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Sym DD 50, Service Manual

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5. CYLINDER HEAD/CYLINDER/PISTON

 

5-5

 

Cylinder/Piston 

Cylinder Removal 

Be careful to pull the cylinder up and prevent 

piston from damage. 

 Caution 

Do not have pry out operation between cylinder 
and crankcase.    Or let radiation fan be knocked 
seriously. 

 

 

Piston Removal 

Place a clean rag onto crankshaft to cover the 

piston. 

Remove piston pin clip (one piece) and then push 

piston pin out the piston. 

 Caution 

y

  Do not damage or scratch the piston. 

y

  Do not apply with lateral force to connecting 

rod. 

y

  Do not let piston pin snap ring falling into 

crankcase. 

 

Piston Ring Removal 

 Caution 

Pry out the opening end of each piston ring and 
then remove the ring from piston. 

 

 

 

 

 

Check if cylinder and piston are worn or damaged, 

and then clean carbon deposit on exhaust opening 

area as the diagram shown. 

 Caution 

Do not scratch both the cylinder and the piston.

 

 

 

 

 

 

 

 

 

 

Piston pin clip 

Piston pin 

Piston

This chapter Contents 

Summary of Contents for DD 50

Page 1: ...DD 50 SERVICE MANUAL FORWARD HOW TO USE THIS MANUAL CONTENTS MECHANISM ILLUSTRATIONS...

Page 2: ...rvice Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the scooter DD 50 series are different from that of...

Page 3: ...o make changes at any time without prior notice and without incurring any obligation whatever Without written consent by SANYANG can not copy any part of this manual There are 4 buttons Forward How to...

Page 4: ...ER PISTON 5 6 1 6 4 ALTERNATOR 6 7 1 7 14 V TYPE BELT DRIVING SYSTEM KICK STARTER 7 8 1 8 6 FINAL DRIVING MECHANISM 8 9 1 9 6 CRANKCASE CRANKSHAFT 9 10 1 10 10 FUEL SYSTEM 10 11 1 11 12 BRAKE SYSTEM 1...

Page 5: ...ever Tail light Rear turn signal Helmet hook Fuel tank cap Engine number Storage box Muffler Battery Fuses C D I Eng Oil tank cap Light Starter switch High Low beam Turn signal Horn switch Air cleaner...

Page 6: ...MODEL ILLUSTRATION FT05T FT05U FT05W Home page Contents...

Page 7: ......

Page 8: ...use SAE 20 JASO FC class oil Warranty will not cover the damage that caused by not apply with the limited engine oil Recommended oil MAX 2 serial oils Grease King Mate G 3 is recommended Gear oil King...

Page 9: ...gine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery Caution y Battery emits explosive gases flame is strictly prohi...

Page 10: ...em z Never bend or twist a control cable to prevent stiff control and premature worn out z Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts be...

Page 11: ...ufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal z Remove residues of the old gasket or sealant before reinst...

Page 12: ...duction GEAR Type Gasoline Clutch Centrifugal dry type Installation and arrangement Vertical below center incline PERFORMANCE Transmission C V T Fuel Used Unleaded 92 95 Speedometer 0 90 km hr Cycle C...

Page 13: ...4 3 0 kg m 12 mm Bolt nut 5 0 6 0 kg m 10 mm Flange bolt nut 3 5 4 5 kg m The torque values listed in below table are for more important tighten torque values Please see above standard values for not...

Page 14: ...onnection 2 6 1 2 Nut for exhaust 2 8 3 3 Brake hose bolts 2 10 3 5 Brake caliper mounting bolts 2 8 3 1 Brake cushion guide bolts 2 6 1 8 Brake cushion guide bolts cap 2 6 1 0 Brake drain valve 1 6 0...

Page 15: ...or tube if they contact a sharp edge or corner Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Keep wire harnesses far away from the exhaust pipes an...

Page 16: ...switch Speedometer Headlight switch Starter switch Throttle cable Headlight Rear brake cable Speedometer cable Throttle cable Main switch Regulator Resistor Horn Front brake cable Speedometer cable F...

Page 17: ...brake cable Fuel unit Fuel pump Spark plug cap Engine oil operation cable Engine oil filling pipe Fuel unit Oil pump Carburetor Throttle cable Fuel filter Fuel pump Battery fuse starting relay CDI se...

Page 18: ...ow the hose with air Dry spark plug Wet spark plug Blowing in normal Blowing clogged 1 No fuel in fuel tank 2 Check if the pipes fuel tank to carburetor and intake vacuum are clogged 3 Float valve clo...

Page 19: ...scoloration Fouled and discoloration No knock Knock 1 Air cleaner clogged 2 Poor fuel supply 3 Lines in fuel tank evaporation system clogged 4 Exhaust pipe clogged 1 Malfunction of CDI 2 Malfunction o...

Page 20: ...retor O ring 1 Spark plug fouled 2 Malfunction of CDI 3 Malfunction of AC generator 4 Malfunction of ignition coil 5 Open or short circuit in spark plug leads 6 Malfunction of main switch 1 Insufficie...

Page 21: ...ulley spring broken 4 Clutch ling broken 5 Driving slide shaft gear groove broken 6 Transmission gear damage 7 Transmission gear worn out or burned Engine running and misfire as motorcycle initial for...

Page 22: ...rication Points Engine suspension bushing Seat lock Rear wheel bearing Steering shaft bearing Speedometer gear front wheel bearing Side stand shaft Main stand shaft Throttle cable Front rear brake lev...

Page 23: ...1 GENERAL INFORMATION 1 16 Note This chapter Contents...

Page 24: ...Carbon Removing For Exhaust Pipe Muffle 2 13 Cylinder Compression Pressure Test 2 13 Headlight Adjustment 2 14 General Information Specification Tire dimension Front 3 00 10 42J Rear 3 00 10 42J Tire...

Page 25: ...Emission check in Idling I I 20 Idle speed check I I 21 Fuel lines I I 22 Throttle operation I I 23 Engine bolt tightening I I 24 Engine screw torque I 25 Carbon cleaning for cylinder head cylinder pi...

Page 26: ...ap the element into cleaning engine oil and then squeeze it out Install the element onto the element seat and then install the air cleaner cover Limit to use SAE 20 JASO FC class engine oil otherwise...

Page 27: ...the fuel line for leaking Engine Oil Line Remove the body cover Check the engine oil line and replace damaged parts Remove the filling pipe from the oil pump and drain oil into a cleaning container Lo...

Page 28: ...le grip play Remove the body cover Wide open the throttle valve and check if the calibration point aligns on the oil pump lever with the mark of pump body Loosen the adjustment nut of the oil pump con...

Page 29: ...for un even wear Caution Wear indicator is distributed on average along the wall rubber for check Battery Open the seat Loosen two screws of battery cap and then remove the cap Check if the battery t...

Page 30: ...r Free play 10 20 mm 3 8 3 4 in Adjust the free play by turning the front brake adjustment nut if necessary Brake Confirmation Caution After brake adjustment it has to check the brake operation to mak...

Page 31: ...ot operate the brake lever after the cap had been removed Otherwise the brake fluid will spread out if operated the lever z Do not mix non compatible brake fluid together Brake Lining Wear Rear Drum B...

Page 32: ...clipping the brake lining Pry out the brake lining with a flat driver if lining is clipped Remove brake lining bolt Take out the lining Tighten Torque Mounting bolt 2 9 3 5 kgf m Pin bolt 1 5 2 0 kgf...

Page 33: ...ive ability Front Shock Absorber Press down the front shock absorber for several times to check it operation Check if the shock absorber assembly is damage Replace it if damage found and can not be re...

Page 34: ...he spark plug seat z Remove the spark plug z Visually inspect the spark plug electrodes for wear z The center electrode should have square edges and side electrode should have a constant thickness Rep...

Page 35: ...move the right side cooling fan cover Check ignition timing with the timing light When engine speed setting to 1800 rpm and if the mark aligns with F mark then it means that the ignition timing is cor...

Page 36: ...plug Insert the compression gauge and wide open the throttle and then rotate the engine by means of the starting motor Compression pressure 7 0 1 kg cm2 Probable causes for low compression pressure z...

Page 37: ...nting bolt Move the headlight for adjustment its light beam Tighten the headlight mounting bolt after adjusted Caution Improper headlight beam adjustment will make in coming driver dazzled or insuffic...

Page 38: ...utions In Operation 3 2 Lubricant 3 2 Trouble Shooting 3 2 Oil Pump Removal 3 3 Oil Pump Installation 3 3 Oil Pump Oil Tube Air Bleeding 3 4 Oil Tank 3 5 Lubrication System Diagram Oil pump Oil output...

Page 39: ...ply SAE 20 JASO FC class oil Otherwise warranty shall not cover the damage z Recommended Oil MAX 2 oil z Oil tank capacity 1 2 lit Trouble Shooting Too much smoke carbon in spark plug 1 Improperly oil...

Page 40: ...z Check if pump body is damaged z Check if pump gear is damaged z Check for oil leaking Caution The oil pump can not be disassembled Oil Pump Installation Install the oil pump onto the crankcase Cauti...

Page 41: ...l with oil Then install the tube onto oil pump z Make sure whether air is in the oil tube or not after installation Caution After bleeding the oil tube and oil pump the oil tube has to be conducted ai...

Page 42: ...rom oil pump and then drain oil to a clean container Remove the oil level switch wire of the oil indicator Remove the mounting bolt on the oil tank upper side and then remove the oil tank Installation...

Page 43: ...3 LUBRICATION SYSTEM 3 6 Notes This chapter Contents...

Page 44: ...4 ENGINE REMOVAL 4 1 Maintenance Information 4 2 Engine removal 4 3 Engine installation 4 5 4 Home page Contents 4 0kgf m 3 3kgf m 1 2kgf m 6 0kgf m...

Page 45: ...ase y Crankshaft Related bolts tightening torque for removal of engine Engine hanger bolt 5 0kgf m Engine bracket bolt 6 0kgf m Rear shock absorber upper mounting bolts 4 0kgf m Rear shock absorber lo...

Page 46: ...from oil pump Remove the oil tube from oil pump and then clip the tube Remove the wire connectors of auto by starter and AC G Remove the upper parts and cable of the carburetor from its upper side Rem...

Page 47: ...ting bolts 2 bolts Support the engine and then remove shock absorber lower mounting bolt Remove two exhaust pipe connection nuts Remove two bolts beside fan cover and exhaust pipe Mounting bolt Shock...

Page 48: ...upper mounting bolts Rear shock absorber lower mounting bolts Exhaust pipe connection nut Muffle mounting bolt 5 0kgf m 4 0kgf m 2 7kgf m 1 2kgf m 3 3kgf m Perform the following inspection and adjust...

Page 49: ...4 ENGINE REMOVAL 4 6 Note This chapter Contents...

Page 50: ...5 CYLINDER HEAD CYLINDER PISTON 5 1 Maintenance Information 5 2 Troubleshooting 5 2 Cylinder Head 5 3 Cylinder Piston 5 5 5 Home page Contents...

Page 51: ...12 030 Piston pin OD 11 994 12 000 11 970 Clearance between piston and piston pin 0 002 0 014 0 030 Piston ring end gap 0 100 0 250 0 400 Piston ID of connecting rod small end 17 05 17 015 17 025 ID 3...

Page 52: ...Head Removal Remove the 4 cylinder head bolts and then remove the cylinder head Caution Loosen the cylinder head bolts with diagonal direction to avoid to damaging it Cleaning Carbon in Combustion Cha...

Page 53: ...and by 2 3 sequences Tighten torque 1 0kgf m Install spark plug Tighten torque 1 4kgf m Replace the exhaust pipe washer with new one and then install exhaust pipe Tighten exhaust pipe connection nut...

Page 54: ...ece and then push piston pin out the piston Caution y Do not damage or scratch the piston y Do not apply with lateral force to connecting rod y Do not let piston pin snap ring falling into crankcase P...

Page 55: ...With the max value to decide cylinder wear out condition Service limit 39 05mm Measure the OD of piston at the 7 mm from the bottom of the piston Service limit 38 935 mm Calculate the clearance betwe...

Page 56: ...pin in the ring groove Install the top ring and the 2nd ring onto the ring groove respective Caution The top ring and the 2nd ring can not be changeable each other Push the rings into ring groove and...

Page 57: ...onto the interfaces of cylinder and crankcase Place a new gasket onto the crankcase Make sure that the piston ring aligns with the lock pin in piston ring groove Caution Make sure that all rings in th...

Page 58: ...6 ALTERNATOR 6 1 Maintenance Information 6 2 Alternator Removal 6 3 Alternator Installation 6 4 6 3 8kgf m Home page Contents...

Page 59: ...an be carried out directly on the scooter y Please refer to Chapter 15 for the relative alternator inspection Torque value Flywheel 3 8kgf m Tool General tool Rotor puller Universal holder Coil resist...

Page 60: ...n cover Remove four bolts and then take out the cooling fan Hold flywheel with universal holder Support the flywheel and the remove the 10 mm nut on the flywheel Remove the flywheel with rotor puller...

Page 61: ...r Caution Connect the alternator wire harness properly and then clip the harness with clipper Install the woodruff key onto the crankshaft groove Caution y Clean dirt and metal pieces inside the flywh...

Page 62: ...e Information 7 2 Trouble Shooting 7 2 Left Crankcase Cover 7 3 Reassembly of Kick Starter 7 4 Installation of the Left Crankcase Cover 7 4 Drive Belt 7 5 Movable Driven Pulley 7 6 Clutch Driven Pulle...

Page 63: ...le driven pulley 34 000 34 025 34 06 ID Inner Diameter OD Outer diameter Torque Values Movable drive face 3 8kgf m Driven pulley 5 5kgf m Clutch outer 3 8kgf m Special Service Tools Clutch spring comp...

Page 64: ...r Install kick start arm rotate the lever slightly and then remove driven gear and washer Remove the kick starter arm kick starter spindle and return spring as well as socket Inspection of kick Starte...

Page 65: ...mporary Slightly rotate the lever and then align driven gear with width tooth on the starter spindle Install the friction spring of drive gear onto convex part of the cover Installation of the Left Cr...

Page 66: ...clutch Do not remove drive belt Remove the drive belt from the groove of driven pulley Inspection Check the drive belt for crack or wear Replace it if necessary Measure the width of drive belt as diag...

Page 67: ...n tighten nut to specified torque value Torque value 3 8kgf m Movable Drive Face Removal Remove left crankcase cover Hold generator flywheel with universal holder and then remove drive face nut Remove...

Page 68: ...le driven face by means of centrifuge force Thus if weight rollers are worn out or damage the centrifuge force will be affected Check if rollers are wear out or damage Replace it if necessary Measure...

Page 69: ...m Measure the inner diameter of drive face and replace it if it exceed service limit Service limit 20 120 mm Reassembly Installation Install weight rollers Install ramp plate Apply with grease 4 5g to...

Page 70: ...aft Install drive face washer and nut Caution y Make sure that two sides of drive face have to be free of grease Clean it with cleaning solvent Hold flywheel with universal holder Tighten nut to speci...

Page 71: ...nut with clutch nut wrench Release the clutch spring compressor and remove clutch and spring from driven pulley Remove socket from sliding pulley Remove guide pin guide pin roller and driven pulley an...

Page 72: ...r diameter of sliding pulley Replace it if exceeds service limit Service limit Outer diameter 33 94 mm Inner diameter 34 06 mm Driven Pulley Bearing Inspection Check if the inner bearing oil seal is d...

Page 73: ...amage or deformation Replace it if necessary Apply with grease onto lock pins Install new clutch weight onto lock pin and then push to specific location Apply with grease onto lock pins But the clutch...

Page 74: ...lace new bearing onto proper position and its sealing end should be forwarded to outside Apply with specified grease Install new inner bearing Caution y Its sealing end should be forwarded to outside...

Page 75: ...tch into clutch spring compressor and press down the assembly by turning manual lever until mounting nut that can be installed Hold the compressor by bench vise and tighten the mounting nut to specifi...

Page 76: ...8 1 Maintenance Information 8 2 Troubleshooting 8 2 Disassembly of Final Driving Mechanism 8 3 Inspection of Final Driving Mechanism 8 4 Bearing Replacement 8 4 Re Assembly of Final Driving Mechanism...

Page 77: ...500 Drive shaft oil seal installer SYM 9120200 Bearing driver 6204 SYM 9110400 Bearing driver 6201 SYM 9610001 Bearing driver 6203 6004UZ SYM 9620000 L crank puller SYM 1130000 L L crank shaft install...

Page 78: ...then remove the cover from the rear wheel side Remove final gear final shaft and counter gear counter shaft Remove the drive shaft from left crankcase Caution y The bearing must be replaced when remov...

Page 79: ...l Inner type bearing puller Re Assembly of Final Driving Mechanism Re assemble the gearbox cover and left crankcase with special tools Special tool Gear Box Cover Final shaft bearing Bearing driver 62...

Page 80: ...new gasket and lock pin Install gearbox cover Install clutch driven pulley assembly Install driven pulley drive belt and left crankcase side cover Install body cover Install rear wheel Fill out specif...

Page 81: ...8 FINAL DRIVING MECHANISM 8 6 Notes This chapter Contents...

Page 82: ...RANKSHAFT 9 1 Maintenance Information 9 2 Troubleshooting 9 2 Crankcase Disassembly 9 3 Crankshaft Removal 9 3 Crankshaft Inspection 9 4 Crankcase Installation 9 5 9 Apply liquid gasket 1 0kgf m Home...

Page 83: ...by using the specified service tools The old bearing onto the crankshaft has to be removed Then install a new bearing onto the crankshaft on the crankcase side Oil seal has to be replaced with new on...

Page 84: ...special bolts to install the crankcase puller onto the left crankcase Remove the crankcase Caution Do not use iron hammer to knock out the crankshaft Remove crankshaft bearing with outer bearing pull...

Page 85: ...ons as diagram show Service limit 0 04 mm Place the crankshaft on a V block measure run out points A and B of the crankshaft with dial gauge Service limit A 0 10 mm B 0 10 mm Check the crankshaft bear...

Page 86: ...al tool Install new bearing into left crankcase Install crankshaft onto the left crankcase Install left crankshaft puller and install bush onto crankshaft Screw the left crankshaft puller onto cranksh...

Page 87: ...crank shaft install bush install new oil seal into the right crankcase Its installation depth is 4mm as the diagram shown With the specified tool to install a new oil seal onto the left crankcase to t...

Page 88: ...emove 10 4 Auto By Starter 10 4 Float Float Valve Jet 10 6 Flaot Level Inspection 10 7 Carburetor Installation 10 7 Reed Valve 10 7 Fuel Pump 10 8 Air Cleaner 10 9 10 Fuel tank Fuel unit Fuel filter V...

Page 89: ...1 3 8 Idle speed 2000 100 rpm Throttle handle free play 2 6 mm I D number PB2BE Main jet 82 Fuel pump output 20 c c minimum Troubleshooting Engine can not be started 1 No fuel in fuel tank 2 Fuel can...

Page 90: ...etor upper part and throttle valve spring Connect the throttle valve cable to the throttle valve Install the throttle valve into the carburetor body Caution Align the groove inside the throttle valve...

Page 91: ...to the terminals of auto by starter and then measure its resistance If the resistance value exceeds specification too much it means that the PTC in the auto by starter is malfunction Then replace the...

Page 92: ...that the auto by starter is in normal Engine is running If the resistor is in open circuit then current will not flow into the PTC Thus the auto by starter is not operated However if the resistor is i...

Page 93: ...e screw forcedly to avoid to damaging the valve seat Remove main jet needle jet seat and idle jet and clean them and each component with compressed air Installation Install the idle jet the needle jet...

Page 94: ...ith bolts Install fuel and vent pipes onto carburetor Install the carburetor upper part Tighten the connection hose Tighten the draining screw Connect the automatic by starter connector Install air cl...

Page 95: ...r installed Fuel Pump Inspection Remove the body cover Warm up the engine and adjust idle speed Remove fuel hose from carburetor and then wait for 5 minutes Measure the output of fuel pump Its output...

Page 96: ...ose from the air cleaner outer case Loosen connection hose clamp Remove 2 bolts and then remove the air cleaner outer case Install in the reverse order of removal procedures Install the air cleaner ou...

Page 97: ...10 FUEL SYSTEM 10 10 Notes This chapter Contents...

Page 98: ...3 Maintenance Information 11 4 Troubleshooting 11 5 Hydraulic Disc Brake 11 6 Disc Brake Air Bleed 11 7 Disc Brake Caliper 11 7 Brake Disc 11 8 Disc Brake Master Cylinder 11 8 Drum Brake 11 11 Front...

Page 99: ...11 BRAKE SYSTEM 11 2 Front Drum Brake System 2 5kgf m 6 0kgf m 0 55kgf m This chapter Contents...

Page 100: ...11 BRAKE SYSTEM 11 3 Rear Drum Brake System 2 5kgf m 11 0kgf m 0 55kgf m This chapter Contents...

Page 101: ...ber parts to avoid damage y Check the operation of the brake system before you go Specifications Item Standard mm Limit mm The thickness of front brake disc 3 5 2 0 Front brake disc run out 0 10 0 3 M...

Page 102: ...ng disc 2 Poor wheel alignment 3 Deformed or warped brake disc Brake noise 1 Dirty lining 2 Deformed brake disc 3 Poor brake caliper installation 4 Imbalance brake disc or wheel Drum Brake Poor brake...

Page 103: ...g brake performance to be reduced or totally lost Connect drain hose to drain valve Open the drain valve on the caliper and operate the brake lever until the old brake fluid is entirely drained out Cl...

Page 104: ...ary 6 Cover the cap Disc Brake Caliper Removal Place a container under the brake caliper and loosen the brake hose bolt and finally remove the brake hoses Caution Do not spill brake fluid on painted s...

Page 105: ...into the cylinder Caution The whole set of master cylinder piston spring diaphragm and cir clip should be replaced as a set Remove the front and rear handlebar covers Remove the leads of brake light s...

Page 106: ...e the whole set comprising piston spring piston cup and cir clip y Make sure there is no dust on all components before assembling Apply clean brake fluid to the piston cup and then install the cup ont...

Page 107: ...brake hose bolt to the specified torque value Torque 3 5kgf m Make sure the hose is installed correctly Install all wires hoses and components carefully so avoid to twisting them together Caution Imp...

Page 108: ...sure the inner diameter of brake drum and record the max value Allowable limit Front 110 5mm Rear 95 5mm Caution y Clean the rust onto the brake drum with 120 sand paper y Measure the inner diameter o...

Page 109: ...hed point Tighten the bolts and nuts to specified torque Torque value 0 5kgf m Use a brake cleaner to clean brake hub and replace the two brake shoes if brake linings are contaminated Caution Brake ef...

Page 110: ...g Handle Cover 12 12 Under Cover 12 13 Body Overview FT05U FT05W 12 Battery cover Luggage box Rear fender Right body cover Left body cover Right side cover Left side cover Handle rear cover Handle fro...

Page 111: ...ver Left body cover Right side cover Left side cover Handle rear cover Handle front cover FT05T Frame number cover Front under spoiler Floor panel Under cover Front cover Front inner upper cover Handl...

Page 112: ...tion y Align the buckles on the guards with slot on the covers y Make sure that each hook is properly installed during the assembly y Never compact forcefully or hammer the guard and the covers during...

Page 113: ...ackward so that their hooks are out of slots y Take out the side cover end part and then remove the cover 2 Installation y Install in reverse order of removal procedures Caution The tail of each cover...

Page 114: ...1 screw y Remove luggage box bolts 4 bolts y Remove oil tank cap and oil guide rubber y Hold the luggage box in both front and rear sides by two hands and then lift up the box to remove it 2 Installa...

Page 115: ...Remove 3 bolts from rear carrier and then remove rear carrier y Remove the luggage box y Remove 4 screws from the two side cover and then remove the side cover y Remove 4 screws from the both sides S...

Page 116: ...12 BODY COVER 12 7 y Remove 1 screw from the front side y Remove the body cover 2 Installation y Install in reverse order of removal procedures Screw This chapter Contents...

Page 117: ...l y Remove 2 screws from the inner cover and front cover y Remove 1 screw from the front cover y Push the front guard up and then remove it 2 Installation y Install in reverse order of removal procedu...

Page 118: ...inner box y Remove 2 screws from the front upper part of the front spoiler and the front inner box y Remove front wheel bolt and wheel y Remove 2 screws from the lower part of the front spoiler y Remo...

Page 119: ...from the floor panel y Remove 5 screws of the fuel filling cap y Remove hook and 1 screw y Remove 1 screw from main switch cover y Remove main switch cover y Remove the front inner box 2 Installation...

Page 120: ...panel 4 bolts 2 Installation y Install in reverse order of removal procedures Front Fender 1 Removal y Remove speedometer cable screw and cable y Remove front wheel bolt and then remove the wheel y R...

Page 121: ...ors y Remove speedometer cable y Remove rear handlebar guard y Remove handle rear cover and meter 2 Installation y Install in reverse order of removal procedures Caution Push the front connection part...

Page 122: ...nder Cover 1 Removal y Remove the right and left side cover y Remove 2 bolts from the under cover y Remove under cover 2 Installation y Install in reverse order of removal procedures 2 bolts 2 bolts T...

Page 123: ...12 BODY COVER 12 14 Note This chapter Contents...

Page 124: ...SUSPENSION 13 1 Maintenance Information 13 2 Troubleshooting 13 2 Steering Handle 13 3 Front Wheel 13 4 Front Shock Absorber 13 8 Front Fork 13 9 13 4 5kgf m 2 7kgf m 1 5kgf m 3 3kgf m 6 0kgf m 0 25k...

Page 125: ...he steering shaft bolt is too tight 2 The steering shaft bearing are damaged 3 The ball and the top cone of the steering shaft are damaged 4 Insufficient tire pressure The Steering Handle Is Tilted 1...

Page 126: ...emove the handle Installation Install handle and align with bolt hole Install bolt and nut and then tighten it Torque value 4 5kgf m Apply with grease onto throttle cable and the sliding surface of ha...

Page 127: ...ts in reverse order of removal procedures Conduct following adjustment y Oil pump control cable y Throttle operation Brake lever free play Front Wheel Removal Remove speedometer cable from speedometer...

Page 128: ...ion seat and turn the wheel to check its bearing free play If the bearing is noisy or its free play is too much replace it Place the wheel on to a rotation seat to check its rim wobbling Turn the whee...

Page 129: ...by grease Drive the left bearing and install the dist collar Install the right bearing Caution y Carefully install the bearing in correct and evenly y Bearing outer face should be faced up as bearing...

Page 130: ...drum and disc must be free of grease Apply with grease onto the dust seal Install the dust seal and side collar Place the front wheel between the front shock absorbers Caution Align the brake disc gr...

Page 131: ...lamp mounting bolt and the clamp Drum Brake Remove the cable clamp mounting bolt and the clamp Remove the front shock absorber upper bolt and the shock absorber Installation Align the cover flange wit...

Page 132: ...o mounted position Caution Do not tilt the ball bearing seats as installation Apply with grease onto the ball bearing seats and install steel balls onto the seats Top 26 balls bottom 29 balls Lubricat...

Page 133: ...10 Install the steering stem mounting nut and tighten the nut by means of holding the top cone race body Torque value 1 5kgf m Install in reverse order of removal procedures Steering stem mounting nu...

Page 134: ...14 REAR WHEEL SUSPENSION 14 1 Maintenance Information 14 2 Troubleshooting 14 2 Rear Wheel 14 3 Rear Shock Absorber 14 4 14 2 7kgf m 4 0kgf m 11 0kgf m 3 3kgf m Home page Contents...

Page 135: ...nut 11 0kgf m Rear wheel hub 2 5kgf m Exhaust muffler nut 1 2kgf m Exhaust muffler bolt 3 3kgf m Troubleshooting Rear wheel wobbling 1 Bend wheel rim 2 Poor tire 3 Loosen wheel shaft Shock absorber to...

Page 136: ...d then remove the rear wheel Inspection As the diagram shown measure wheel rim wobbling with a dial gauge Service limit Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Brake Hub Replacement Remove 4 nuts o...

Page 137: ...upper lower bolts Remove rear shock absorber Installation Install the rear shock absorber Tighten the upper lower mounting bolts to specified torque Torque value Upper mounting bolt 4 0kgf m Lower mo...

Page 138: ...5 9 Starting System 15 12 Oil Level Switch 15 14 Fuel Unit 15 15 Switch Horn 15 16 Bulb Replacement 15 18 15 Spark Plug AC Generator Fuse Box Battery IG Coil Fuel Unit Main Switch Reg Rec Comp Start H...

Page 139: ...attery y The voltage must be checked with the voltmeter while charging the battery y As C D I assembly does not require an ignition timing check In case ignition timing is incorrect check C D I and AC...

Page 140: ...tarter motor is out of work Intermittent power supply y The connector of the charging system becomes loose y Poor connection of the battery cable y Poor connection or short circuit of the discharging...

Page 141: ...0 13 2V Undercharged 12 V Charging Remove the battery Connect the positive terminal of the charger to the battery positive terminal Connect the negative terminal of the charger to the battery negativ...

Page 142: ...as the test process goes to avoid possible damage to the ammeter and the fuse y Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate...

Page 143: ...ammeter Connect a tachometer Turn on the headlight to high beam and start the engine Accelerate the engine to the specified revolution per minute and measure the charging voltage Specified Charging Cu...

Page 144: ...re and green wire while the headlight harness is still in connection Measure alternating current voltage with a voltmeter Gradually increase engine speed and read the voltage in each specified rpm Con...

Page 145: ...tor Voltage Regulator Multi meter Multi meter White A Yellow L Red B Green E White A 4 7 Yellow B 2 4 4 8 Red B 4 7 Green E 2 4 4 8 If the resistance values are abnormal among the pins replace the vol...

Page 146: ...15 ELECTRICAL EQUIPMENT 15 9 Ignition System Black Red Blue Yellow Black White Black Yellow Green This chapter Contents...

Page 147: ...rimary coil resistance Resistance 0 19 0 23K A B Measure the secondary coil resistance Resistance 8 2 9 3K A C Remove the high voltage coil cap and measure its negative terminal for the secondary coil...

Page 148: ...System Circuit Inspection ITEM Measure at Standard at 20 Main Switch Black white green Continuity as main switch OFF Exciter Coil Black Red Green 400 800 Pulse Generator Blue Yellow green 50 200 Prim...

Page 149: ...ove left crankcase cover Remove starter motor pinion Install the starter motor pinion in reverse order of removal Starter Motor Pinion Inspection y Pinion reduction gear for wear out or damage replace...

Page 150: ...y be short circuit if dark surface on the shifter found Caution Do not clean the shifter surface with sandpaper Check continuity 1 both the shifter surface and shaft 2 among the shifter surfaces It ca...

Page 151: ...onnect oil gauge connector and check voltage between wire and ground Removal Installation Remove oil tank Remove oil level switch from the oil tank Install the oil level switch in reverse order of rem...

Page 152: ...ring in CW direction until matching to the arrow Inspection 1 Connect the fuel unit connector Turn the main switch ON Move the float in up and down and make sure that the fuel indicator can be reache...

Page 153: ...tch Wire color Black Black White Green Red Mark BAT2 IG E BAT1 LOCK OFF ON Winker light switch Wire color Gray Light blue Orange Mark WR R L R N L Horn Switch Wire color Light green Black Mark HO BAT2...

Page 154: ...Mark ST E FREE PUSH Front Rear Brake Light Switch If the switch is in continuity as braking it is in normal The switch is non adjustable Horn If the horn give out sound as connecting to 12V battery i...

Page 155: ...ont cover Remove front winker light lens Replace front winker light bulb Install the all removed parts Tail light Brake light Rear winker light Remove 2 screws and then remove outer cover Remove 2 scr...

Page 156: ...16 ELECTRICAL DIAGRAM 16 1 DD 50 ELECTRICAL DIAGRAM 16 Home page Contents...

Page 157: ...16 ELECTRICAL DIAGRAM 16 2 Notes Home page Contents...

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