 4 0 6 0 kgf m Rear caliper mounting bolt 18 28 N m 1 8 2 8 kgf m C O P Y R I G H T E D ...

Page 227: ...SERVICING INFORMATION TROUBLESHOOTING 8 1 SPECIAL TOOLS 8 9 TIGHTENING TORQUE 8 12 SERVICE DATA 8 14 WIRE AND CABLE ROUTING 8 24 WIRING DIAGRAM 8 30 CONTENTS 8 C O P Y R I G H T E D ...

Page 228: ...on 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 camshaft drive chain 1 Stretched camshaft drive chain 2 Worn camshaft sprockets 3 Cam chain tensioner adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of cluth plates 3 Disto...

Page 229: ...hift pawl 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 adjustment in carburetor 8 Clogged jets 1 Valve springs weakened 2 Valve timing out of adjustment 3 Worn cams 4 Spark plug gap too narrow 5 Defective ignition coil 6 ...

Page 230: ...of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe 1 Heavy carbon deposit on piston head 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Fuel level too low in float chamber 5 Air leak from intake pipe 6 Use of incorrect engine oil 7 Defective cooling system Check with inspection win dow drain out excess oil Replace Replace ...

Page 231: ...ck and clean Overflow and fuel level fluctuations 1 Needle valve is worn or damaged 2 Spring in needle valve is borken 3 Float is not working properly 4 Foreign matter has adhered to needle valve 5 Fuel level is too high or low Replace Replace Check and adjust Clean Adjust float height RADIATOR COOLING SYSTEM Engine overheats 1 Not enough engine coolant 2 Radiator core clogged with dirt or scale 3...

Page 232: ... 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 Replace Clean and tighten ground connection Unstable charg...

Page 233: ...r 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 Battery sulfation 1 Charging rate too low or too high Whe...

Page 234: ...s 5 Defective or incorrect front tires 6 Damaged or worn suspension arms and related bearings 7 Distorted front wheels 8 Loose chassis nuts and bolts 1 High tire pressure 2 Worn steering linkage connections 3 Loose suspension system bolts 1 Worn or loose front wheel hub bearings 2 Improper front wheel alignment 1 Loose nuts and bolts 2 Damaged or worn front wheel hub bearings 3 Insufficiently lubr...

Page 235: ...on 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 tightening of c...

Page 236: ...0 20508 Cylinder gauge set Measure inside diameter of cylinder 09900 20605 Dial calipers Meassure width of conrod big 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...

Page 237: ... 09921 20210 Bearing remover 12mm Used to remove bearing with the rotor remove sliding shaft 09923 73210 Bearing remover 17mm Used to remove bearing with the rotor remove sliding shaft 09913 50121 Oil seal remover 09913 70122 Bearing installer Used to remove the oil seal Used to drive bearing in 09913 75820 Bearing installer Used to drive bearing in 09913 76010 Bearing installer Used to drive bear...

Page 238: ...8 11 SERVICING INFORMATION 09930 30164 Rotor remover Used to remove rotor Special tools PartNumber PartName Description C O P Y R I G H T E D ...

Page 239: ...ug Engine oil drain plug Engine oil inlet hose union bolt Engine mounting nut Engine mounting bolt Spark plug Camshaft housing bolt Cam chain tensioner mounting bolt Cam chain tension adjuster mounting bolt Cam chain tension adjuster bolt Crankcase bolt Clutch sleeve hub nut Primary drive gear nut Camshaft housing bolt Horn mounting bolt Gearshift cam stopper Gear position switch bolt 13 11 14 8 1...

Page 240: ...nsion arm pivot nut Tie rod end nut Tie rod lock nut Throttle case bolt Parking brake housing bolt Rear brake master cylinder rod lock nut Rear cushion rod nut Rear cushion lever nut Rear sprocket mounting bolt Rear axle shaft nut inner outer Handlebar clamp bolt Parking brake adjuster lock nut Rear brake caliper holder pin Rear brake caliper pin bolt 4 0 6 0 4 0 6 0 7 0 10 0 4 0 6 0 5 0 8 0 4 9 1...

Page 241: ...6 5 30 9 lbs at length 35 5 mm 1 40 in 1 25 1 65 0 049 0 065 IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX Inner Outer Inner Outer 0 35 0 014 0 05 0 002 0 50 0 02 0 35 0 014 36 9 1 45 39 9 1 57 VALVE GUIDE 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 Valve seat widt...

Page 242: ...x 11 0 0 433 Approx 10 0 0 394 0 25 0 40 0 010 0 016 0 40 0 55 0 016 0 022 1 21 1 23 0 0476 0 0484 1 01 1 03 0 040 0 041 2 01 2 03 0 079 0 080 1 170 1 190 0 0461 0 0469 0 970 0 990 0 0382 0 0390 1st 2nd 1st 2nd 1st 2nd 1st 2nd Oil 1st 2nd CYLINDER PISTON PISTON RING Compression pressure Piston to cylinder clearance Cylinder bore Piston diam Cylinder or cylinder head distortion Piston ring free end...

Page 243: ...ess Drive plate claw width Driven plate distortion Clutch spring free length 2 62 0 103 3 12 0 123 15 1 0 595 15 1 0 595 0 1 0 004 51 6 2 032 CLUTCH 10 15 0 4 0 6 2 92 3 08 0 115 0 121 3 42 3 58 0 135 0 141 15 9 16 0 0 626 0 630 15 9 16 0 0 626 0 630 54 2 2 134 Unit mm in NO 1 NO 2 NO 1 NO 2 ITEM STANDARD NOTE ITEM STANDARD LIMIT C O P Y R I G H T E D ...

Page 244: ...0 040 0 05 0 002 CONROD CRANKSHAFT Cam height Camshaft O D Camshaft housing I D Camshaft journal oil clearance Camshaft runout Cylinder head cover distortion Cam chain pin Arrow 3 15th pin 39 98 40 02 1 574 1 576 39 98 40 02 1 574 1 576 21 959 21 980 0 8645 0 8654 22 012 22 025 0 8666 0 8671 IN EX IN EX IN EX IN EX 39 88 1 570 39 88 1 570 0 15 0 006 0 10 0 004 0 05 0 002 CAMSHAFT CYLINDER HEAD Uni...

Page 245: ... 143 44 14 4 85 5 00 0 191 0 197 4 85 5 00 0 191 0 197 5 3 5 4 0 209 0 213 5 3 5 4 0 209 0 213 0 50 0 020 319 4 12 58 TRANSMISSION DRIVE BELT 2 538 33 13 1 684 32 19 1 261 29 23 1 040 26 25 0 885 23 26 2 231 29 13 RK 520EXW 102 317 5 12 50 1st 2nd 3rd 4th 5th Reverse 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 30 40 1 2 1 6 1 2 0 04 0 08 Unit mm in ITEM STANDARD ...

Page 246: ... N J Pilot jet P J Throttle valve TH V By pass B P Valve seat V S Starter jet G S Pilot screw P S Pilot outlet P O PV Stroke P V Throttle cable play BDS42 TYPE 42 1 300 1 500 rpm 13 0 51 162 5 50 6DFY08 54 3 O 6M 45 105 1 5 42 5 STD 1 1 29 6 3 5 0 12 0 20 ITEM SPECIFICATION CARBURETOR 1 0 9 2 0 8 3 0 8 Unit mm in C O P Y R I G H T E D ...

Page 247: ...e coolant type Engine coolant capacity Over 8 mm 90 Over 0 32 in 194 THERMOSTAT COOLING FAN COOLANT Valve opening Valve closing OFF ON ON OFF OFF ON ON OFF 76 169 71 160 Approx 120 248 Approx 113 235 Approx 95 203 Approx 88 190 1 4 ℓ Use an antifreeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 ITEM STANDARD LIMIT C O P Y R I G H T E D ...

Page 248: ...istance Magneto no load voltage Battery standard charging voltage CR8E 0 7 0 8 0 028 0 032 CR7E CR8E CR9E Over 8mm 0 32 90 110 Ϊ 0 3 0 8 Ϊ YTX9 BS 12V 8Ah 15A Pick up coil Charging coil G L Y Y Type Gap Hot type Standard type Cold type BTDC 6 1 500rpm Over 70V 5 000 rpm 13 5 15 0V 5 000 rpm 1 320 at 20 68 Unit mm in ITEM STANDARD NOTE C O P Y R I G H T E D ...

Page 249: ...Right left High beam indicator lamp Coolant temperature indicator lamp Fuel indicator lamp Reverse indicator lamp 5W LED type 10W 4 LCD type 3 4W 3 4W 3 4W 3 4W 3 4W 3 4W 55W 55W 5W ITEM SPECIFICATION HI LO POSITION WATTAGE CAUTION Do not use except the specified bulb Wattage LED Light Emitting Diode LCD Liquid Crystal Display Unit W C O P Y R I G H T E D ...

Page 250: ... end of S direction counter clockwise Turn to H direction clockwise Turn to S direction counter clockwise End of S direction counter clockwise Turn to H direction clockwise STANDARD REAR SHOCK ABSORBER DAMPING FORCE Compression Tension Softer Standard Stiffer Turn to S direction counter clockwise 1 turn from end of S direction counter clockwise Turn to H direction clockwise Turn to S direction cou...

Page 251: ...75 kg 165 lbs Caster Camber 4 0 0 16 4 3 0 17 15 870 15 913 0 6248 0 6265 12 700 12 743 0 5000 0 5017 15 827 15 854 0 6227 0 6242 12 657 12 684 0 4983 0 4994 32 1 26 32 1 26 DOT4 DOT4 21 7 10 20 11 9 10 5 5 9 8 355 14 0 when one person riding from the ground 0 5 mm 0 0 2 in 7 3 0 3 0 0 12 3 0 0 12 0 3 0 012 6 0 24 4 0 16 4 0 16 Front Rear Front Rear Front Rear Front Rear Front Rear Front Rear Fron...

Page 252: ...d gasoline is recommened API Over SL SAE 10W 40 2 500 2 600 2 700 1 900 100 550 150 FUEL OIL Change Filter change Overhaul Oil tand side Filter side Engine side Oil hose side TIRE PRESSURE COLD INFLATION TIRE PRESSURE FRONT ONE PERSON TWO PERSONS 0 3 kgf cm2 30 kPa 4 4 psi 0 35 kgf cm2 35 kPa 4 9 psi 0 35 kgf cm2 35 kPa 4 9 psi 0 3 kgf cm2 30 kPa 4 4 psi REAR ITEM STANDARD NOTE C O P Y R I G H T E...

Page 253: ...SERVICING INFORMATION 8 26 WIRE AND CABLE ROUTING C O P Y R I G H T E D ...

Page 254: ...8 27 SERVICING INFORMATION C O P Y R I G H T E D ...

Page 255: ...SERVICING INFORMATION 8 28 C O P Y R I G H T E D ...

Page 256: ...8 29 SERVICING INFORMATION C O P Y R I G H T E D ...

Page 257: ...SERVICING INFORMATION 8 30 C O P Y R I G H T E D ...

Page 258: ...8 31 SERVICING INFORMATION C O P Y R I G H T E D ...

Page 259: ... Black with White tracer WB White with Black tracer Gr Gray Sb Light blue L Blue W White YB Yellow with Black tracer BL Black with Blue tracer WL White with Blue tracer YW Yellow with White tracer GR Green with Red tracer GL Green with Blue tracer WL White with Blue tracer YR Yellow with Red tracer C O P Y R I G H T E D ...

Page 260: ... 80 2 85 2 90 2 95 3 00 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2...

Page 261: ...0 2 95 3 00 2 30 2 35 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 2 40 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 2 45 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 2 50 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 05 3 10 3 15 3 20 3 25 3 30 2 55 2 60 2 65 2 70 2 75 2 80 2 85 2 90 2 95 3 00 3 0...

Page 262: ...Prepared by 1st Ed MAR 2007 Manual No 99000HP8910 Printed in Korea C O P Y R I G H T E D ...

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