KYMCO 125 MOVIE S INJECTION Manual Download

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. FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

12-1

SERVICE INFORMATION

GENERAL INSTRUCTIONS

•

Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front

wheel off the ground and be careful to prevent the motorcycle from falling down.

•

During servicing, keep oil or grease off the brake drum and brake linings.

•

Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake

disk with high-performance brake degreaser and replace the brake pads.

•

Do not use brake fluid for cleaning.

•

Bleed air from the brake system if the brake system is removed or the brake is soft.

•

Do not allow any foreign matters to enter the brake system when filling it with brake fluid.

•

Brake fluid will damage painted surfaces and plastic parts. When servicing the brake system, use

shop towels to cover and protect rubber, plastic parts and coated surfaces. Wipe off any spilled

brake fluid with a clean shop towel.

•

Inspect the brake system before riding.

SPECIFICATIONS

Item

Standard (mm)

Service Limit (mm)

Axle shaft runout

0.2

Radial

2.0

Axial

2.0

Front brake drum I.D

110

111

Front brake lining thickness

4.0

2.0

Front shock absorber spring free length

259

251

Brake disk thickness

3.5

3.8

3.0

Brake disk runout

0.30

Brake master cylinder I.D.

12.700

12.743

12.75

Brake master cylinder piston O.D.

12.657

12.684

12.64

Brake caliper piston O.D.

30.148

30.198

30.140

Brake caliper cylinder I.D.

30.230

30.280

30.29

TORQUE VALUES

Steering stem bolt

4.0

5.0kg-m

Brake caliper bleed valve

0.6kg-m

Steering stem lock nut

8.0

12.0kg-m

Brake fluid tube bolt

2.5

3.5kg-m

Steering top cone race

0.5

1.3kg-m

Brake pad pin bolt

1.5

2.0kg-m

Front shock absorber bolt 2.0

2.5kg-m

brake caliper bolt

2.9

3.5kg-m

Front axle nut

6.0kg-m

Brake master cylinder bolt

1.0

1.4kg-m

Front wheel rim runout

SERVICE INFORMATION.................... 12-1

HYDRAULIC BRAKE ........................... 12-10

TROUBLESHOOTING .......................... 12-2

FRONT SHOCK ABSORBER ............... 12-16

FRONT WHEEL...................................... 12-3

STEERING HANDLEBAR .................... 12-19

FRONT BRAKE...................................... 12-6

STEERING STEM .................................. 12-20

HYDRAULIC BRAKE DRAWING....... 12-9

Summary of Contents for 125 MOVIE S INJECTION

Page 1: ...sembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 FRAME COVERS EXHAUST MUFFLER 2 INSPECTION ADJUSTMENT 3 LUBRICATION SYSTEM 4 FUEL SYSTEM 5 ENGINE REMOVAL INSTALLATION 6 CYLINDER HEAD VALVES 7 CYLINDER PISTO...

Page 2: ...f Engine Serial Number 1 ENGINE SERIAL NUMBER 1 ENGINE SERIAL NUMBER 1 1 LUBRICATION POINTS 1 13 SPECIFICATIONS 1 2 CABLE HARNESS ROUTING 1 15 SERVICE PRECAUTIONS 1 3 WIRING DIAGRAM 1 20 TORQUE VALUES 1 11 TROUBLESHOOTING 1 21 TOOLS 1 12 ...

Page 3: ... cold mm Exhaust 0 12 Idle speed rpm 1700rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 0 9 liter Cooling Type Forced air cooling Air cleaner type No Paper element wet Fuel capacity 7 8 liters Type VE45 Piston dia mm 24 Venturi dia mm 22 1 equivalent Throttle type Butterfly type Type CDI Ignition timing 13 3 BTDC...

Page 4: ...ng bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally n Use genuine parts and lubricants n When servicing the motorcycle be sure to use special tools for removal and installation n After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly ...

Page 5: ...l working safety n Disconnect the battery negative terminal before operation n When using a spanner or other tools make sure not to damage the motorcycle surface n After operation check all connecting points fasteners and lines for proper connection and installation n When connecting the battery the positive terminal must be connected first n After connection apply grease to the battery terminals ...

Page 6: ...capacity n After operation terminal caps shall be installed securely n When taking out the connector the lock on the connector shall be released before operation n Hold the connector body when connecting or disconnecting it n Do not pull the connector wire n Check if any connector terminal is bending protruding or loose Confirm Capacity ...

Page 7: ...rminal cover or loose negative terminal n Check the double connector cover for proper coverage and installation n Insert the terminal completely n Check the terminal cover for proper coverage n Do not make the terminal cover opening face up n Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact...

Page 8: ...sure that it is not interfering with any moving or sliding parts n When fixing the wire harnesses do not make it contact the parts which will generate high heat n Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws n Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws No Contact ...

Page 9: ...a sharp edge or corner n When rubber protecting cover is used to protect the wire harnesses it shall be installed securely n Do not break the sheath of wire n If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it n When installing other parts do not press or squeeze the wires Do not pull too tight Do not press or squeeze the wire ...

Page 10: ...ns n When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions n Be careful not to drop any parts n When rust is found on a terminal remove the rust with sand paper or equivalent before connecting n Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind Do you unders...

Page 11: ...g methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gear Oil 90 Use special tool Caution Warning 12 3 Refer to page 12 3 Engine Oil Grease Gear Oil Special ...

Page 12: ... face seal cover bolt Starter clutch cap bolt Drive face nut Spark plug Starter clutch lock nut Cam chain tensioner screw 2 4 1 2 4 2 1 1 1 1 3 3 1 1 1 1 8 8 30 6 8 5 6 8 12 12 4 6 12 10 22 6 0 9 0 9 1 5 1 2 2 0 0 9 1 0 1 3 5 5 5 5 0 3 1 2 5 5 1 2 9 5 0 4 Double end bolt Double end bolt Apply oil to threads Left hand threads FRAME Item Q ty Thread dia mm Torque kg m Remarks Steering stem lock nut ...

Page 13: ... assembly collar Crankshaft assembly shaft Attachment Lock nut wrench Lock nut wrench Ball race remover extension Ball race remover Spring compressor Spring compressor attachment Spring compressor attachment Spring compressor attachment Lock nut wrench Driver outer extension Float level gauge Valve spring compressor Valve seat cutter 24 5mm 45 IN EX Valve seat cutter 25mm Plane cutter 32 IN Valve ...

Page 14: ...t right side oil seal Crankshaft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip GenuineKYMCO Engine Oil SAE10W 30 API SE SF or SG Engine Oil Starter idle gear Friction springmovable part shaft movablepart Shaft movable grooved part Starter spindle movable pa...

Page 15: ...ied This will avoid abnormal noise and rise the durability of the motorcycle Seat Lock Rear Wheel Bearings Grease Front Brake Cable Speedometer Cable Throttle Cable Main Stand Pivot Speedometer Gear Front Wheel Bearings Brake Cam Anchor Pin Front Shock Absorber Lower Mount Bushings Pivot Engine Oil Grease Grease Grease Grease Front Brake Lever Pivot Engine Oil Rear Brake Cable Brake Cam Anchor Pin...

Page 16: ...itch Wire Rear Stop Switch Wire Throttle Cable Regulator Rectifier Resistor Buzzer Front Brake Fluid Tube Rear Brake Cable Speedometer Cable Horn Instrument Cable Ignition Switch Secondary Air Cleaner Charging Indicator Front Brake Fluid Tube Front Brake Reservoir ...

Page 17: ...RAL INFORMATION 1 16 Throttle Cable Regulator Rectifier Speedometer Cable Wire Harness Secondary Air Inlet Tube Charging Indicator Secondary Air Inlet Tube Resistor Front Brake Fluid Tube Rear Brake Cable be ...

Page 18: ...1 GENERAL INFORMATION 1 17 Wire Harness Ground Reserve Fuse Fuse Battery Cable Battery Cable CDI Unit Battery Cable Battery Cable CDI Unit ...

Page 19: ...1 GENERAL INFORMATION 1 18 Fuel Valve Vacuum Tube Throttle Cable Fuel Vapor Recovery Tube Vacuum Tee Fuel Tube Ignition Coil Auto Bystarter Wire Crankcase Breather Tube Ground A C Generator Wire ...

Page 20: ...arter Relay Fuel Tube Carburetor Vacuum Tube Auto Bystarter Wire Starter Motor Wire Auto Bystarter Fuel Vapor Tube Fuel Unit Fuel Unit Wire Harness Crankcase Breather Tube Vacuum Tee Charcoal Canister Purge Control Valve Reed Valve Starter Relay ...

Page 21: ...1 GENERAL INFORMATION 1 20 WIRING DIAGRAM R Red O Orange B Black P Pink W White Br Brown G Green LG Light green V Violet SB Light blue L Blue GR Gray Y Yellow ...

Page 22: ...ston rings Leaking cylinder head gasket Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it into spark plug cap to test spark by connecting ...

Page 23: ...carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause Engine speed increases Correct timing Engine speed does not increase sufficiently Incorrect timing Check ignition timing using a timing light Test cylinder compression Check carburetor for...

Page 24: ... coil Broken or shorted spark plug wire Faulty ignition switch Faulty air cut off valve Damaged vacuum tube Clogged or damaged air vent hole Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment Symptom Probable Cause Check ignition timing Check air cut off valve Check carburetor gasket for air leaks Check carburetor pilot screw ...

Page 25: ...Clean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel supply Correct timing Incorrect timing Check valve spring tension Check valve clearance Fuel flows freely Fuel flow restricted Correct Incorrect Not clogged Clogged Correctly adjusted Incorrectly adj...

Page 26: ...er coupler red wire and battery wire to engine ground and test voltage Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Battery has voltage with ignition switch ON Normal Voltage does not increase Battery has no voltage with ignition switch ON Resistance too high Normal voltage No voltage Measure resistance between AC generator coil terminals...

Page 27: ...ÅFaulty ignition coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abnormal Measure resistance between terminals of CDI unit coupler Check related parts Check ignition coil with a CDI unit tester Weak or no spark Not loose Good spark Loose Good Good Check spark plug ...

Page 28: ...2 FRAME COVERS EXHAUST MUFFLER 2 0 2FRAME COVERS LAYOUT 2 ...

Page 29: ...bles and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Exhaust muffler air leaks Clogged exhaust muffler SERVICE INFORMATION 2 1 FRAME COVERS 2 2 TROUBLESHOOTING 2 1 EXHAUST MUFFLE...

Page 30: ...the two screws on the rear end of each of the rear right and left side covers Remove the two screws on the front end of each of the rear right and left side covers Remove the rear right and left side covers by pulling them backward The installation sequence is the reverse of removal FRAME BODY COVER REMOVAL Remove the two bolts attaching the rear part of the frame body cover Remove the two screws ...

Page 31: ... frame body cover Disconnect the seat lock wire Remove the frame body cover FRAME CENTER COVER REMOVAL Remove the two screws on the bottom of the frame center cover Remove the frame center cover FRONT SIDE COVERS REMOVAL Remove the front cover 2 4 Remove the bolt and six screws attaching each of the front right and left side covers Remove the front side covers by pulling them outward The installat...

Page 32: ...move the handlebar front cover bolt Remove the two screws that combine the handlebar front cover with the front tool box Remove the handlebar front cover HANDLEBAR REAR COVER REMOVAL Disconnect all of the wire connectors couplers and the speedometer cable Remove the two screws attaching the handlebar rear cover Remove the handlebar rear cover The installation sequence is the reverse of removal Fro...

Page 33: ...everse of removal FRONT TOOL BOXREMOVAL Remove the bolt attaching the front tool box Remove the front tool box The installation sequence is the reverse of removal BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom cover Remove the bottom cover The installation sequence is the reverse of removal CDI Unit Bottom Cover Battery Front Tool Box Floor Board Bolts Bolt When removing first dis...

Page 34: ...ck bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m Be sure to install a new exhaust muffler packing collar ...

Page 35: ...rottle grip free play 2_ 6mm Spark plug gap 0 6_ 0 7mm Spark plug Standard NGK C7HSA C6HSA C8HSA Valve clearance IN 0 12mm EX 0 12mm Idle speed 1700 100rpm Engine oil capacity At disassembly 0 9 liter At change 0 75 liter Gear oil capacity At disassembly 110cc At change 90cc 3 SERVICE INFORMATION 3 0 FINAL REDUCTION GEAR OIL 3 7 MAINTENANCE SCHEDULE 3 2 DRIVE BELT 3 7 FUELLINE 3 3 BRAKE SHOE 3 8 T...

Page 36: ...g BTDC 13 3 1700 100rpm CHASSIS Front brake free play 10_ 20mm Rear brake free play 10_ 20mm TIRE PRESSURE 1 Rider 2 Riders Front 1 75kg cm 2 1 75kg cm 2 Rear 2 00kg cm 2 2 25kg cm 2 TIRE SIZE Front 100 90 10 Rear 100 90 10 TORQUE VALUES Front axle nut 6 0kg m Rear axle nut 11 0kg m ...

Page 37: ... Gear oil Note 3 R New motorcycle 300km R R Valve clearance A A A A Carburetor I I C Air Cleaner Note 2 3 Replace at every 3000km Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I I I I I I I Drive belt I Suspension I I I Nut bolt fastener I Tire I I I Steering head bearing I I I In the interest of safety we recommend these items should be serviced only by an autho...

Page 38: ...Free Play 2_ 6mm Major adjustment of the throttle grip free play is made at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Lock Nut Adjusting Nut Fuel Filter Do not smoke or allow flames or sparks...

Page 39: ...rainy areas SPARK PLUG Remove the spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK C7HSA C6HSA C8HSA Measure the spark plug gap Spark Plug Gap 0 6_ 0 7mm Cracks Damage The air cleaner element has a viscous type paper element Do not clean it with compressed air Be sure to install the air clean...

Page 40: ... and adjust by turning the adjusting nut Valve Wrench CARBURETOR IDLE SPEED Remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700 100rpm When the engine misses or run erratic adjust the pilot screw Throttle Stop Screw Inspect and adjust valve clearance while the ...

Page 41: ...arm up the engine before compression test Remove the met in box and frame center cover 2 3 Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 12 8kg cm 570rpm If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn piston rings Worn piston cy...

Page 42: ...ll with the recommended oil Oil Capacity At disassembly 110cc At change 90cc Reinstall the oil check bolt and check for oil leaks Torque 1 2kg m DRIVE BELT Remove the left crankcase cover 9 2 Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule Drive Belt Oil Check Bolt Sealing Washer Was Place the mo...

Page 43: ...l when the brake is fully applied Refer to page13 3 for brakeshoereplacement BRAKE SYSTEM FRONT BRAKE Measure the front brake lever free play Free Play 10_ 20mm If the free play do not fall within the limit adjust by turning the adjusting nut REARBRAKE Measure the rear brake lever free play Free Play 10_ 20mm Arrows Was Adjusting Nut Punch Mark Was ...

Page 44: ...screw CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary 9 14 SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assem...

Page 45: ...d bolts for looseness Tighten them to their specified torque values if any looseness is found 1 11 WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure TIRE PRESSURE 1 Rider 2 Riders Front 1 75kg cm 2 1 75kg cm 2 Rear 2 00kg cm 2 2 25kg cm 2 TIRE SIZE Front 100 90 10 Rear 100 90 10 Check the front axle nut for looseness Check the rear axle nut for looseness...

Page 46: ...MENT 3 11 STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing 12 20 ...

Page 47: ...4 LUBRICATION SYSTEM 4 0 Oil Pump Oil Filter Screen Crankshaft 4 LUBRICATION SYSTEM 4 Rocker Arm Shaft ...

Page 48: ...service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm Inner rotor to outer rotor clearance æ 0 12 Oil pump Outer rotor to pump body clearance æ 0 12 Rotor end to pump body clearance 0 05_ 0 10 0 2 TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter o...

Page 49: ...ace if necessary Install the oil filter screen spring and filter screen cap Torque 1 5kg m Fill with the specified SAE15W40 API SG CD engine oil to the proper level Oil Capacity At disassembly 0 90 liter At change 0 75 liter Check for oil leaks and then start the engine and let it idle for few minutes Recheck the oil level Oil Dipstick O ring Oil Filter Screen Cap Place the motorcycle upright on l...

Page 50: ...erator flywheel 14 6 Remove the nine right crankcase cover bolts and the right crankcase cover Remove the gasket and dowel pins Remove the starter idle gear and starter clutch 16 6 Remove the two bolts and oil separator cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain Oil Separator Cover Gasket ...

Page 51: ...w Remove the two oil pump mounting bolts and the oil pump DISASSEMBLY Remove the screw and disassemble the oil pump INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 12mm Measure the inner rotor to outer rotor clearance Service Limit 0 12mm Oil Pump Pump Body ...

Page 52: ...wel pin Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding INSTALLATION Install the oil pump into the crankcase Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the oil pump with the arrow on the pump body facing up and fil...

Page 53: ...ts Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft Install and tighten the pump driven gear nut Torque 1 0kg m Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch 16 8 Install the gasket and dowel pins Oil Separator Cover Gasket Dowel Pin ...

Page 54: ...4 LUBRICATION SYSTEM 4 7 Right Crankcase Cover Stator Bolts Pulser Coil Install the right crankcase cover and tighten the nine bolts Torque 0 9kg m Diagonally tighten the bolts in 2_ 3 times ...

Page 55: ...5 FUEL SYSTEM 5 0 5 FUEL SYSTEM 5 ...

Page 56: ...uum diaphragm When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel SPECIFICATIONS Item Standard Venturi dia mm 22 1 Identification number VE020B Float level mm 18 5 Main jet 110 Slow jet 35 Idle speed 1700 100rpm Throttle grip free play 2_ 6mm Pilot screw opening 3 1 2 SPECIAL TOO...

Page 57: ... air leak Fuel overflowing Incorrect idle speed Intake air leak Incorrectly adjusted pilot screw Contaminated fuel Clogged idle system or auto bystarter passages Faulty auto bystarter Incorrectly adjusted float level Clogged idle system or auto bystarter passages Lean mixture Rich mixture Clogged fuel jets Faulty auto bystarter Faulty float valve Faulty float valve Float level too low Float level ...

Page 58: ...able from the carburetor Loosen the carburetor intake manifold band and air cleaner connecting tube band screws and then remove the carburetor AUTO BYSTARTER OPERATION INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 10W max 10 minutes minimum after stopping the engine If the reading is not within the limit replace the auto bystarter with a new one Auto Bystar...

Page 59: ...tarter is normal REMOVAL Remove the set plate screws and set plate Remove the auto bystarter from the carburetor AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part is found replace the auto bystarter as a set INSTALLATION Insert the auto bystarter into the carburetor body until it bottoms Position the set plate into the groove in the aut...

Page 60: ...f valve cover and then tighten the two screws VACUUM CHAMBER DISASSEMBLY Remove the two vacuum chamber cover screws and the cover Remove the spring and vacuum diaphragm piston Spring Screws Vacuum Diaphragm Be sure to set the vacuum diaphragm lip into the groove on the carburetor When installing the air cut off valve cover make sure that the vacuum diaphragm is properly installed Vacuum Diaphragm ...

Page 61: ...n diaphragm in the carburetor body and align the tab on the diaphragm with the groove in the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber Vacuum Chamber Cover Becareful not to damage thediaphragm Hold the vacuum piston while tightening the vacuum chamber co...

Page 62: ...through all passages of the carburetor body Pilot Screw Be careful not to damage the fuel jets and pilot screw Before removing turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this Do not force the pilot screw against its seat to avoid seat damage Float Valve Float Float Pin Valve Seat Also remove and clean the vacuum chamber and air cu...

Page 63: ...dle jet holder main jet and pilot screw Standard Opening 3 1 2turns Install the float valve float and float pin Float Valve Return the pilot screw to the original position as noted during removal Float Pin Pilot Screw Slow Jet Main Jet Needle Jet Holder Needle Jet ...

Page 64: ... Connect the throttle cable to the throttle wheel on the carburetor Connect the fuel tube and vacuum tube to the carburetor Connect the auto bystarter wire connector Perform the following inspections and adjustments Throttle grip free play 3 3 Carburetor idle speed 3 6 Special Auto Bystarter Wire Connector Vacuum Tube Connecting Tube Band Throttle Cable Check the operation of the float valve and f...

Page 65: ...pm Turn the pilot screw in or out slowly to obtain the highest engine speed Slightly accelerate several times to make sure that the idle speed is within the specified range If the engine misses or runs erratic repeat the above steps The pilot screw is factory pre set and no adjustment is necessary During carburetor disassembly note the number of turns of the pilot screw and use as a reference when...

Page 66: ...ect the fuel unit wire connector Disconnect the fuel tube and vacuum tube at the auto fuel valve Remove the four fuel tank mounting bolts and fuel tank INSTALLATION Install the fuel tank in the reverse order of removal Fuel Unit Wire Connector Fuel Tank Auto Fuel Valve Vacuum Tube ...

Page 67: ... Check the vacuum diaphragm for poor installation or damage and inspect the fuel tube for clogging FUEL UNIT REMOVAL Disconnect the fuel unit wire connector Turn the fuel unit retainer counterclockwise and remove the fuel unit INSTALLATION Inspect the fuel unit gasket for damage Install the fuel unit by aligning the groove in the fuel unit with the tab on the fuel tank No Smoking Fuel Unit Retaine...

Page 68: ...LEANER Loosen the air cleaner connecting tube band screw Disconnect the transmission case breather tube from the air cleaner case Remove the two bolts and air cleaner case The installation sequence is the reverse of removal Make sure that the arrow on the retainer is aligned with the arrow on the fuel tank Retainer Arrow Air Cleaner Case ...

Page 69: ...6 ENGINE REMOVAL INSTALLATION 6 0 6 6 4 0kg m 7 0kg m ...

Page 70: ...ed to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal Use shop towels to protect the motorcycle body during engine removal Parts requiring engine removal for servicing æ Crankcase æ Crankshaft SERVICE INFORMATION 6 1 ENGINE INSTALLATION 6 4 ENGINE REMOVAL 6 2 ...

Page 71: ...the starter relay Remove the spark plug cap and disconnect the ignition coil wire from the set plate Disconnect the fuel tube at the carburetor side Disconnect the auto fuel valve vacuum tube from the tee tube Disconnect the throttle cable from the carburetor Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube Starter Relay Auto Bystarter Wire Connector Fuel...

Page 72: ... generator cooling fan cover bolts and cooling fan cover Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger Remove the engine hanger bracket bolt and nut Remove the engine hanger bracket Engine Mounting Bolt Rear Shock Absorber Upper Mount Bolt Engine Hanger Bracket Ignition C...

Page 73: ...TALLATION Install the engine and tighten the engine mounting bolt Torque 7 0kg m Tighten the rear shock absorber upper mount bolt Torque 4 0kg m Install the removed parts in the reverse order of removal After installation inspect and adjust the following Throttle grip free play 3 3 Rear brake adjustment 3 8 Bushings Engine Mounting Bolt Bolt Stopper Rubbers Rear Shock Absorber Upper Mount Bolt Rou...

Page 74: ...7 CYLINDER HEAD VALVES 7 0 7 7 0 8kg m 1 2kg m 2 0kg m ...

Page 75: ...f removal SPECIFICATIONS Item Standard mm Service Limit mm IN 0 12 æ EX 0 12 æ Cylinder head compression pressure 12 8kg cm ñ 570rpm Cylinder head warpage æ IN 25 965 25 57 EX 25 810 25 41 IN 10 000_ 10 015 10 10 EX 10 000_ 10 015 10 10 Valve rocker arm shaft IN 9 972_ 9 987 9 91 O D EX 9 972_ 9 987 9 91 IN 1 0 1 8 EX 1 0 1 8 IN 4 975_ 4 990 4 90 EX 4 955_ 4 970 4 90 IN 5 000_ 5 012 5 03 EX 5 000_...

Page 76: ...ead operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler Compression too low Worn valve stem or valve guide Damaged valve stem seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or ...

Page 77: ...e the cam chain tensioner cap screw and the O ring Turn the cam chain tensioner screw clockwise to tighten it Turn the flywheel counterclockwise so that the T mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Cylinder Head Cover O ring Tensioner Screw Round Hole Camshaft Gear Scre...

Page 78: ...ove the camshaft gear from the cam chain and remove the camshaft CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 25 57mm replace if below EX 25 41mm replace if below Cam Chain Camshaft Gear Diagonally loosen the cylinder head nuts in 2 or 3 times Camshaft Holder Nut Bolt Washer Dowel Pins Camshaft ...

Page 79: ...OLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 91mm replace if over EX 9 91mm replace if over Camshaft Holder If the valve rocker arm contact surface is worn check each cam lobe f...

Page 80: ...L Remove the camshaft 7 3 Remove the carburetor 5 3 Remove the exhaust muffler 2 6 Remove the carburetor intake manifold Remove the cooling fan cover 14 6 Remove the engine cover bolts and screws Separate the engine cover joint claws Intake Manifold ...

Page 81: ... valve stem seals using a valve spring compressor Valve Spring Compressor Valve Spring Compressor Attachment Valve Spring Compressor Cylinder Head Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Dowel Pins Avoid damaging the cylinder mating surface Be careful not to drop any gasket material into the engine Cam Chain Guid...

Page 82: ... gauge Service Limit 0 05mm repair or replace if over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner 31 2mm replace if below Outer 34 1mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 90mm replace i...

Page 83: ... guide from the camshaft side The cylinder head should still be hot for installation of a new guide Valve Guide Driver Valve Guide Driver If the stem to guide clearance exceeds the service limits replace the guides as necessary Reface the valve seats whenever the valve guides are replaced The cylinder head must be heated evenly and rapidly to avoid warpage Valve Guide Reamer Be careful not to dama...

Page 84: ...he valve must be replaced Inspect the valve seat width Service Limit 1 8mm replace if over If the seat is too wide or too narrow the seat must be ground using a valve seat cutter VALVE SEAT CUTTERS Refer to the Instructions supplied with the Valve Seat Refacing Equipment for details When refacing the seat apply a force of 4_ 5kg to press the valve seat cutter for grinding operation Valve Seat Cutt...

Page 85: ...g a 45 cutter Use a 32 cutter to remove the upper existing valve seat material Use a 60 cutter to remove the lower existing valve seat material Install a 45 finish cutter and cut the seat to the proper width Standard Seat Width 1 0mm Roughness Old Seat Width Be careful not to grind too much Old Seat Width ...

Page 86: ...the valve spring seats and valve stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters Valve Spring Compressor Valve Spring Compressor Attachment Be sure to install new valve stem seals Old Seat Width Old Seat Width Contact t...

Page 87: ...SSEMBLY Install the exhaust valve rocker arm to the EX mark side of the camshaft holder Install the intake valve rocker arm and the rocker arm shafts Gasket Valve Rocker Arm Cam Chain Guide Cylinder Head Camshaft Holder Be careful not to damage the valves Dowel Pins Align the cutout on the front end of the intake valve rocker arm shaft with the bolt of the camshaft holder Align the cross cutout on...

Page 88: ...nto the cylinder head Install the cam chain over the camshaft gear Install the dowel pins Install the camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts and two bolts Torque Cylinder head nut 2 0kg m Adjust the valve clearance 3 5 Turn the cam chain tensioner screw counter clockwise to release it Dowel Pins Nut Washer Punch Marks Cam Chain Round Hole Apply en...

Page 89: ...m chain tensioner cap screw Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts Cylinder Head Cover O ring Be sure to install the O ring into the groove properly Be sure to install the O ring into the groove properly ...

Page 90: ...8 CYLINDER PISTON 8 0 8 8 Do not bend ...

Page 91: ...02_ 15 008 15 04 Piston pin O D 14 994_ 15 000 14 96 Piston to piston pin clearance 0 002_ 0 014 0 02 Connecting rod small end I D bore 15 016_ 15 034 15 06 TROUBLESHOOTING When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression E...

Page 92: ... Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston and remove the piston Dowel Pins Gasket Cylinder Piston Piston Rings Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase ...

Page 93: ... clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 15 04mm replace if below Take care not to damage or break the piston rings during removal Use the piston head to push each piston...

Page 94: ...iston pin in both X and Y directions Service Limit 52 50mm repair or replace if below Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if below The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels is subject to the maximum value calculated Service Limits True ...

Page 95: ...15 06mm replace if below PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Second Side Rail Top Be careful not to damage or break the piston and piston rings All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking Second Top Side Rail Oil Ring ...

Page 96: ...piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Gasket Cylinder Be careful not to drop foreign matters into the crankcase Position the piston IN mark on the intake valve side Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Be careful not to damage or break the piston rings Stagger ...

Page 97: ...osely install the cylinder base bolts Install the cam chain guide Install the cylinder head 7 13 Tighten the cylinder base bolts Insert the tab on the cam chain guide into the cylinder groove Cylinder Base Bolt Cam Chain Guide ...

Page 98: ...9 DRIVE AND DRIVEN PULLEYS KICK STARTER 9 0 9 5 5kg m 5 5kg m 5 5kg m ...

Page 99: ...63 7 Driven face O D 33 965_ 33 485 33 94 Movable driven face I D 34 000_ 34 025 34 06 Weight roller O D 17 920_ 18 080 17 40 TORQUE VALUES Drive face nut 5 5kg m Clutch outer nut 5 5kg m Clutch drive plate nut 5 5kg m SPECIAL TOOLS Universal holder Clutch spring compressor Driver handle A Lock nut wrench 39mm Outer driver 32x35mm Bearing driver Pilot 20mm Bearing driver TROUBLESHOOTING Engine sta...

Page 100: ... crankcase cover Remove the seal rubber and dowel pins INSTALLATION Install the dowel pins and seal rubber Install the left crankcase cover and tighten the left crankcase cover bolts Install the cable clamp to the specified location and tighten the bolt Cable Clamp Left Crankcase Cover Air Tube Band Bolts Dowel Pins Seal Rubber Left Crankcase Cover Bolts Screw ...

Page 101: ...ive pulley face Universal Holder Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch driven pulley and drive belt INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 19 0mm replace if below Drive Pulley Face Universal Holder Special Use specified genuine parts for replace ment M...

Page 102: ...LEYS KICK STARTER 9 4 Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers Drive Pulley Collar Ramp Plate Weight Roller Movable Drive Face Assembly ...

Page 103: ...e Measure each weight roller O D Service Limit 17 4mm replace if below Measure the movable drive face bushing I D Service Limit 24 06mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 23 94mm replace if below ...

Page 104: ...9 DRIVE AND DRIVEN PULLEYS KICK STARTER 9 6 ASSEMBLY Install the weight rollers into the movable drive face Install the ramp plate Weight Roller Ramp Plate ...

Page 105: ...ar into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Lay the drive belt on the driven pulley Set the drive belt on the drive pulley collar Drive Pulley Collar Driven Pulley Drive Belt Movable Drive Face Assembly Drive Pulley Collar ...

Page 106: ... nut Universal Holder Remove the clutch outer INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 125 5mm replace if over Drive Pulley Face Starting Ratchet Special Special Do not get oil or grease on the drive belt or pulley faces Clutch Outer Drive Face Nut Drive Pulley Universal Holder Universal Holder When installing the drive pulley face compress ...

Page 107: ...with the clutch spring compressor Clutch Spring Compressor Outer Driver 32x35mm Set the clutch spring compressor in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Clutch Driven Pulley Special Special Clutch Spring Compressor Be sure to use a clutch spring compressor to av...

Page 108: ...the driven face Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 163 7mm replace if below Check the driven face for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Movable Driven Face Guide Roller Pin O ring Guide Roller Oil Seal ...

Page 109: ...ing and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Bearing Driver Seat the snap ring in its groove Apply grease to the driven face bore areas Inner Bearing Outer Bearing Discard the removed bearing and replace with a new one Pack all bearing cavities with 9_ 9 5g grease Specified grea...

Page 110: ...9 12 Press a new needle bearing into the driven face Bearing Driver Pilot 20mm CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Circlip Retainer Plate Special Keep grease off the clutch linings Clutch Lining ...

Page 111: ...ive plate Install the retainer plate and secure with the circlips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the driven pulley faces and remove any grease from them Install the oil seal onto the moveable driven face Apply grease to the O rings and install them onto the moveable driven face Circlip Oil Seal Retainer Plate Clutch Weights Shoes Drive Plate Springs Movable Driven Face ...

Page 112: ...stall the drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 5kg m Clutch Spring Compressor Outer Driver 32x35mm INSTALLATION Install the clutch driven pulley onto the drive shaft Be sure to clean the driven face off any grease Align the flat surface of the driven face with the flat on the clutch drive plate Keep grease off t...

Page 113: ...nstall the left crankcase cover 9 2 KICK STARTER REMOVAL Remove the left crankcase cover 9 2 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Universal Holder Clutch Outer Friction Spring Kick Starter Spindle Special Circlip...

Page 114: ...r weakness or damage Inspect the kick starter spindle bushings for wear or damage Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or damage Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage Return Spring Starter Driven Gear Shaft Forcing Part Friction Spring Starter Driven Gear Kick Starter Spindle Spindle Return Sprin...

Page 115: ...tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw Rear Brake Cable Clamp When installing the return spring use a screw driver to press the inward and outward return spring hooks into their original positions respectively Left Crankcase Cover For drum brake be sure to installthe rear brake cable clamp to the specified location and install the brake cable ...

Page 116: ...10 FINAL REDUCTION 10 0 10 ...

Page 117: ...1 2kg m SPECIAL TOOLS Driver handle A Outer driver 32x35mm Outer driver 37x40mm Outer driver 42x47mm Pilot 15mm Pilot 17mm Pilot 20mm Crankcase assembly tool Assembly shaft Assembly collar TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Oil leaks Oil level too high Worn or damaged oil seal SERVICE INFORMATION 10 1 FINAL REDUCTION INSPECTION...

Page 118: ...transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Inspect the final gear and final shaft for wear damage or seizure Dowel Pin Final Gear Countershaft Drive Shaft Dowel...

Page 119: ...ANSMISSION CASE COVER Remove the transmission case cover bearings using a bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover Drive Shaft Bearing Final Shaft Final Shaft Bearing Countershaft Bearing Drive Shaft Bearing Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bear...

Page 120: ...l Remove the left crankcase bearings using a bearing remover Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase Pilot Drive Shaft Bearing Remover 12mm ...

Page 121: ... onto the countershaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 9 14 Install the rear wheel 13 2 Install the rear brake cable 13 4 Washer Countershaft Transmission Case Cover Bolts ...

Page 122: ... change 0 09 liter Install and tighten the oil check bolt Torque 1 0_ 1 5kg m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Drain Bolt Oil Check Bolt Hole Oil Filler ...

Page 123: ...11 CRANKCASE CRANKSHAFT 11 0 11 ...

Page 124: ...wheel rear shock absorber Section 13 Starter motor Section 16 Oil pump Section 4 SPECIFICATIONS Item Standard mm Service Limit mm Connecting rod big end side clearance 0 10_ 0 35 0 55 Crankshaft Connecting rod big end radial clearance 0_ 0 008 0 05 Runout æ 0 10 TORQUE VALUES Crankcase bolt 0 9kg m Cam chain tensioner slipper bolt 1 0kg m Cam chain cover bolt 0 9kg m SPECIAL TOOL Gear remover TROU...

Page 125: ... chain and cam chain tensioner slipper Remove the two crankcase attaching bolts Separate the left and right crankcase halves Remove the gasket and dowel pins Cam Chain Tensioner Slipper Cam Chain Bolts Do not damage the crankcase gasket surface Dowel Pins Crankcase Bolts Gasket Before removing the cam chain cover screw two 6mm bolts into the threaded holes in the cam chain cover Cam Chain Cover Th...

Page 126: ... crankcase Clean off all gasket material from the crankcase mating surfaces Remove the oil seal from the right crankcase Check the oil seal lip for wear or deterioration The installation sequence is the reverse of removal Avoid damaging the crankcase mating surfaces ...

Page 127: ...earance at two points at right angels to the shaft Service Limit 0 05mm replace if over Measure the crankshaft runout Service Limit 0 10mm replace if over Turn the crankshaft bearings and check for excessive play If they do not turn smoothly quietly or if they fit loosely in the crankshaft replace the crankshaft as a set Connecting Rod Big End Measuring Location Crankshaft Bearings ...

Page 128: ...l pins and a new gasket onto the left crankcase Tighten the two crankcase attaching bolts Torque 0 9kg m Install the cam chain Install the cam chain tensioner slipper Cam Chain Gasket Crankcase Bolts Dowel Pins Cam Chain Tensioner Slipper Place the right crankcase over the crankshaft and onto the left crankcase ...

Page 129: ...NKSHAFT 11 6 Install the two O rings Install a new oil seal and O ring onto the cam chain cover Install the cam chain cover onto the left crankcase and tighten the two bolts Torque 0 9kg m Bolts O ring O rings Oil Seal ...

Page 130: ...12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION 12 0 12 4 5kg m 0 9kg m 4 5kg m ...

Page 131: ... with a clean shop towel Inspect the brake system before riding SPECIFICATIONS Item Standard mm Service Limit mm Axle shaft runout æ 0 2 Radial æ 2 0 Axial æ 2 0 Front brake drum I D 110 111 Front brake lining thickness 4 0 2 0 Front shock absorber spring free length 259 251 Brake disk thickness 3 5_ 3 8 3 0 Brake disk runout æ 0 30 Brake master cylinder I D 12 700_ 12 743 12 75 Brake master cylin...

Page 132: ...teers to one side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper oil Poor brake performance Front shock absorber noise Incorrectly adjusted brake Slider bending Worn brake linings Loose fork fasteners Contaminated brake lining surface Lack of lubric...

Page 133: ...t axle nut and pull out the axle Remove the front wheel Remove the front brake panel INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 1 2 of the total indicator reading Service Limit 0 2mm replace if over WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Screw Speedometer Cable ...

Page 134: ...it loosely in the hub BEARING REPLACEMENT Remove the front wheel bearings and distance collar Bearing Remover Bearing Remover Head 12mm Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Outer driver 32x35mm Driver handle A Pilot 12mm Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the se...

Page 135: ...coat of grease to the axle shaft Install the front wheel by aligning the brake panel groove with the front fork tab Insert the axle shaft Connect the speedometer cable and secure it with the screw Install and tighten the axle nut Torque 6 0kg m Install the front brake cable and adjust the front brake lever free play 3 8 Pawls If not aligned the retaining pawl will be deformed when the axle nut is ...

Page 136: ...oes and springs and replace the brake shoes Inspect the brake panel dust seal for damage and replace if necessary BRAKE PANEL DISASSEMBLY Remove the brake shoes Remove the brake arm and return spring Remove the wear indicator plate and felt seal Remove the brake cam Remove the speedometer gear and brake panel collar Brake Cam Brake Arm Wear Indicator Plate Return Spring Keep oil or grease off the ...

Page 137: ... hole in the brake panel Apply engine oil to the felt seal and install it to the brake panel Install the wear indicator plate on the brake cam by aligning the tooth on the plate with the groove on the brake cam Brake Shoe Speedometer Gear Brake Panel Dust Seal Brake Arm Brake Cam Felt Seal Wear Indicator Plate Return Spring 1 0kg m Wear Indicator Plate Brake Cam Felt Seal Hole Return Spring ...

Page 138: ...panel collar and install it into the brake panel Apply grease to the speedometer gear and then install it into the brake panel Install the brake shoe springs to the brake shoes and then install the brake shoes into the brake panel INSTALLATION Install the brake panel onto the front wheel 12 5 Install the front wheel 12 5 Adjust the front brake lever free play Brake Arm Brake Cam Brake Shoe Springs...

Page 139: ...12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION 12 9 HYDRAULIC BRAKE DRAWING ...

Page 140: ...iper Remove the brake pad pin to remove the brake pads When operating the brake lever the brake reservoir cap must be tightened securely to avoid splash of brake fluid When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid Spilled brake fluid on brake pads or brake disk reduces stopping power Clean the brake pads a...

Page 141: ...AL First drain the brake fluid from the hydraulic brake system DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage Bolts ...

Page 142: ...rvice Limit 12 6mm Before assembly inspect the lst and 2nd rubber cups for wear or damage ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and snap ring Install the rubber cover Install the brake lever During assembly the main piston and spring must be installed as a unit without exchange When assembl...

Page 143: ...l the handlebar covers 2 4 Connect the front and rear stop switch wire connectors Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in page 12 10 BRAKE CALIPER FRONT REMOVAL Remove the brake caliper and brake pad springs 12 11 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper DISA...

Page 144: ...emoved pistons Check each piston cylinder for scratches or wear and replace if necessary Push the piston oil seals outward to remove them Clean each oil seal groove with brake fluid Check each piston for scratches or wear Measure each piston O D with a micrometer gauge Service Limit 26 90mm Check each caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 45mm Compre...

Page 145: ...towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper and tighten the two bolts Torque 2 9_ 3 5kg m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Torque 2 5_ 3 5kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system 12 10 Install th...

Page 146: ...ve the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a vise Remove the lock bolt on the front shock absorber tube Shock Absorber Tube Washer Bolt Circlip Shock Absorbers Dust Boot When holding the shock absorber tube place a shop towel to protect it and do apply too much fo...

Page 147: ...ge or wear Measure the front shock absorber spring free length Service Limits Right 251mm Left 251mm ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube Install the shock absorber spring onto the front shock absorber tube and tighten the lock bolt on the top Shock Absorber Spring Install the front shock absorber spring with theclosely wou...

Page 148: ...e oil into the front shock absorber Specified Oil SS 8 Oil Capacity 55 1cc Install the circlip Install the dust boot INSTALLATION Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Install the front wheel 12 5 Pliers close Circlip Dust Boot Align the upper mount bolt hole with the groove on the front...

Page 149: ...der holder bolts to remove the brake master cylinder Remove the throttle seat screw Remove the throttle seat from the handlebar and disconnect the throttle cable from the throttle pipe Remove the throttle pipe from the handlebar Remove the steering stem lock bolt collar nut and the handlebar Brake Master Cylinder Screw Bolts Collar Throttle Pipe Throttle Pipe Bolt Nut Rear Brake Lever Throttle Sea...

Page 150: ...e bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver BALL RACE REPLACEMENT Drive out the top and bottom ball races Top Cone Race Steering Stem Lock Nut Wrench Be careful not to lose the steel balls 26 on top race and 19 on bottom race Clean the openings of frame covers with clean shop towels Be careful not to damage the steering stem and front fork Bottom ...

Page 151: ...y grease to the ball races and install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0_ 12 0kg m Install the front wheel 12 15 Top Cone Race Special Outer Dr...

Page 152: ...N 12 22 HANDLEBAR INSTALLATION Install the handlebar onto the steering stem tube and then install and tighten the bolt Torque 4 5kg m Install the front wheel 12 15 Install the brake levers 12 19 Install the handlebar covers 2 4 Collar Nut Bolt ...

Page 153: ...13 REAR WHEEL REAR BRAKE REAR SUSPENSION 13 0 13 3 5kg m 1 0kg m 2 5kg m 4 0kg m 11 0kg m 1 2kg m ...

Page 154: ...0kg m Rear shock absorber upper mount bolt 4 0kg m Rear shock absorber lower mount bolt 2 5kg m Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m Brake arm bolt 1 0kg m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Brake not adjusted properly Faulty tire Worn brake linings Axle not tightened properly Worn brake shoes at cam contacting area Soft rear sho...

Page 155: ...al shaft bearing for excessive play and the final shaft for bending Inspect the rear wheel and wheel rim for runout INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle shaft threads Then tighten the rear axle nut Torque 11 0_ 13 0kg m Install the exhaust muffler 2 6 Tighten the exhaust muffler joint lock nuts and exhaust muffler lock bolt Torque Exhaust muffler joint lock nu...

Page 156: ...nnect the rear brake cable Remove the rear brake shoes Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Remove the brake cam REAR BRAKE ASSEMBLY Apply grease to the anchor pin Apply grease to the brake cam and install it Install the brake shoes Keep oil or grease off the brake linings Bolt Wear Indicator Plate Adjusting Nut Brake Arm Brake Shoe Brake Cam Brake A...

Page 157: ...the brake arm return spring Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel 13 2 Adjust the rear brake lever free play 3 8 Align the wide groove on the wear indicator plate with the wide tooth of the brake cam Align the scribed line on the brake arm with the punch mark on the brake cam Adjusting Nut Brake Arm Pin Brake Cable Punch Mark Wear In...

Page 158: ...r mount bolts Remove the rear shock absorber DISASSEMBLY Install the rear shock absorber compressor as the figure shown Compress the rear shock absorber spring Loosen the lower joint lock nut Remove the lower joint Remove the lock nut rubber and damper Bolt Install the rear shock absorber lower joint into the rear shock absorber compressor Rear Shock Absorber Compressor Bolt Lock Nut ...

Page 159: ... reverse order of disassembly Tighten the lock nut Torque 3 5_ 4 8kg m INSTALLATION Install the rear shock absorber First install the upper mount bolt and then the lower mount bolts and tighten them Install the air cleaner case and tighten the two bolts Install the frame body cover Torque Upper Mount Bolt 4 0kg m Lower Mount Bolt 2 5kg m Install the shock absorber spring with loosely wound coils f...

Page 160: ... CHARGING CIRCUIT Fuse Regulator Rectifier A C Generator Battery Regulator Rectifier Charging Indicator ACG G Y Charging Indicator Light B R L R B R W Y R G Battery 12V7AH Resistors Charging Indicator G Y Auto Bystarter G B P W Ignition Switch R B G ...

Page 161: ...ifier will be damaged Turn off the ignition switch before operation It is not necessary to check the MF battery electrolyte or fill with distilled water Check the load of the whole charging system Do not quick charge the battery Quick charging should only be done in an emergency Remove the battery from the motorcycle for charging When replacing the battery do not use a traditional battery When cha...

Page 162: ...attery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch lighting system Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier Charging indicator light does not come on Dead ba...

Page 163: ...ble to the battery negative terminal Charging current Standard 0 7A Quick 3 0A Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open circuit voltage 12 8Vmin Battery Cover Screw When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel Keep flames and sparks away from a charging battery Turn po...

Page 164: ...d the fuse terminal as shown Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 13 5_ 15 5V 0 5 A max 5000rpm max If the limit voltage is not within the specified range check the regulator rectifier 14 5 LIGHTINGSYSTEM LIMIT VOLTAGE INSPECTION Remove the front cover 2 4 Limit Voltage 12_ 14V 5000...

Page 165: ...s are normal check the regulator rectifier coupler for loose connection and measure the resistances between the regulator rectifier terminals Replace the regulator rectifier if the readings are not within the specifications in the table Probe Probe White Yellow Red Green White 3K 100K Yellow 5K 100K Red Green 5K 100K Do not touch the tester probes with your finger because human body has resistance...

Page 166: ...ire and engine ground with an electric tester Standard 0 1_ 1 0W at 20 Replace the A C generator lighting coil if the reading is not within the specifications RESISTOR INSPECTION Remove the front cover 2 4 Measure the resistance between the resistor lead and engine ground Resistances 30W5 9W 5 0_ 7 0W 5W5 0W 4 0_ 6 0W A C GENERATOR REMOVAL Remove the rear right side cover 2 2 Remove the four bolts...

Page 167: ...ler Measure the resistance between each terminal Use an electric tester for testing Take readings in KW range Unit KW Probe Probe Red Black Red Brown Blue Red Blue Green Red Black 3_ 5 12Ë50 16Ë50 7Ë30 Red Brown B lue 24Ë50 40Ë70 25_ 3 5 15_ 2 0 Red Blue Green 8Ë35 15Ë45 15Ë20 5_ 7 Red Red Blue Red Black Brown Blue Green Charging Indicator ...

Page 168: ...ts Hold the flywheel with an universal holder Remove the flywheel nut Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Flywheel Puller Remove the A C generator wire connector Cooling Fan Special Special Universal Holder Flywheel Puller A C Generator Wire Connector ...

Page 169: ... A C generator stator INSTALLATION Install the A C generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 5kg m Stator 0 9kg m Install the A C generator wire rubber sleeve and A C generator wire set plate A C Generator Wire Rubber Sleeve Bolts Wire Set Plate Woodruff Key Flywheel Cooling Fan Fan Cover Stator A C Generator Wire Set P...

Page 170: ...lywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and tighten the flywheel nut Torque 5 5kg m Universal Holder Install the cooling fan Torque 0 9kg m The inside of the flywheel is magnetic Make sure that there is no bolt or nut before installation Special Cooling Fan Universal Holder Woodruff Key A C Generator Wi...

Page 171: ...14 BATTERY CHARGING SYSTEM A C GENERATOR 14 11 Install the fan cover Install the rear right side cover 2 2 0 Fan Cover ...

Page 172: ...ION CIRCUIT Ignition Coil Pulser Coil Ignition Switch CDI Unit A C Generator CDI Unit Spark Plug G Spark Plug Battery Charging Indicator Control Unit R B A C Generator R B Pulser Coil Br L R B B R G R Regulator Rectifier Y W G Y W L Y B L Y G B Y B Y ...

Page 173: ...ce is also described in this section Inspect the ignition switch according to the continuity table specified in page 20 3 Inspect the spark plug referring to Section 3 Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Item Standard Standard type C7HSA NGK Spark plug Hot type C6HSA NGK Cold type C8HSA NGK Spark plug gap 0 6_ 0 7mm Ignition timing F mark Full advance 13...

Page 174: ...or broken CDI ground wire Faulty ignition coil Dead battery or faulty regulator rectifier Faulty pulser coil Faulty ignition coil connector Normal high voltage but no spark at plug Faulty pulser coil Faulty spark plug Electric leakage in ignition secondary circuit Faulty ignition coil Good spark at plug but engine won t start Faulty CDI unit or incorrect ignition timing Improperly tightened A C ge...

Page 175: ... 80 150 40 0 5 15 Blue Yellow 100 250 40 90 Green 10 30 60 200 Blue Yellow Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use a Sanwa Electric Tester or Kowa Electric Tester In this table Needle swings then returns indicates that there is a charging current applied to a conden...

Page 176: ... Measure the secondary coil resistances with and without the spark plug cap Resistances with plug cap 7_ 12KW 20 without plugcap 3_ 5KW 20 1 Turn the CDI tester changeover switch to 12V and connect the ignition coil to the tester 2 Turn the tester power switch ON and check the spark from the watch window _Good Normal and continuous spark _Faulty Weak or intermittent spark This test is to inspect t...

Page 177: ...ING INSPECTION Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When the engine is running at 1700rpm the ignition timing is correct if the F mark aligns with the index mark within 3 Ignition Timing 13 BTDC 1700rpm This test is performed with the stator installed in the engine The CDI unit is not adjustable If the ignition timing is incorrect inspect ...

Page 178: ... SYSTEM 16 0 16 STARTING CIRCUIT Starter Relay Starter Button Starter Motor Stop Switches G G Y Ignition Switch Fuse Front Stop Switch R B Y R B Starter Button Battery Starter Motor Starter Relay Rear Stop Switch ...

Page 179: ...ock nut wrench Universal holder TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not start Faulty starte...

Page 180: ...essary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity Front Cover Starter Motor Cable Bolts Commutator Before removing the starter motor turn the ignition switch OFF ...

Page 181: ...ty between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity replace with new ones Check if the needle bearing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage Wire Terminal Bearing Dust Seal ...

Page 182: ...ound Inspect the starter relay voltage Inspect the starter relay ground circuit Inspect the starter relay operation STARTER RELAY VOLTAGEINSPECTION Place the motorcycle on its main stand Measure the voltage between the starter relay connector green yellow wire and engine ground Turn the ignition switch ON and the battery voltage should be normal when the brake lever is fully applied If the battery...

Page 183: ... cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal if there is continuity INSTALLATION Connect the starter motor cable connector and properly install the waterproof rubber jacket Check the O ring for wear or damage and replace if necessary Apply grease to the O...

Page 184: ...ar or damage and replace if necessary Measure the starter drive gear I D Service Limit 32 06mm replace if over Inspect the needle bearing for wear or damage and replace if necessary CLUTCH BODY DISASSEMBLY Remove the rollers plungers and springs from the clutch body Inspect the clutch body for wear or damage and replace if necessary Inspect each roller and plunger for wear or damage and check for ...

Page 185: ... the starter idle gear I D Service Limit 10 05mm replace if over Measure the starter idle gear shaft O D Service Limit 9 94mm replace if below Clutch Cover Starter Idle Gear Idle Gear Shaft Starter Drive Gear Lock Nut Needle Bearing Clutch Body Roller Spring Clutch Cover Plunger Cap Bolt Anchor Pin ...

Page 186: ...e needle bearing and starter drive gear and then install them to the clutch body INSTALLATION Install the starter clutch onto the crankshaft Apply engine oil to the starter idle gear and shaft and then install them Hold the starter drive gear with the universal holder and tighten the starter clutch lock nut Torque 9 5kg m Universal Holder Install the right crankcase cover 4 7 Special Note that the...

Page 187: ...ENTS SWITCHES 17 0 Turn Signal Switch Stop Switches Horn Button 17 17 Headlight Dimmer Switch Fuel Unit Starter Button Ignition Switch Auto Bystarter Headlight Switch ELECTRICAL EQUIPMENT LAYOUT Auto Bystarter Resistor ...

Page 188: ...auto bystarter Faulty ignition switch Faulty auto bystarter resistor Fuse burned out Poorly connected or broken wire Weak battery Clogged carburetor Burned bulb Faulty switch Faulty horn Poorly connected broken or shorted wire Fuel gauge pointer does not register Fuel gauge pointer does not move correctly Faulty fuel gauge Faulty fuel gauge Faulty fuel unit Faulty fuel unit Poorly connected broken...

Page 189: ...taching the headlight Remove the headlight The installation sequence is the reverse of removal After installation adjust the headlight beam 3 9 FRONT TURN SIGNAL LIGHT Remove the front cover 2 4 Remove the front turn signal bulb socket and replace the bulb The installation sequence is the reverse of removal POSITION LIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the rear cover 2 2 Remove the...

Page 190: ...o mounting bolts to remove the ignition switch holder Remove the two screws to remove the ignition switch for replacement HANDLEBAR SWITCHES HEADLIGHT SWITCH INSPECTION Remove the handlebar front and rear covers 2 4 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals HL CL TL PO RE OFF N P N H Color Blue White Yellow Brown Brown White Pink Ignition Switch ...

Page 191: ...RN SWITCH HO BATZ FREE PUSH Color Light Green Black TURN SIGNAL SWITCH R L WR L N R Color Light Blue Orange Gray DIMMER SWITCH HL HI LO PASS PASS LO N HI Color Blue White Blue White Black Horn Button Turn Signal Switch Y R O B L W L Starter Switch W Gr G B G Sb Dimmer Switch Headlight Switch ...

Page 192: ...ttery is connected across the horn wire terminals FUEL GAUGE INSPECTION Remove the rear right side cover 2 2 Disconnect the fuel gauge wire connector Turn the ignition switch ON Connect the green and yellow white wires and the fuel gauge needle should move from E to F Connect the green and blue white wires and the fuel gauge needle should move from F to E FUEL UNIT REMOVAL Remove the met in box 2 ...

Page 193: ...rter wire connector Measure the resistance between the yellow and green black wire terminals Resistance 10W max RESISTOR INSPECTION Remove the front cover 2 4 Disconnect the green black and green wires and measuring the resistance between the wire terminals Resistance 5W max If the needle remains at it indicates that the resistor is faulty and must be replaced Install the fuel unit by aligning the...

Page 194: ...lebar rear cover 2 4 Disconnect the right and left handlebar switches wire couplers Disconnect the speedometer cable Remove the instrument bulb sockets Disconnect the three fuel gauge wires Remove the instrument wire clamp screw Remove the three screws attaching the instruments to the handlebar rear cover Remove the instruments Switch Couplers Speedometer Cable Bulb Socket Handlebar Rear Cover Scr...

Page 195: ...S INSTRUMENTS SWITCHES 17 8 DISASSEMBLY Remove the screws to disassemble the instruments ASSEMBLY INSTALLATION The assembly and installation sequence is the reverse of removal Clamp Bulb Socket Fuel Gauge Wires ...

Page 196: ...________________________________________________________ EVAPORATIVEEMISSIONCONTROLSYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING 18 1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION 18 2 TROUBLESHOOTING 18 2 EVAPORATIVE EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE 18 3 SERVICE INFORMATION 18 4 MOTORCYCLE ENGINE EVAPORATIVE EMISSION CONTROL...

Page 197: ...18 EVAPORATIVE EMISSION CONTROL SYSTEM 18 1 SCHEMATIC DRAWING S EVAPORATIVE EMISSION CONTROL SYSTEM LOCATION Charcoal Canister Purge Control Valve Fuel Tank ...

Page 198: ...vapor in the charcoal canister is drawn into the engine for re burning Charcoal Canister Absorb and store the vaporized HC from the fuel tank and carburetor The vaporized HC is absorbed in the charcoal canister and the specified volume of HC in the emission should not exceed 2g P C V Completely recover the HC of blow by gas in the crankcase for re burning Through the P C V system the blow by gas f...

Page 199: ...r idle speed Inspect clean or adjust Oil filter Clean filter screen Ignition timing Inspect ignition timing Ignition Parts Spark plug Clean inspect or replace Ignition system wire connection Check wire connectors Exhaust Emission Secondary air inlet line Check for leaks clogged or loose pipe connection Control System Intake manifold bolt Check manifold connector and replace if necessary Evaporativ...

Page 200: ...ons of tubes for proper installation Replace any damaged tube with a new one Make sure to tighten the connector of each tube securely Install the charcoal canister with the drain hole facing down TOOLS Vacuum pump Pressure pump SPECIFICATIONS Purge control valve vacuum pressure 45mm Hg Charcoal canister capacity 90cc Charcoal canister installation angle tilt 60 ...

Page 201: ... LOCATIONS SIMPLE 1 Charcoal canister fuel tank Point Ç Blow compressed air into the tube at Point Ç to test leakage 2 Vacuum tube Point É Blow compressed air into the tube at Point É to test leakage C LEAKAGE TEST DIAGRAM SIMPLE Purge Control Valve Vacuum Fuel Valve Air Release Metric System U Tube Rubber Tube Water in Tube Leakage Test Point Compressed Air Tee Air Cleaner Carburetor Fresh Air Fu...

Page 202: ...leaner and apply vacuum pressure of 250mm Hg The specified vacuum must be maintained for one minute Replace the purge control valve with a new one if vacuum is not maintained Connect a vacuum pump to the purge control valve tube that goes to the carburetor vacuum tube and apply vacuum pressure of 45mm Hg The specified vacuum must be maintained for one minute Replace the purge control valve with a ...

Page 203: ... must be over 9 4 liters per minute and replace the purge control valve with a new one if the specified flow is not reached INSTALLATION 1 Install the purge control valve in the reverse order of removal 2 Route and reconnect the purge control valve tubes properly and securely To prevent damage to the purge control valve do not use high air pressure sources Use a hand operated pressure pump only Be...

Page 204: ...er Blow the hose with mouth The charcoal canister is normal if air can be blown into it If clogged replace it with a new one 4 Check the charcoal for cracks and replace if necessary INSTALLATION Install the charcoal canister in the reverse order of removal The charcoal canister must be installed at its original position to avoid damage of performance Do not bend twist or kink the tubes during inst...

Page 205: ...e the two screws attaching the air cleaner element and remove the element 3 Wash the air cleaner element squeeze out and allow to dry Soak the element in clean engine oil and squeeze out the excess oil 4 Blow compressed air from inside to clean the P C V element 5 Install the air cleaner element and the P C V element 6 The installation sequence is the reverse of removal Never use gasoline or high ...

Page 206: ...the engine and warm up for several minutes Engine surface temperature 60 _ 80 2 Adjust the idle speed to 1700 100 rpm 3 Connect the emission tester sampling pipe to the exhaust muffler Standard CO 2 0_ 3 0 max HC 4000PPM max 4 If CO or HC exceeds the specified values adjust the carburetor pilot screw P S until CO and HC are within the specified standard values P S Adjusting turns 3 1 2 5 If the ad...

Page 207: ...______ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUSTEMISSIONCONTROLSYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING 19 1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION 19 2 TROUBLESHOOTING 19 2 SERVICE INFORMATION 19 3 ...

Page 208: ... 19 1 SCHEMATIC DRAWING EXHAUST EMISSION CONTROL SYSTEM LOCATION Secondary Air Cleaner Carburetor Reed Valve Reed Valve Air Injection Cut off Valve Secondary Air Cleaner Air Injection Cut off Valve Charcoal Canister Purge Control Valve ...

Page 209: ...ch air is re burned to reduce CO When the throttle valve closes suddenly the air injection cut off valve is actuated by vacuum to close and cut off secondary air in order to prevent exhaust muffler backfiring due to air in the exhaust system Reed Valve Control the secondary air inlet to reduce CO When the motorcycle speed is less than 50km per hour the reed valve operates to draw secondary air int...

Page 210: ...alding caused by the exhaust muffler Note the locations of tubes for proper installation Replace any damaged tube with a new one Make sure to tighten the connector of each tube securely TOOLS Vacuum pump SPECIFICATIONS Air injection cut off valve actuating pressure 250mm Hg 30 liter min Reed valve stopper clearance 4 6mm ...

Page 211: ... DISASSEMBLY 1 Remove the two screws attaching the air cleaner cover to remove the cover 2 Remove the air cleaner element 3 Inspect the air cleaner INSTALLATION 1 The installation sequence is the reverse of removal The secondary air cleaner must be assembled and installed properly to avoid dust entering the air cleaner Connecting Tube Bolt O ring Secondary Air Cleaner Air Outlet Tube Cover Screws ...

Page 212: ...d be at least 30 liter min when a vacuum of 250mm Hg is applied 3 The flow should be at least 1 6 liter min when a vacuum of 320mm Hg is applied 4 Check each connecting tube for cracks or damage and replace if necessary INSTALLATION 1 The installation sequence is the reverse of removal When installing be careful not to bend or twist the tubes and check for proper installation The tube length is ve...

Page 213: ...reed valve cover and the reed valve 2 Check the reed valve for cracks damage big clearance or weak reeds Replace if necessary 3 Check the gasket and O ring for damage or deterioration and replace if necessary 4 Reed valve stopper clearance 4 6mm INSTALLATION Install the reed valve in the reverse order of removal When installing be careful not to bend or twist the tubes and check for proper install...

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KYMCO 125 MOVIE S INJECTION, Manual

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