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10-5

CYLINDER/PISTON

Be careful not to damage the piston and rings during
assembly.

Do not confuse the top and second rings.

Space 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 is stamped on the piston head should
be facing the correct direction.

“

”

MARK : TO INTAKE SIDE

“

”

MARK : TO EXHAUST SIDE

PISTON / PISTON RING INSTALLATION

●

Clean the piston heads, ring lands and skirts.

●

Carefully install the piston rings onto the piston with
the markings facing up.

●

After installing the rings they should rotate freely,
without sticking.

PISTON INSTALLATION

●

Install the piston and insert the piston pin.

TOP RING

SECOND RING

SIDE RAIL

PISTON

SPACER

OIL RING

SIDE RAIL

20mm

120° 120°

MARK

CRANK SHAFT

Содержание S2 125

Страница 1: ......

Страница 2: ...ms service information and troubleshooting guide Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication ma...

Страница 3: ......

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

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 expended 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: ...1 9 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

Страница 13: ...er Filter 14 0 kgf 550 rpm 5 BTDC 14 ABDC 18 BBDC 1 BTDC 0 12 0 12 mm 0 12 0 12 mm OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRON...

Страница 14: ...10W 4 12V 21 5W 14V 3W 14V 3W 2 12V 2W 2 14V 1 4W 12V 5W TYPE VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY RED...

Страница 15: ...ND BOLT SIDESTAND PIVET SEREW SIDESTAND PIVET NUT FRAME ITEM REFERENCE TORQUE VALUE THREAD DIA mm Q TY 1 1 kgf m 2 5 kgf m 0 8 kgf m 1 0 kgf m 5 5 kgf m 7 5 kgf m 5 5 kgf m 1 0 kgf m 1 2 kgf m 5 5 kgf...

Страница 16: ...rnings or cautions MEANING Indicates dangerous area Serious accident may result if instructions are not followed The following symbols indicate oil adding oil change or parts MEANING Add oil If there...

Страница 17: ...LH SEAT LOCK CABLE SEAT LOCK CABLE AUTO CHOKE WIRE WIRE CLIP LH SEAT LOCK CABLE THROTTLE CABLE HAZARD SW WIRE DOMESTIC USE ONLY WIRE CLIP FUEL UNIT CORD FUEL UNIT COUPLER LH SEAT LOCK CABLE SIDE STAND...

Страница 18: ...EARTH CABLE ACG CORD HOSE CLAMP RR BRAKE HOSE CABLE GUIDE WINKER SW CORD THROTTLE CABLE SEAT LOCK CABLE HAZARD SW WIER DOMESTIC USE ONLY COMBI METER COUPLER FUEL SUPPLY TUBE FUEL BREATHER TUBE TUBE CL...

Страница 19: ...WIER CLIP ACG CORD START MAGNETIC SW START MOTOR CABLE EARTH CABLE START MAGNETIC SW CORD REG RECTIFIER CORD BATTERY CABLE HEAD LIGHT RELAY WINKER RELAY EARTH CABLE BATTERY BOX COUPLER NOTE WHITE COL...

Страница 20: ...E CLIP ACG WIRE TO FUEL TANK ACG CORD TUBE CLIP TUBE CLIP TO INSULATOR FUEL PUMP TO CARBULATOR TUBE CLIP START MOTOR CABLE START MAGNET SW ASS Y BATTERY CABLE FRAME BODY COMP BATTERY CABLE 12V 10AH BA...

Страница 21: ...MEMO...

Страница 22: ...PLAY 2 6mm SPARK PLUG CR8EH 9 SPARK PLUG GAP 0 8 0 9mm IN 0 12 0 02mm EX 0 12 0 02mm CARBURETOR IDLE SPEED 1 700 100rpm CYLINDER COMPRESSION PRESSURE 14 2kgf 550rpm VALVE CLEARANCE COLD TIRE PRESSURE...

Страница 23: ...2 INSPECTIONS ADJUSTMENTS TORQUE VALUES SPARK PLUG 1 1kgf m CYLINDER HEAD COVER BOLTS 1 0kgf m VALVE ADJUSTING NUTS 1 1kgf m TIMING HOLE CAP 0 6kgf m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUG...

Страница 24: ...ed out by authorized maintenance shops dealers or other designated repair shops NOTE 1 After the odometer reading exceeds 12 000km repeat maintenance service at intervals indicated in the table 2 Afte...

Страница 25: ...djustment loosen the lock nut and turn adjuster After adjusting tighten lock nut After adjustment is completed recheck the throttle grip free play For simple adjustment use the adjuster under the thro...

Страница 26: ...olvents for cleaning parts may result in a fire or explosion TIMING CHECKING RH SHROUD Inspect and adjust the valve clearance when the engine is cool under 35 C 95 F Remove the cylinder head cover Tur...

Страница 27: ...the engine Remove the plug maintenance cover Stop engine and remove the spark plug cap and spark plug Install a compression gauge Open the throttle completely and crank the engine with the starter mo...

Страница 28: ...for wear or damage Check scheduled maintenance period replace the new drive belt if possible Fill the recommended oil SAE90 GEAR OIL CAPACITY At disassembling 200cc At replacing 180cc Erect the main...

Страница 29: ...an impair braking efficiency A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability BRAKE SYSTEM Check the front brake hose for cracks or damage If any le...

Страница 30: ...uspension Loose or worn suspension parts will lead to deterioration in the vehicle s safety and operation efficiency SIDE STAND Erect the main stand Pull the lower end of the side stand and see if it...

Страница 31: ...Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value Check all pins clips hose clamps and cable stays FRONT WHEEL 2 00 200 2 00 200 R...

Страница 32: ...EXTERNAL PARTS 3 SERVICE INFORMATION 3 1 SEAT 3 2 PILLION SEAT 3 2 LUGGAGE BOX TOP COVER 3 2 REAR GRIP 3 2 LUGGAGE BOX 3 3 CENTER COVER 3 3 BODY SIDE COVER 3 3 BODY COVER 3 4 REAR FENDER 3 4 FLOOR SI...

Страница 33: ...ease the seat lock by turning the main switch key to open seat Pull the pillion seat forward and remove it Install in the reverse order of removal FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANGE NUTS FLANG...

Страница 34: ...Remove the air duct cover in dissembling LH body side cover SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CATCH SEAT CA...

Страница 35: ...er of removal REAR FENDER Remove the body cover Loosen the 4 washer bolts and remove the Rr fender Install in the reverse order of removal FLOOR SIDE COVER Remove the center cover Loosen the 3 body co...

Страница 36: ...the 4 special screws R L 2Ea for each to remove the under cover Install in the reverse order of removal HANDLE COVER Loosen the washer screw and tapping screw securing the under handle cover Loosen t...

Страница 37: ...al FRONT UNDER COVER A Remove the front cover and windscreen Loosen the 7 tapping screws securing the inner cover Install in the reverse order of removal FRONT UNDER COVER B Loosen the 2 flange bolts...

Страница 38: ...be clip Remove the breather tube Loosen the 3 screws securing the inner cover Remove the bag holder Loosen the 2 tapping screws securing the speedometer cover Install in the reverse order of removal S...

Страница 39: ...curing Ex pipe comp Loosen the 3 bolts securing the Rr Fork Remove the Ex muffler comp REAL WHEEL MUDGUARD Loosen the 2 flange bolts of RH Loosen the flange bolt securing the air cleaner and mudguard...

Страница 40: ...EN CAP 1 5 f m OIL FILTER COVER BOLT 1 1 f m OIL PUMP MOUNTING BOLT 1 1 f m OIL DRAIN PLUG BOLT 2 5 f m 4 SERVICE INFORMATION 2 1 TROUBLESHOOTING 2 2 ENGINE OIL LEVEL INSPECTION 2 3 ENGINE OIL CHANGE...

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: ...fter opening oil filter cap of cylinder head cover OIL CAPACITY 1 1 After disassembly 0 9 After Oil change with Oil in the Oil hose removed 0 8 After Oil filter change 0 75 After Oil change API servic...

Страница 43: ...shion lower bolt 13 7 Muffler 3 8 Rear swing arm 13 7 Rear caliper 13 3 Shroud 8 2 Cooling fan 8 2 A C generator 8 2 RH crankcase cover 8 4 Starter driven gear 8 7 Reduction gear 8 5 Starting clutch a...

Страница 44: ...ith fresh cleaning oil OIL PUMP INSPECTION Assemble the inner and outer rotors to the oil pump body Measure the pump body clearance SERVICE LIMIT 0 23mm TOOL FEELER GAUGE Measure the pump side clearan...

Страница 45: ...e oil pump to the RH crankcase Install the following parts Oil pump drive gear and driven gear Starting clutch assembly 8 8 Starter driven gear and reduction gear 8 5 8 7 A C generator 8 2 RH crank ca...

Страница 46: ...tween core fins with compressed air or wash off dirt with water After installing start the engine and check for leak Stop the engine and check the oil level FIN OIL RADIATOR RADIATOR RUBBER RADIATOR C...

Страница 47: ...filler hole gradually Tighten the drain cock packings and oil bolts TORQUE VALUE 3 2kgf m Install the front wheel 12 4 Install the front cover 3 5 FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS F...

Страница 48: ...r sliding parts not shown here add oil or grease CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable and apply oil If the cable has expanded replace it FRONT BRAKE LEVE...

Страница 49: ...MEMO...

Страница 50: ...with new ones when disassembled 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 dete...

Страница 51: ...perly Air screw is adjusted improperly Compression pressure is low Air Fuel mixture is either too lean or rich Carburetor is blocked Mis firing occurs when driving at high speeds Ignition system is da...

Страница 52: ...he fuel tank be sure to close the fuel tank cap Gasoline is extremely flammable Avoid fire during work and pay particular attention to electric sparks Furthemore the evaporated gasified gasoline is hi...

Страница 53: ...HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLDER NEEDLE HOLD...

Страница 54: ...at for scores scratches clogging and damage Replace if necessary Check the float valve operation Remove the main jet main jet holder holder washer jet screw jet washer needle jet slow jet pilot jet wa...

Страница 55: ...der main jet and slow jet Tighten the pilot jet until it seats lightly then turn it out as much as the number recorded during removal Install the pilot jet rubber CARBURETOR BODY PLUNGER ASS Y DIAPHRA...

Страница 56: ...arburetor body Install the diaphragm spring Install the diaphragm cover with its cutout aligned with the hole in the tab of diaphragm Install the auto bystarter wiring plate to the diaphragm and tight...

Страница 57: ...the luggage box 3 2 INSPECTION Check the carburetor insulator O ring for wear or damage CABURETOR INSULATOR REMOVAL Remove the luggage box 3 2 Remove the center cover 3 3 Remove the air cleaner 2 5 R...

Страница 58: ...uretor is overhauled or a new pilot screw is installed Before adjusting the pilot screw check the following items Fuel system electrical system for troubling Spark plug for cleaning and gap adjusting...

Страница 59: ...MEMO...

Страница 60: ...body TRANSMISSION SECTION 11 STARTING CLUTCH SECTION 8 OIL PUMP SECTION 4 A C GENERATOR SECTION 8 STARTER MOTOR SECTION 16 CONTINUOUSLY VARIABLE TRANSMISSION SECTION 7 CYLINDER HEAD CYLINDER PISTON S...

Страница 61: ...or wiring cable Remove the battery earth cable from the RH shroud groove Disconnect the high tension cord from the engine Remove the bleeder tube from the cylinder head cover Loosen the parking brake...

Страница 62: ...of removal TORQUE VALUE ENGINE HANGER BOLT FRONT 4 5 f m REAR 4 5 f m Check the following after the engine is installed Engine oil Electric systems Adjust of the parking brake free play Inspection of...

Страница 63: ...7 0 LH CRANKCASECOVER CONTINUOUSLYVARIABLE TRANSMISSION LH CRANKCASE COVER...

Страница 64: ...EFACEBUSHINGINNERDIAMETER 24 000 24 013mm 24 05mm DRIVE FACE BOSS OUTER DIAMETER 23 980 23 993mm 23 96mm DRIVE BELT WIDTH 22mm 20 50mm WEIGHT ROLLER OUTER DIAMETER 19 95 20 02mm 19 50mm CLUTCH OUTER I...

Страница 65: ...sket and dowel pin INSTALLATION Install the new gasket and dowel pin after removing the gasket of the crankcase surface Tighten the LH crankcase cover bolts Align the bolts to uniform the tightening l...

Страница 66: ...driven pulley from the drive shaft Remove the driven pulley sub assembly with the drive belt in place Remove the drive belt from the driven pulley groove and drive pulley groove Loosen the drive face...

Страница 67: ...LT INSTALLATION Temporarily install the driven pulley sub assembly on the drive shaft Put the drive belt over the movable drive face Install the drive face to the LH crank shaft and install the kick s...

Страница 68: ...AL Remove the LH crankcase cover Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 2 Hold the drive face using the drive face holder and remove the nut TOOL DRIVE...

Страница 69: ...t is exceeded Measure the I D of the drive face Replace it if the service limit is exceeded Movable drive face boss outer diameter SERVICE LIMIT 23 960mm Movable drive face inner diameter SERVICE LIMI...

Страница 70: ...nut to the specified torque TORQUE VALUE 7 0 8 0 kgf m TOOL DRIVE FACE HOLDER Install the LH crankcase cover Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 2 T...

Страница 71: ...n pulley sub assembly from the drive shaft Remove the drive belt DISASSEMBLY Install a clutch spring compressor on the pulley assembly and tighten the tool to gain access to the nut Hold the clutch sp...

Страница 72: ...ve the guide pins and guide pin rollers and the movable driven face Remove the O ring and oil seals from the movable driven face Remove the movable driven face SEAL COLLAR OIL SEAL OIL SEAL O RINGS O...

Страница 73: ...r race fits securely Replace the bearing if necessary Movable Driven Face Spring Inspection Measure the free length of the driven pulley spring and replace if the service limit is exceeded SERVICE LIM...

Страница 74: ...ng into place with the sealed end toward the outside Install the snap ring securely If the driven face has an oil seal at inner bearing side remove the oil seal first If a ball bearing is used on the...

Страница 75: ...iven pulley spring and clutch in the clutch spring compressor Compress the assembly by turning the tool handle until the lock nut can be installed Clamp the clutch spring compressor in a vise and tigh...

Страница 76: ...Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 3 Install the drive face Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 5 Install the LH crankcase cover Xh...

Страница 77: ...8 0 A C GENERATOR STARTER CLUTCH FLYWHEEL STATOR COMP RH SHROUD COOLING FAN...

Страница 78: ...IONS TORQUE VALUES FLY WHEEL BOLT 5 5 kgf m STARTER CLUTCH LOCK NUT 9 5 kgf m RH CRANKCASE COVER BOLT 1 1 kgf m TOOLS SPECIAL SOCKET 12 7 x 28 x 120 A C G ROTOR PULLER 8 SERVICE INFORMATION 8 1 SHROUD...

Страница 79: ...2 Body cover 3 4 Center cover 3 3 Engine 6 2 RH shroud comp 8 2 SHROUD REMOVAL Remove the following parts Luggage box 3 2 Center cover 3 3 Engine 6 2 Remove the A C G wiring coupler and connector con...

Страница 80: ...g pan screws remove the stator TOOLS A C G ROTOR PULLER UNIVERSAL HOLDER DRIVE FACE HOLDER FLANGE NUT UNIVERSAL HOLDER A C G ROTOR PULLER FLYWHEEL PAN SCREWS PAN SCREWS Insert the puller shaft and rem...

Страница 81: ...he wire harness and install the wiring with the clamp Insert the battery earth cable to the shroud groove Install the rear cushion under bolt Install the RH floor side cover 4 7 Install the center cov...

Страница 82: ...wear or damage and replace with a new one as necessary STARTER REDUCTION GEAR REMOVAL Remove the starter reduction gear and shaft INSPECTION Check the reduction gear for wear or damage Measure the inn...

Страница 83: ...swing arm 13 7 RH crankcase cover 8 4 Remove the LH crankcase cover and hold the drive face with the drive face holder Loosen the starter clutch lock nut with a special socket TORQUE VALUE 9 5 kgf m T...

Страница 84: ...r clutch Check the starter driven gear for wear or damage Measure the inner diameter of the starter driven gear SERVICE LIMIT A 32 10 mm B 39 53 mm STARTER CLUTCH INSPECTION Remove the starter driven...

Страница 85: ...IVE FACE HOLDER Install the following parts RH crankcase cover 8 2 A C Generator 8 2 Cooling fan 8 2 RH shroud 8 2 Rear swing arm 13 7 Rear caliper 13 3 EX muffler 3 8 RH floor side cover 3 4 LH crank...

Страница 86: ...MEMO...

Страница 87: ...9 0 CYLINDER HEAD VALVE INLETVALVE ROCKER ARM EXHAVST VALVE ROCKER ARM CAM SHAFT HOLDER CAM SHAFT COMP CARBURETOR INSULATOR CYLINDER HEAD COMP CYLINDER HEAD GASKET INLETVALVE EXHAVST VALVE...

Страница 88: ...f m SPARK PLUG 1 2 kgf m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m CYLINDER HEAD COVER BOLT 0 9 kgf m CYLINDER HEAD BOLT...

Страница 89: ...rned 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 10 Excessive...

Страница 90: ...n is located at the top dead center Make all camshaft lobes face downward If all camshaft lobes face upward rotate the crankshaft to the left for 1 turn 360 and align the T mark with the index mark on...

Страница 91: ...haft for wear or damage Measure the inner diameter of the rocker arm SERVICE LIMIT 12 060 mm Measure the outer diameter of the rocker arm shaft SERVICE LIMIT 11 950 mm Check the cam lobes of the camsh...

Страница 92: ...emove the cylinder head Manually turn the camshaft bearing outer race and check if it turns smoothly Check the bearing for wear or damage Remove the cylinder head gasket dowel pin and cam chain guide...

Страница 93: ...out binding Measure and record the valve stem outer diameter in three places along the valve guide sliding area SERVICE LIMIT IN 4 920 mm EX 4 900 mm Replace the valve with a new one if the service li...

Страница 94: ...ed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed Rotate the reamer clockwise never counterclockwise w...

Страница 95: ...cles Avoid damaging the head when driving the valve guide out Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valve is installed slanted that causes oil leaks from th...

Страница 96: ...ALVE SEAT REFACING Reface the worn valve seat by using valve seat cutters and grinders Using a 45 degree cutter remove any roughness or irregularities from the seat Using a 37 degree cutter remove of...

Страница 97: ...act area is too low on the valve the seat must be raised using a 55 degree inner cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too high on the valve...

Страница 98: ...e slightly when setting it Take precautions not to allow compound to get into the clearance between the stem and guide while the valve is being set Replace the stem seals with new ones whenever a stem...

Страница 99: ...r insulator groove Tighten the carburetor insulator with mounting bolts Install the cam chain tensioner and assemble pivot bolts TORQUE 1 0 kgf m Install the spark plug TORQUE 1 2 kgf m Install the cy...

Страница 100: ...e the crankshaft counterclockwise and align the T mark of the flywheel with the index mark of the RH crank case cover Check the camshaft assembly for abnormal condition and place it on the cylinder he...

Страница 101: ...from the cam chain tensioner lifter Rotate the tensioner shaft clockwise with a small driver and insert the shaft into the body completely Install the cam cover plate Apply engine oil to the threaded...

Страница 102: ...sioner shaft clip from the tensioner lifter Assemble the O ring and pan screws to the tensioner lifter TORQUE VALUE 0 4 kgf m Fix the tensioner shaft with a hard clip Assemble a new gasket to the tens...

Страница 103: ...10 0 CYLINDER PISTON CYLINDER CYLINDER GASKET PISTON TOP RING SECOND RING OIL RING...

Страница 104: ...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 10 2 PISTON PISTON RING 10 3 CYLINDER INSTA...

Страница 105: ...three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 56 100 mm Measure the piston outer diameter Calculate the piston to cylinder clearance Take t...

Страница 106: ...the connecting rod Do not let the clip fall into the crankcase Remove the piston pin clip using a pair of pliers Press the piston pin out of the piston INSPECTION Clean carbon deposits from the pisto...

Страница 107: ...n outer diameter 90 to the piston pin bore and at the point specified 10mm near the bottom of the piston skirt Replace the piston if the service limit is exceeded SERVICE LIMIT 55 825 mm PISTON PIN IN...

Страница 108: ...mark that is stamped on the piston head should be facing the correct direction IN MARK TO INTAKE SIDE EX MARK TO EXHAUST SIDE PISTON PISTON RING INSTALLATION Clean the piston heads ring lands and skir...

Страница 109: ...he cylinder head mating surface Do not scratch the surface Install a new cylinder gasket and dowel pins Install the lower part of the cam chain guide to the part of the crankcase and install the cam c...

Страница 110: ...MEMO...

Страница 111: ...11 0 TRANSMISSION CRANKSHAFT CRANKCASE RH CRANKCASE LH CRANKCASE CRANKSHAFT...

Страница 112: ...following parts must be removed prior to changing the LH crank case Follow the removal procedure specified in each section TRANSMISSION SECTION 11 PARKING BRAKE SECTION 14 To assemble the crank case...

Страница 113: ...OVER SHAFT REMOVER HEAD SLIDING WEIGHT ASSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission da...

Страница 114: ...ear brake caliper 13 3 Remove the rear wheel 13 5 Loosen the rear cushion upper bolt Remove the transmission bleeder tube from the mission cover groove Loosen the 8 transmission cover bolts Remove the...

Страница 115: ...inal shaft and the counter shaft comp TRANSMISSION INSPECTION Check the drive shaft for wear or damage Check the final shaft for wear or damage Check the counter shaft for wear or damage FINAL SHAFT C...

Страница 116: ...the case tightly without play Turn the inner race and check that the bearing turns smoothly and quietly Replace the bearings if necessary Install the bearing to the case with special tools TOOLS DRIVE...

Страница 117: ...8 4 Install the rear cushion upper bolt Install the transmission bleeder tube Remove the oil check bolt release the transmission oil filler ACG cap or the LH crankcase until the oil overflow through...

Страница 118: ...a plastic hammer CRANKSHAFT REMOVAL Remove the crankshaft from the RH crankcase by using a crankshaft remover If the bearing is left on the RH crankcase use the driver handle and the outer driver to...

Страница 119: ...ransmission and crankshaft INSPECTION Check that the bearing outer race fits the case tightly without play Turn the inner race and check that the bearing turns smoothly and quietly Replace the bearing...

Страница 120: ...aft bearing and oil seal Remove the countergear bearing Apply clean engine oil to a new bearing and assemble it to the crankcase TOOLS DRIVER HANDLE A DRIVER PILOT OUTER DRIVER Install a new final sha...

Страница 121: ...crankcase Install the removed parts Install the engine on the frame 6 2 CRANKCASE INSTALLATION Install the dowel pins and a new gasket Install the cam chain to the LH crankcase Make sure that the gas...

Страница 122: ...MEMO...

Страница 123: ...12 0 FRONT WHEEL FRONT FORK STEERING BRAKE STEERING HANDLE STEERING STEM FRONT DISK FRONT TIRE FRONT CASTING WHEEL FRONT FORK...

Страница 124: ...BER BOLT 1 98 2 45 f m FRONT AXLE NUT 4 41 4 9 f m BRAKE CALIPER BOLT 2 45 3 43 f m 12 SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 2 STEERING HANDLE 12 3 FRONT WHEEL 12 4 FRONT WHEEL BEARING 12 5 SPEE...

Страница 125: ...uide bushings Insufficient fluid in forks Loose front fork fasteners Lack of grease in speedometer gear box Brake lever soft or spongy Air in hydraulic system Mixed brake fluid and wet Contaminated br...

Страница 126: ...e the throttle grip from the handlebar Remove the handlebar lock nut and take out the bolt Remove the handlebar INSTALLATION Install the handlebar onto the steering stem and install the handlebar coll...

Страница 127: ...e actual runout is 1 2 of the total indicator reading SERVICE LIMIT 0 2mm replace if over Adjust the throttle grip free play to the specified range of 2 6mm Install the brake master cylinders by align...

Страница 128: ...y sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left...

Страница 129: ...GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER G...

Страница 130: ...rst drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove the two bolts securing the brake master cylinder Remov...

Страница 131: ...INDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTE...

Страница 132: ...SPRING Replace the piston spring cups and snap ring as a set Be sure that each part is free from dust or dirt before reassembly When cleaning with the brake fluid use the specified brake fluid Instal...

Страница 133: ...lable Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this...

Страница 134: ...evel is near the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Tighten the bleeder valve TORQUE VALUE 0 4 0 7 kgf m Be sure that the brake fl...

Страница 135: ...caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the brake hose 12 12 FRONT WHEEL FRONT FOR...

Страница 136: ...N PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON...

Страница 137: ...ghten the oil bolt to the specified torque TORQUE VALUE 3 4kgf m Fill the brake fluid to the upper limit line and bleed air FRONT FORK REMOVAL Remove the following parts Front under cover Front brake...

Страница 138: ...lt turns idle but cannot be removed temporarily assemble the spring and the fork tube cap bolt first Hold the bottom case firmly with a vise taking precautions not to distort or damage it SPRING VISE...

Страница 139: ...if the deflection is greater than 0 2mm 12 16 FRONT WHEEL FRONT FORK STEERING BRAKE Take precautions not to damage the interior and exterior rim of the bottom case OIL SEAL STOPPER RING OIL SEAL STOPP...

Страница 140: ...ew locking agent to the socket bolt thread and assemble the socket bolt to the fork piston TORQUE VALUE 2 0kgf m Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil sea...

Страница 141: ...L STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL...

Страница 142: ...ball assembly top cone race and ball race for damage or abnormal and replace as necessary Check the bottom cone race for wear and damage STEERING STEM REMOVAL Remove the following parts Handle cover...

Страница 143: ...ring top thread onto the steering head Tighten the top thread to specified torque then loosen the top thread 1 8 turn TORQUE VALUE 0 15 0 25kgf m Recheck that the steering stem moves smoothly without...

Страница 144: ...MEMO...

Страница 145: ...13 0 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Страница 146: ...gned to minimize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION LOWER BOLT 3 5 4 5 f m REAR CUSHION ROD LOCK NUT 3 0 4 5 f...

Страница 147: ...re pressure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear...

Страница 148: ...m leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the break hose DISASSEMBLY Remove the rear break caliper Inspect caliper assembly Remove the pad sprin...

Страница 149: ...aliper BRAKE CALIPER ASSEMBLY Clean the piston seal and the dust seal with the brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing t...

Страница 150: ...fler 3 8 Remove the rear brake caliper assembly from the rear swing arm Loosen the 3 rear brake disk bolts remove the rear brake disk from the rear wheel Remove the rear swing arm 13 7 Remove the rear...

Страница 151: ...the rear swing arm 13 8 Tighten the rear axle U nut to the specified torque TORQUE VALUE 6 0 8 0 kgf m Install the rear brake caliper assembly to the rear swing arm Install the EX muffler 3 8 Install...

Страница 152: ...SHION REMOVAL Remove the luggage box Remove the air cleaner Remove the upper bolt Remove the lower bolt Remove the rear cushion INSTALLATION Install in the reverse order of removal TORQUE VALUE 3 92kg...

Страница 153: ...NUT REAR SWING ARM DISASSEMBLY Disassemble the rear wheel outside collar from the rear swing arm Disassemble the oil seal 28 42 7 and radial ball bearing 6302UU Install in the reverse order of remova...

Страница 154: ...MEMO...

Страница 155: ...G SYSTEM GREEN GREEN REGULATOR RECTIFIER AC GENERATOR YELLOW ENGINE EARTH BATTERY 12V 10AH _ MAIN SWITCH FUSE 15A BLACK RED BLACK CABLE RED YELLOW YELLOW FRAME EARTH REGULATOR RECTIFIER MAIN SWITCH A...

Страница 156: ...tedly 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 n...

Страница 157: ...oose broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Battery...

Страница 158: ...the charger negative cable to the battery negative terminal When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the...

Страница 159: ...erminal and ground cable With the ignition switch off measure the leakage current LEAK CURRENT Not to exceed 0 5A max TOOL DIGITAL TESTER A C GENERATOR INSPECTION AMPERE METER EARTH CABLE BATTERY TERM...

Страница 160: ...move the regulator rectifier coupler Measure each terminal Replace the regulator rectifier unit if the resistance value between the terminals is abnormal RESISTANCE VALUE Tester Tester Unit 20 R B Y Y...

Страница 161: ...BLUE YELLOW GREEN AC GENERATOR PULSE GENERATOR 12V 10AH BATTERY _ SIDE STAND SWITCH MAIN SWITCH FUSE 15A BLACK WHITE PINK BLACK BLUE YELLOW BLACK YELLOW GREEN GREEN RED RED GREEN TO LIGHT RELAY BATTER...

Страница 162: ...moving wiring 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 inspe...

Страница 163: ...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 164: ...0 PVA MEASUREMENT DisconnecttheA Cgeneratorblue yellowwireconnector Connect the peak voltage adaptor probes to the pulse generator wire terminal of the wire harness side connector and ground Crank the...

Страница 165: ...If the resistance is open wire disconnect the spark plug cap and measure the secondary coil resistance STANDARD VALUE 17 21 Measure resistance between the primary coil terminal and high tension cord...

Страница 166: ...iming is correct if the index mark is set within the advance mark Install in the reverse order of removal SIDE STAND IGNITION CUT OFF SWITCH INSPECTION Remove the floor mat Remove the RH floor side co...

Страница 167: ...e the LH floor side cover 3 4 Loosen the side stand switch mounting 2 bolts Release the wire clamps and remove the side stand switch INSTALLATION Install in the reverse order of removal Check the side...

Страница 168: ...MEMO...

Страница 169: ...BATTERY _ STARTER RELAY M STARTER MOTOR GREEM YELLOW CABLE FUSE 15A BLACK MAIN SWITCH RR STOP SWITCH FR STOP SWITCH GREEN STOP LAMP STARTER SWITCH YELLOW RED GREEN GREEM YELLOW CABLE BATTERY MAIN SWIT...

Страница 170: ...en the engine cannot turn over The engine may not be turned over if the stop switch is faulty SPECIFICATION 16 1 Always turn the ignition switch OFF before servicing the starter motor The moter could...

Страница 171: ...at starter magnetic switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 7 Connect the starter magnetic s...

Страница 172: ...sh holder set Check for continuity between and terminals of the brush holder If there is continuity replace with a new one STARTER MOTOR REMOVAL Release the seat lock with the main key Remove the lugg...

Страница 173: ...dividual commutator bars and the armature shaft There should be no continuity Check the needle bearing and oil seal Do not rotate smoothly Replace with a new one Damage oil seal Replace with a new one...

Страница 174: ...al set and flange nut Align the brush holder set with the rear bracket groove and install the brush holder set Apply grease to both ends of the armature shaft and install the 2 washers REAR BRACKET BR...

Страница 175: ...tery cable from the starter magnetic switch terminal Remove the starter motor cable from the starter magnetic switch terminal Disconnect the yellow red connector and green yellow connector from the wi...

Страница 176: ...Apply battery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there is continuity betwee...

Страница 177: ...MEMO...

Страница 178: ...these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity test on normal parts can be carried out without removing...

Страница 179: ...Remove the headlight Disconnect the connector of handle switch Check for continuity between teminals Remove the Fr cover Remove the coupler wire Test each teminal of handle switch HEADLIGHT SWITCH RED...

Страница 180: ...s FUEL UNIT Remove the foor panel Be cover full not to be damaged for the wire Check the base packing for damage Measure the resistance between the fuel unit upper and lower BAT2 HI BLACK BLUE HI COLO...

Страница 181: ...e taillight bulb and winker bulb When replacing the bulb be sure not to put finger and contaminated gloves prints on the headlight bulb as they may create hot spots on the bulb and cause is to fail No...

Страница 182: ...R PASSING HORN S W LIGHT RELAY CDI HORN Lg 2P MINI 4P RR STOP SW HL HL BAT 2 BAT HI 4 W R L 2 HO BAT B B 9P MINI B SIDE O B Sb Lg Gr COLOR COMB GROUND MARKING R G L Y W P DC CDI UNIT B Y B W B Y B COI...

Страница 183: ...SERVICEMANUAL 2004 11 PRINTED 2004 11 PUBLICATION NO COPY...

Страница 184: ...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...

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