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SM48-0401-01E

HEAD OFFICE (FACTORY)
#58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA
TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524

OVERSEAS SALES OFFICE
#13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA
TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997

Содержание ROADWIN VJ125 - SERVICE

Страница 1: ...01E HEAD OFFICE FACTORY 58 SUNG SAN DONG CHANGWON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7524 OVERSEAS SALES OFFICE 13 5 SUNG SOO 1DONG 1GA SUNG DONG GU SEOUL KOREA TEL 82 2 498 6465 FAX 82 2...

Страница 2: ...ause of trouble refer to Section 21 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication...

Страница 3: ......

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

Страница 5: ...e bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test and remove the cleaning oil with compresse...

Страница 6: ...rection in case of the single sided sealed ball bearing Install the open direction or double sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer...

Страница 7: ...ll the oil seal so that the manufacturer marked surface directs outer surface direction not covered with oil Pay attention not to bend or damage the lip Apply the grease to the lip 20 Connect the tube...

Страница 8: ...er in case of water proof coupler Recheck the condition of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After co...

Страница 9: ...following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting t...

Страница 10: ...ng T start broaden the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start fro...

Страница 11: ...ess not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please read...

Страница 12: ...NFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The engine serial number is stamped on left crankcase FRAME SERIAL NUMBER LOCATION The frame serial number is stamped on the left side of...

Страница 13: ...aulic Disk REAR BRAKE Hydraulic Disk FUEL CAPACITY 16 FUEL RESERVE CAPACITY 1 1 CASTER ANGLE 25 2 TRAIL 93 5mm FRONT FORK OIL CAPACITY 265 2 5cc TYPE Air Cooled 4 stroke SOHC CYLINDER NUMBER ARRANGEME...

Страница 14: ...1 T GEAR RATIO 5th 0 923 24 26 T GEARSHIFT PATTERN Left foot operated return system 1 N 2 3 4 5 IGNITION TYPE DC CDI Ignition IGNITION TIMING F MARK 8 BTDC 1 600 rpm FULL ADVANCE 28 BTDC 4 000 rpm AC...

Страница 15: ...R PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW TAPPET VALVE ADJUST HOLE CAP TAPPET ADJUST NUT PRIMARY DRIVE GEAR NUT CLUTCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET...

Страница 16: ...M14 1 5 M8 1 25 M10 1 25 M8 1 25 M6 1 0 M22 1 0 M22 1 0 M8 1 25 M8 1 25 M8 1 25 M14 1 25 M10 1 25 6mmTapping M8 1 25 M8 1 25 M8 1 25 U NUT U NUT SOCKETBOLT 3 0 30 1 2 12 5 9 59 4 2 42 3 4 34 3 0 30 1...

Страница 17: ...ates reference page Example Refer to page 3 1 Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease with the ratio 1 1 Use m...

Страница 18: ...IPTION REFERENCE SECTION REMARK CLUTCH CENTER HOLDER 7 ACG ROTOR PULLER 8 VALVE GUIDE DRIVER 9 VALVE GUIDE REAMER 9 UNIVERSAL BEARING PULLER 11 BEARING REMOVER SET 11 THREAD ADAPTER 11 ASSEMBLY SHAFT...

Страница 19: ...Y CABLE BATTERY EARTH CABLE HARNESS COVER WIRE CLIP ST MAG BATTERY CABLE BATTERY EARTH CABLE ST MAG SW WIRE C CLUTCH CABLE WINKER SW CORD CHOKE CABLE CABLE GUIDE LH FR WINKER HEAD LIGHT CABLE GUIDE SP...

Страница 20: ...OSE THROTTLE JUNCTION CABLE GUIDE IGN COIL CORD CHOKE CABLE THROTTLE CABLE TO ACCELERATION PUMP THROTTLE CABLE TO CARB ST MAG SW WIRE FUSE CODE ST MAG BATTERY CABLE FUSE BOX BATTERY EARTH CABLE BATTER...

Страница 21: ...MAG SW ASS Y ST MOTOR CABLE BATTERY EARTH CABLE SIDE STAND SW CORD RR STOP SW CORD RESERVE TANK RR BRAKE HOSE RR BRAKE HOSE GUIDE RR BRAKE RESERVE TUBE RR BRAKE HOSE RR CALIPER RR BRAKE HOSE RESERVE T...

Страница 22: ...RH CABLE GUIDE COMBI METER CORD WINKER SW CORD RH WINKER CORD LH WINKER CORD WIRE CLIP COMB SW CORD COMB SW WIRE HAZARD SW CORD DETAIL OF HEAD LIGHT CASE PART WINKER SW WIRE WINKER WIRE WIRE CLIP WIRE...

Страница 23: ...MEMO...

Страница 24: ...HT AIM 2 12 CLUTCH SYSTEM 2 12 SIDE STAND 2 13 SUSPENSION 2 14 BOLTS NUTS FASTENERS 2 14 WHEELS TIRES 2 15 STEERING HEAD BEARINGS 2 15 THROTTLE GRIP PLAY 2 6mm SPARK PLUG CR8EH 9 SPARK PLUG GAP 0 8 0...

Страница 25: ...1 kgf m 11N m AC GENERATOR CAP 0 6 kgf m 6N m CRANKSHAFT HOLE CAP 0 8 kgf m 8N m AIR CLEANER CASE COVER SCREW 0 43kgf m 4 3N m REAR AXLE NUT 8 8kgf m 88N m DRIVE SPROCKET BOLT 1 2kgf m 12N m DRIVEN S...

Страница 26: ...r repair centers NOTES 1 At higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in unusually wet or dusty areas 3 Replace every 2 years or...

Страница 27: ...2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER...

Страница 28: ...OKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREW...

Страница 29: ...ole before inserting the spark plug To prevent damage to the cylinder head handtighten the spark plug before using a wrench to tighten to the specified torque Do not overtighten the spark plug Inspect...

Страница 30: ...USTING WRENCH B SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPAR...

Страница 31: ...USTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTI...

Страница 32: ...drive and driven sprockets If any are loose torque them TORQUE DRIVE SPROCKET BOLT 1 2kgf m 12N m DRIVE SPROCKET NUT 5 9kgf m 59N m Always replace the chain and sprocket as a set When installing the d...

Страница 33: ...KE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to page 15 6 for brake pad replacement Do not mix a dust or different types...

Страница 34: ...bleeding procedures REAR BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to page 15 6 for brake pad replacement FRONT BR...

Страница 35: ...specified by local laws and regulations An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance BRAKE STOP SWITCH BRAKE STOP SWITCH BRAKE STOP...

Страница 36: ...side stand moves too freely check the side stand spring Check the axial movement of the side stand Check the side stand switch Sit astride the motorcycle and raise the side stand Start the engine wit...

Страница 37: ...secured Support the motorcycle with the main stand Check a wear of the rear fork bush by moving the rear wheel aside If there is a free play replace the rear fork bush Tighten all nuts and bolts of th...

Страница 38: ...e If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings section 13 STEERING HEAD BEARINGS Check that the cables do not interfere with handlebar rotation STA...

Страница 39: ...MEMO...

Страница 40: ...5 f m 15N m OIL FILTER SOCKET BOLT 1 2 f m 12N m OIL FILTER COVER BOLT 1 1 f m 11N m OIL PUMP MOUNTING BOLT 1 1 f m 11N m 3 SERVICE INFORMATION 3 1 TROUBLESHOOTING 3 2 ENGINE OIL LEVEL INSPECTION 3 3...

Страница 41: ...ption External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed often enough Faulty head gasket Worn piston rings L...

Страница 42: ...AUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL...

Страница 43: ...FT PUMP SHAFT PUMP SHAFT PUMP SHAFT OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OI...

Страница 44: ...PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHA...

Страница 45: ...the oil pump to operate smoothly SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RIN...

Страница 46: ...H LEVER PIVOTS THROTTLE CABLE CHOKE CABLE SPEEDOMETER CABLE CLUTCH CABLE BRAKE LEVER PIVOTS SIDE SAND PIVOT FRONT FORK DUST SEAL LUBRICATION POINTS Use general grease unless specified here Apply oil o...

Страница 47: ...4 0 FUEL SYSTEM...

Страница 48: ...al gasoline and then put in a vessel If it is desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be...

Страница 49: ...justment Excessively lean or rich mixture Clogged fuel system Intake air leak Clogged fuel system Lean mixture Clogged carburetor jets Clogged fuel tank breather Clogged fuel strainer screen Twisted p...

Страница 50: ...T BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOL...

Страница 51: ...COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER AIR CLEANER CONNECTING TUBE BAND AIR CLEANER CONNECTING TUBE B...

Страница 52: ...HROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTT...

Страница 53: ...rottle valve with the throttle stop screw on the carburetor and install the valve on the carburetor Inspect the following items Throttle grip free play 2 6mm Idling speed 1 600 100 rpm Gasoline is ext...

Страница 54: ...RAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRIN...

Страница 55: ...EWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALV...

Страница 56: ...LOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE...

Страница 57: ...W JET SLOW JET FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT...

Страница 58: ...THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW...

Страница 59: ...ed with the throttle stop screw PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW...

Страница 60: ...MEMO...

Страница 61: ...5 0 COOLING SYSTEM...

Страница 62: ...5 COOLING SYSTEM SERVICE INFORMATION GENERAL SAFETY TORQUE VALUE OIL THROUGH BOLT 3 2kgf m 32N m 5 SERVICE INFORMATION 5 1 RADIATOR 5 2 Wait until the engine is cool before servicing the cooling syst...

Страница 63: ...diator from the frame Remove the oil through bolts from the cylinder and RH LH radiator hose Replace the radiator when the choked area of radiator core is over 20 of radiant heat area SCREWS SCREWS SC...

Страница 64: ...MEMO...

Страница 65: ...6 0 ENGINE REMOVAL INSTALLATION...

Страница 66: ...ection 7 Geashift section 7 A C Generator section 8 Starter clutch section 8 The following works require engine removal for service Cylinder head valve section 9 Cylinder piston section 10 Transmissio...

Страница 67: ...R BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS CLUTCH CABLE CLUT...

Страница 68: ...BLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS F...

Страница 69: ...7 0 CLUTCH GEARSHIFT...

Страница 70: ...FREE LENGTH 35 5 34 2 CLUTCH DISK THICKNESS 2 9 3 0 2 6 CLUTCH PLATE WARPAGE 0 2 CLUTCH OUTER I D 28 000 28 013 28 030 CLUTCH OUTER GUIDE O D 27 967 27 980 27 950 TORQUE VALUES CLUTCH LOCK NUT 6 5kgf...

Страница 71: ...plate warpage Clutch lock nut loose High fluid level or high fluid weight Clutch disengages Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play Difficult to thrust...

Страница 72: ...ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER RO...

Страница 73: ...R CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER HOLE HOLE HOLE HOLE HOLE HOLE...

Страница 74: ...H OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE...

Страница 75: ...TE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CL...

Страница 76: ...R SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM BOLT BOL...

Страница 77: ...torque GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM...

Страница 78: ...T WASHER THRUST WASHER THRUST WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WA...

Страница 79: ...NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm Remove the lo...

Страница 80: ...OCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT...

Страница 81: ...stall the right crankcase cover bolts Tighten the bolts crisscross pattern in 2 3 steps securely TORQUE 1 1kgf m 11N m Connect the clutch cable end to the clutch lever then install the clutch wire hol...

Страница 82: ...MEMO...

Страница 83: ...8 0 A C GENERATOR STARTER CLUTCH...

Страница 84: ...gine installed in the frame SPECIFICATIONS ITEM STANDARD VALUE SERVICE LIMIT O D 39 622 39 635 39 607 STARTER DRIVEN GEAR I D 22 010 22 022 22 100 STARTER IDLE GEAR I D 10 013 10 045 10 100 STARTER ID...

Страница 85: ...R WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATO...

Страница 86: ...R L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK...

Страница 87: ...AR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER...

Страница 88: ...diameter SERVICE LIMIT 9 970mm STARTER IDLE GEAR GEAR SHAFT REDUCTION GEAR GEAR SHAFT STARTER CLUTCH INSPECTION Check the operation of the one way clutch by turning the driven gear You should be able...

Страница 89: ...nt to the starter clutch outer mounting bolt threads Hold the flywheel with a flywheel holder and tighten the starter clutch mounting socket bolts TORQUE 3 2kgf m 32N m Install the starter driven gear...

Страница 90: ...GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLA...

Страница 91: ...CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWI...

Страница 92: ...OVER L REAR COVER L REAR COVER L REAR COVER L REAR COVER L REAR COVER PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MAR...

Страница 93: ...9 0 CYLINDER HEAD VALVES...

Страница 94: ...T 1 0 kgf m 10N m SPARK PLUG 1 1 kgf m 11N m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m 20N m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m 12N m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m 4N m CYLINDER HEAD CO...

Страница 95: ...n 3 Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 9 Exce...

Страница 96: ...MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER...

Страница 97: ...HAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM...

Страница 98: ...t for wear or damage Measure the height of the cam lobe SERVICE LIMIT IN 37 110 mm EX 36 870 mm Be sure to check the valve clearance CAMSHAFT BEARINGS Remove the gasket dowel pins and cam chain guide...

Страница 99: ...spark plug cover from the cylinder head PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT...

Страница 100: ...er of the new valve guide If the clearance is not within the service limit replace the valve VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE...

Страница 101: ...eat contact and results in the valve seat refacing not able to be performed Use cutting oil on the reamer during this operation Rotate the reamer clockwise never counterclockwise when inserting and re...

Страница 102: ...s 60 35 4 45 5 IN 22mm Ex 22mm IN 23mm EX 20mm IN 24 5mm Ex 24 5mm 37 VALVE SEAT Valve faces and stem tips cannot be ground If a valve face or stem tip is rough worn unevenly or contacts the seat impr...

Страница 103: ...5 degree finish cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter Refinish the seat to specifications using a 45 degree finish cutter Using a 60...

Страница 104: ...STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL SPRING SEAT SPRING SEAT SPRING SEAT SPRING SEAT S...

Страница 105: ...cylindermatingsurface Install the cam chain guide to the cylinder Install the dowel pins and new gasket Install the cam chain tensioner and assemble pivot bolts TORQUE 1 0 kgf m 10N m Install the spar...

Страница 106: ...AFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLE...

Страница 107: ...nstall the camshaft holder Apply engine oil to the threaded part install the camshaft holder nut and bolts and tighten them driving with 2 3 times TORQUE 2 0 kgf m 20N m Tighten the cylinder head bolt...

Страница 108: ...TING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS Fill clean engine oil into the operating parts of the cylinder head Adjust the valve...

Страница 109: ...10 0 CYLINDER PISTON...

Страница 110: ...installation of piston ring Damaged piston ring Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston 10 SERVICE INFORMATION 10 1 TROUBLESHOOTING 10 1 CYLINDER REMOVAL...

Страница 111: ...n an X and Y axis Take the maximum reading to determine the out of round Calculate the cylinder for taper at three levels in an X and Y axis Take the maximum reading to determine the taper If any of t...

Страница 112: ...of the piston Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the clip fall into the crankcase PISTON DISASSEMBLY Clean carbon deposits from the piston Ins...

Страница 113: ...reading to determine the inner diameter Replace the piston if the inner diameter is over the service limit SERVICE LIMIT 15 040 mm Measure the piston pin outer diameter at three points Replace the pi...

Страница 114: ...the ring end gaps 120 degrees apart Space the side rail gaps 40mm or more apart as shown Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase The mark that...

Страница 115: ...ge the piston rings Be careful not to drop the cam chain into the crankcase Install the lower part of the cam chain guide to the part of the crankcase and install the cam chain guide by aligning the p...

Страница 116: ...MEMO...

Страница 117: ...11 0 CRANKCASE TRANSMISSION CRANKSHAFT...

Страница 118: ...RTER MOTOR SECTION 18 ITEM STANDARD VALUE SERVICE LIMIT FORK I D 12 000 12 018 12 050 SHIFT FORK SHAFT POLE THICKNESS 4 930 5 000 4 500 SHAFT O D 11 976 11 994 11 960 MAIN SHAFT O D M3 M5 19 967 19 98...

Страница 119: ...bent Shift fork shaft bent Gear shift spindle claw bent Shift drum guide grooves damaged Shift drum guide pin damaged Transmission jumps out of gear Gear dogs worn Shift fork shaft bent Shift drum sto...

Страница 120: ...GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH CAM CHAIN CAM CHAIN CAM CHAI...

Страница 121: ...R SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIF...

Страница 122: ...meter and outside diameter SERVICE LIMIT M5 OUTSIDE DIAMETER 22 930mm M3 M2 OUTSIDE DIAMETER 22 950mm C1 OUTSIDE DIAMETER 19 930mm M3 C2 INSIDE DIAMETER 20 050mm C1 INSIDE DIAMETER 16 550mm Measure ou...

Страница 123: ...a bearing puller to remove it TOOL UNIVERSAL BEARING PULLER RIGHT LEFT FEELER GAUGE CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKS...

Страница 124: ...SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMEN...

Страница 125: ...NKSHAFT INSTALLATION Coat a new left crankshaft bearing with clean engine oil and install new bearings into the right crankcase TOOLS DRIVER ATTACHMENT 72 78mm PILOT 35mm Install the crankshaft into t...

Страница 126: ...EARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER...

Страница 127: ...SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SH...

Страница 128: ...IFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HO...

Страница 129: ...CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH...

Страница 130: ...MEMO...

Страница 131: ...12 0 EXTERNAL PARTS...

Страница 132: ...for leaks after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 12 SERVICE INFORMA...

Страница 133: ...LT BOLT CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTI...

Страница 134: ...BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT...

Страница 135: ...BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKE...

Страница 136: ...RONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT...

Страница 137: ...13 0 FRONT WHEEL FRONT FORK STEERING...

Страница 138: ...t the motorcycle SPECIFICATIONS TORQUE VALUES STEERING HANDLE PIPE BOLT 2 6kgf m 26N m FRONT BRAKE DISK BOLT 4 2kgf m 42N m FRONT AXLE NUT 5 9kgf m 59N m FORK TOP BRIDGE PINCH BOLT 2 6kgf m 26N m FORK...

Страница 139: ...ficient tire pressure Worn tire Steers to one side Damaged incorrectly tightened steering head bearing Unbalance of left right cushion Bent front fork Bent front axle shaft and inclind tire Worn tire...

Страница 140: ...BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSIN...

Страница 141: ...NDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HAND...

Страница 142: ...OP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE HANDLE PIPE HANDL...

Страница 143: ...PIPE THROTTLE PIPE THROTTLE PIPE SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SW...

Страница 144: ...OLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BRAKE CALIP...

Страница 145: ...PEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX...

Страница 146: ...D BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING R...

Страница 147: ...T SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL FR WHEEL SIDE COLLAR FR CASTING WHEEL RADIAL BALL BEARING GEAR BOX RETAINER SPEEDOMETER GEAR LH FR BRAKE DISK FR TIRE FR DISTANCE COLLAR RADIAL...

Страница 148: ...BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOM...

Страница 149: ...LT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE P...

Страница 150: ...SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DESASSEMBLY Remove the fork pipe bolt from the fork Remove the fork spring and expand and release the fork pipe several times to drain...

Страница 151: ...NG SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SL...

Страница 152: ...OTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE...

Страница 153: ...RK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK...

Страница 154: ...T PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE Install the oil seal stopper ring into the...

Страница 155: ...SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING O RING O RING O RING O RING O RING O RING O RING O RING O RI...

Страница 156: ...IDGE FORK TOP BRIDGE FORK TOP BRIDGE SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS BOTTOM PINCH BOLT BOTTOM PINCH BOLT BOTTOM PINCH BO...

Страница 157: ...BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANG...

Страница 158: ...E RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SE...

Страница 159: ...ding INSTALLATION STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL...

Страница 160: ...interference BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE...

Страница 161: ...14 0 REAR WHEEL REAR SUSPENSION...

Страница 162: ...d caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR BRAKE DISK BLOT 4 2 f m 42N m REAR AXLE NUT 8 8 f m 88N m REAR CUSHION UPPER NUT 3 4 f m 34N m REAR CUSHION LOWER BOLT 3 4 f m 34...

Страница 163: ...not tightened properly Insufficient air in tire Worn rear fork bush Soft suspension Weak spring Improper rear cushion adjust Incorrect rear damper Hard suspension Improper rear cushion adjust Bent dam...

Страница 164: ...LOCK NUT LOCK NUT LOCK NUT LOCK NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE SHAFT AXLE SHA...

Страница 165: ...n and driven sprocket at the same time GOOD REPLACE DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEA...

Страница 166: ...OVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT DAMPER...

Страница 167: ...P RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUS...

Страница 168: ...SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER...

Страница 169: ...the bag around the drill motor and briefly run the drill motor inside the bag this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start DUST...

Страница 170: ...ARD MOUNTING BOLTS LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT L...

Страница 171: ...AL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP Remove the U nut and swin...

Страница 172: ...CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP...

Страница 173: ...ove of the swingarm Install the rear wheel mudguard Install the rear wheel 14 7 Install the removed parts in the reverse order of removal LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FL...

Страница 174: ...MEMO...

Страница 175: ...15 0 HYDRAULIC BRAKE FRONT REAR...

Страница 176: ...isconnecting the hose Bleed the air in case of removing the brake hose 15 SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 2 BRAKE FLUID REPLACEMENT AIR BLEEDING 15 3 BRAKE PAD DISK 15 6 FRONT MASTER CYLIN...

Страница 177: ...restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pad disk Misaligned wheel Clogged restricted brake hose jo...

Страница 178: ...SERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR...

Страница 179: ...E BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER...

Страница 180: ...ze the brke lever or push the brake pedal open the bleeder valve 1 2 turn and then close the valve 2 Release the brake lever or pedal until the bleeder valve has been closed 3 Repeat steps 1 and 2 unt...

Страница 181: ...E CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CA...

Страница 182: ...R PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS B...

Страница 183: ...ADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS HANGER PINS HANGER PINS HANGER PINS HANGER...

Страница 184: ...limit Replace the brake disk if the wheel bearings are normal Remove the bolts from the master cylinder holder and remove the master cylinder assembly FRONT MASTER CYLINDER REMOVAL Drain the front hyd...

Страница 185: ...T STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW BOOT BOOT BOOT BOO...

Страница 186: ...damage Measure the master cylinder piston O D SERVICE LIMIT 12 645mm ASSEMBLY Check the master cylinder for abnormal scratches Measure the master cylinder I D SERVICE LIMIT 12 755mm MASTER CYLINDER C...

Страница 187: ...TON PISTON PISTON PISTON PISTON PISTON PISTON FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP...

Страница 188: ...OLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASH...

Страница 189: ...LTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS C...

Страница 190: ...TER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SPRING SPRI...

Страница 191: ...ndary cup Install the spring secondary cup and master piston assembly MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MA...

Страница 192: ...MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER C...

Страница 193: ...EDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP PISTON SEAL...

Страница 194: ...liper cylinder I D SERVICE LIMIT 25 42mm ASSEMBLY Check the caliper pistons for scratches scoring or other damage Measure the caliper piston O D SERVICE LIMIT 25 27mm CALIPER BRACKET PISTONS PISTON SE...

Страница 195: ...LIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DU...

Страница 196: ...BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPE...

Страница 197: ...the pad ASSEMBLY CALIPER BRACKET PIN BOLT A PISTONS PISTON SEALS PIN BOLT DUST PLUGS HANGER PINS PAD SPRING INNER PAD OUTER PAD RR CALIPER BRACKET PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PIST...

Страница 198: ...KET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS COTTER PIN COTTER PIN...

Страница 199: ...AIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER P...

Страница 200: ...MEMO...

Страница 201: ...Br W Br W Br W CDI UNIT Br W B CABLE HEADLIGHT RELAY HEADLIGHT 12V 35 35W SPEEDOMETER ILLUM 12V 2W X 2EA 12V 3W TAIL LIGHT 12V 5W BATTERY 12V 10AH Y Y A C GENERATOR REG RECTI MAIN SWITCH FUSE 15A Y B...

Страница 202: ...atedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to...

Страница 203: ...ire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator Charging System faulty Check the battery current leakage 16 4 Check the regulator rectifier 16 5 Battery is f...

Страница 204: ...RMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL BATTERY HOLDER BATTERY HOLDER BATTERY HOLDER BATTERY HOLDE...

Страница 205: ...MINALS MAIN FUSE When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in...

Страница 206: ...es touch your fingers Use the following recommended tester Using another manufacturer s equipment may not allow you to obtain the specified values REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR REC...

Страница 207: ...Remove the LH side cover 12 2 Disconnect the A C generator cord coupler Measure the resistance between the yellow leads RESISTANCE VALUE 0 5 1 5 20 If the resistance values are much larger than the s...

Страница 208: ...MEMO...

Страница 209: ...RY 12V 10AH G G W L B Y R G B P B W G W G L Y A C GENERATOR PULSE GENERATOR HEADLIGHT RELAY L Y W L B Y CDI UNIT B W MAIN SWITCH B Black Y Yellow L Blue G Green R Red W White P Pink 17 0 IGNITION SYST...

Страница 210: ...ring Connect the same color couplers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to...

Страница 211: ...nnected CDI unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty ignition system control circuit such as side stand switch 6 Faulty peak voltage adaptor 7 Faulty CD...

Страница 212: ...agonosis above and if there is no spark at plug check the CDI unit and ignition coil by using a CDI tester TOOL DIGITAL TESTER Inspection Items ITEM GROUNDWIRE IGNITIONCOIL PRIMARYCOIL PULSEGENERATOR...

Страница 213: ...D CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BL...

Страница 214: ...ition timing is incorrect Read the instruction for timing light operation SIDE STAND SWITCH IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION C...

Страница 215: ...HERE IS CONTINUITY NORMAL IF THERE IS NO CONTINUITY TERMINALS STANDARD ITEM ON Side stand retracted OFF Side stand lowered REPLACEMENT Remove the RH side cover 12 2 Disconnect the side stand coupler f...

Страница 216: ...MEMO...

Страница 217: ...ITION CONTROL UNIT SIDE STAND SWITCH STARTER MAGNETIC SWITCH STARTER SWITCH MAIN SWITCH NEUTRAL LAMP Y R FUSE 15A BATTERY 12A 10AH B CABLE B CABLE B G R GEAR POSITION G Y G W B W Lg R Lg R B W B W BAT...

Страница 218: ...ehicle A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while the engine is...

Страница 219: ...netic switch coil ground wire 18 9 Connect the starter magnetic switch coupler Measure the starter magnetic voltage at the starter magnetic switch coupler 18 9 Check the starter magnetic switch operat...

Страница 220: ...CABLE CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUT...

Страница 221: ...ER REAR COVER REAR COVER WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE AR...

Страница 222: ...ld be no continuity Check for continuity between the insulated brush and cable terminal There should be continuity Check for continuity between each commtator bar and armature shaft There should be no...

Страница 223: ...R CASE ASSEMBLY BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BR...

Страница 224: ...MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATU...

Страница 225: ...BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS O RING O RING O RING O RING O RING O RING O RING O...

Страница 226: ...ton The coil is normal if the starter magnetic switch clicks If you don t hear the switch CLICK inspect the magnetic switch using the procedure below BATTERY WIRE CABLE BATTERY WIRE CABLE BATTERY WIRE...

Страница 227: ...INSTALLATION Install in the reverse order of removal STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH ST...

Страница 228: ...MEMO...

Страница 229: ...LIGHTS METER SWITCHES 19 0 STARTER RELAY NEUTRAL SWITCH RIGHT HANDLEBAR SWITCH IGNITION SWITCH LEFT HANDLEBAR SWITCH HORN FUEL UNIT FR STOP SWITCH WINKER RELAY...

Страница 230: ...n 2 terminals If there is coil resistance within circuits or to check the large resistance resulting form the connector corrosion an ohmmeter is required to check the circuit resistance value The foll...

Страница 231: ...adlight Battery discharged Wiring and switch resistance high Headlight Hi Low bean cannot be charged Faulty light bulb Faulty dimmer switch Fuel meter indicator malfunctioning Coupler separated Harnes...

Страница 232: ...n the ignition switch OFF and let the bulb cool down before replacement If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to prevent early bulb failure...

Страница 233: ...or rear brake pedal applied When ever any one does not turn on replace the stop tail light bulb WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER...

Страница 234: ...ATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SO...

Страница 235: ...PPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER COMBINATI...

Страница 236: ...TOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MA...

Страница 237: ...SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER...

Страница 238: ...CH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH...

Страница 239: ...connector Broken wire harness Be careful not to damage the wire Be careful not to damage the float arm Check the base packing for damage JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUM...

Страница 240: ...om the standard value replace the fuel unit WIRE TERMINAL GREEN AND YELLOW WHITE GREEN AND BLUE WHITE BLUE WHITE AND BLUE WHITE FLOATUPPERLINE 30 36 400 700 450 750 FLOATLOWERLINE 400 750 140 160 450...

Страница 241: ...MEMO...

Страница 242: ...WINKER RELAY B Gr G 2 BAT COMB SW 1 BAT W W G Y L MINI 3P L W G W Y B B R 2P R FUEL UNIT FR STOP SW BAT 3 ST HL TL B G Y MINI 6P Y R V G Y G Y Br L Br V Y R LIGHT START SW Y Y Y Y Y Y B L A C G G B Y...

Страница 243: ...er compression Low compression Low speed of starter crank Incorrect valve clearance Faulty valve seat Worn cylinder and piston rings Seized valve Improper valve timing 4 Start by following normal Engi...

Страница 244: ...gine speed increased Engine speed doesn t increase Closed carburetor choke Clogged fuel aisle Clogged air cleaner Clogged fuel tank breather Clogged muffler 4 Accelerate lightly Correct Incorrect Faul...

Страница 245: ...lity fuel being used Lean fuel mixture Clutch slipping 12 Check for engine overheating Correct Incorrect Incorrect valve clearance Faulty C D I unit Faulty pulse generator 1 Check ignition timing and...

Страница 246: ...EED 1 Check the ignition timing and Incorrect Faulty valve clearance adjustment valve clearance Faulty CDI unit Faulty pulse generator 2 Disconnect fuel tube at Fuel flows No fuel to fuel tank carbure...

Страница 247: ...amaged Faulty float Balance coil damaged or shorted Terminal loose Faulty terminal connection Balance coil lead shorted or damaged GAUGE READING INACCURATE IGNITION SWTICH ON 1 Operate the turn signal...

Страница 248: ...Balance coil lead shorted or damaged GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit 2 Remove the tank and operate the float 3 Move...

Страница 249: ...MEMO...

Страница 250: ...MEMO...

Страница 251: ...SERVICEMANUAL 2004 1 PRINTED 2004 1 PUBLICATION NO C COPY...

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