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AGB-21G

SERVICE MANUAL

Содержание AGB-21G

Страница 1: ...AGB 21G SERVICE MANUAL ...

Страница 2: ......

Страница 3: ...gula tions before riding 1 THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY Do not attempt to operate this machine at maximum power until you are totally familiar with its character istics 2 THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTECTIVE APPAREL When operating this machine always wear an approved helmet with go...

Страница 4: ...s Carbon monoxide is a dangerous gas which can cause unconscious ness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park the machine on a slope or soft ground as it may fall over 9 THE ENGINE EXHAUST PIPE MUF FLER AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN Be careful not to touch them or to...

Страница 5: ...ying your machine e g for weight reduction take note of the above limits of weight HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine A CAUTION indicates ...

Страница 6: ...INDEX GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL 3 4 5 6 7 ...

Страница 7: ...ch 8 9 Fuel tank 21 Air filter 22 Left side cover 23 Drive chain 24 Shift pedal 25 Side stand 26 Fuel cock 27 Spark plug 28 Right side cover 29 Kick starter cank 2 Front fork NOTE The machine you have purchased may differ slightly from those shown in the following Designs and specifications are subject to change without notice Rear brake pedal Front axle ...

Страница 8: ...ealer for positive identification of the model you own 2 If your machine is stolen the authorities will need the number to search for and identify your machine VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the right of the steering head pipe ENGINE SERIAL NUMBER The engine serial number is stamped into the elevated part of the right side of the engine ķ ...

Страница 9: ...se proper tools and cleaning equip ment Refer to SPECIAL TOOLS sec tion 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will spee...

Страница 10: ...RINGS AND OIL SEALS 1 Install the bearing s and oil seal s with their manufacturer s marks or num bers facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bearings liberally when installing CAUTION Do not use compressed air to spin the bearings dry This c...

Страница 11: ...that it will not come off 5 If the terminal comes off bend up the pin and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wireharness For a field remedy use a contact revitalizer available on ...

Страница 12: ...olding tool This tool is used when loosening or tightening the fly wheel magneto securing nut Dial gauge and stand Stand These tools are used to check each part for runout or bent Crankshaft installing tool pot bolt Spacer crankshaft installer Adapter M12 These tools are used to install the crankshaft Piston pin puller set This tool is used to remove the piston pin Steering nut wrench This tool is...

Страница 13: ... of the constant mesh 4 speed transmission are ideally spaced The gears can be shifted by using the shift pedal on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter crank so the engine can be sta...

Страница 14: ...el cock supplies fuel from the tank to carburetor while filtering the fuel The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position SPARK PLUG WRENCH This spark plug wrench is...

Страница 15: ...a l i o h t i W Engine Air cooled 4 stroke e p y t e n i g n E d e n i l c n i d r a w r o f r e d n i l y c e l g n i S t n e m e g n a r r a r e d n i l y C m c 3 67 12 t n e m e c a l p s i D 3 Bore s 0 54 e k o r t s s 54 mm 1 9 o i t a r n o i s s e r p m o C r e t r a t s k c i K m e t s y s g n i t r a t S p m u s y r D m e t s y s n o i t a c i r b u L Oil type or grade At 5 C 40 F or high...

Страница 16: ... c s i d e l p i t l u m t e W e p y t h c t u l C Transmission Primary reduction system Gear 2 7 7 3 8 1 7 6 o i t a r n o i t c u d e r y r a m i r P Secondary reduction system Chain drive Secondary reduction ratio 43 15 2 867 d e e p s 4 h s e m t n a t s n o C e p y t n o i s s i m s n a r T n o i t a r e p o t o o f t f e L n o i t a r e p O 8 1 8 2 1 1 6 3 t s 1 o i t a r r a e G 8 3 9 1 6 1...

Страница 17: ... r o f c i p o c s e l e T n o i s n e p s u s t n o r F n o i s n e p s u s s s o r c o n o m e p y t k n i l m r a g n i w S n o i s n e p s u s r a e R Shock absorber r e p m a d l i o g n i r p s l i o C r e b r o s b a k c o h s t n o r F r e p m a d l i o g n i r p s l i o C r e b r o s b a k c o h s r a e R Wheel travel m m 0 0 2 l e v a r t l e e h w t n o r F m m 0 0 2 l e v a r t l e e h...

Страница 18: ...u O Camshaft t f e L e v i r d n i a h C d o h t e m e v i r D Camshaft cap inside diameter 31 963 31 979 mm Camshaft outside diameter 32 009 32 034 mm m m 071 0 0 3 0 0 e c n a r a e l c p a c o t t f a h S Cam dimensions Intake A 26 555 26 675 mm 26 30 mm B 20 99 21 01 mm 20 95 mm Exhaust A 26 316 26 436 mm 26 00 mm B 20 99 21 01 mm 20 95 mm m m 3 0 0 t i m i l t u o n u r t f a h s m a C A B ...

Страница 19: ...m EX 22 9 23 1 mm B face width IN 1 1 1 5 mm EX 1 1 1 5 mm C seat width IN 0 9 1 1 mm 1 6 mm EX 0 8 1 0 mm 1 6 mm D margin thickness IN 0 65 0 95 mm EX 0 65 0 95 mm Stem outside diameter IN 4 97 4 985 mm 4 94 mm EX 4 955 4 97 mm 4 925 mm Guide inside diameter IN 5 000 5 012 mm 5 050 mm EX 5 500 5 512 mm 5 550 mm Stem to guide clearance IN 0 015 0 042 mm 0 08 mm EX 0 030 0 057 mm 0 10 mm t i m i L ...

Страница 20: ... IN 22 45 mm EX 25 45 mm Compressed force m m 5 4 2 2 t a N 4 6 52 N I d e l l a t s n i EX 105 129 N at 25 45 mm 3 1 N I t i m i l t l i T 0 8 mm 35 1 X E 0 8mm Direction of winding e s i w k c o l C N I w e i v p o t e s i w k c o l C X E Piston Piston to cylinder clearance 0 025 0 05 mm 0 1 mm Piston size D 53 965 53 975 mm Measuring point H 10 mm e d i s N I m m 4 0 t e s f f o n o t s i P t i...

Страница 21: ...installed 0 040 0 080 mm 0 12 mm 2nd ring r e p a T e p y T Dimensions B s 98 0 T s 2 20 mm m m 0 3 0 5 1 0 d e l l a t s n i p a g d n E 0 60 mm m m 0 8 0 0 0 4 0 0 e c n a r a e l c e d i S 0 12 mm Oil ring Dimensions B s 2 9 1 T s 2 45 mm m m 0 5 0 0 2 0 d e l l a t s n i p a g d n E Crankshaft Crank width A 40 15 40 20 mm Runout limit C 0 03 mm 0 05 mm Big end side clearance D 0 15 0 35mm 0 60...

Страница 22: ...I d o h t e m e s a e l e r h c t u l C Shifter r a b e d i u g d n a m u r d m a C e p y t r e t f i h S m m 5 0 0 t i m i l g n i d n e b r a b e d i u G Kickstarter e p y t t e h c t a r d n a k c i K e p y T r o t e r u b r a C Z26 5K P r e r u t c a f u n a m e p y T JINGKE K J k r a m D I 5 8 J M t e j n i a M J A M t e j r i a n i a M ø1 0 26 5 38 ø2 0 8 g 2 0 3 0 mm N J e l d e e n t e J I...

Страница 23: ...he engine must be cold Check the valve seats and valve stems for wear VALVE SPRINGS Inspect Replace ƽ ƽ Check the free length and the tilt VALVE LIFTERS Inspect Replace ƽ ƽ Check for scratches and wear CAMSHAFTS Inspect Replace ƽ ƽ Inspect the camshaft sur face Inspect the decompres sion system TIMING CHAIN SPROCKETS TIMING CHAIN Inspect Replace ƽ ƽ Check for wear on the teeth and for damage PISTO...

Страница 24: ...slack 30 40 mm OUTSIDE NUTS AND BOLTS Retighten ƽ ƽ Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Replace ƽ ƽ ƽ Use foam air filter oil or equivalent oil OIL FILTER Replace ƽ ƽ OIL STRAINER frame Clean ƽ FRAME Clean and inspect ƽ ƽ FUEL TANK COCK Clean and inspect ƽ ƽ BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surfa...

Страница 25: ...pect lube and retighten ƽ ƽ Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing ƽ ƽ ƽ ƽ Lithium base grease TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate ƽ ƽ ƽ ƽ ƽ ƽ ƽ Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricat...

Страница 26: ...e d n a e k a r b t n o r f f o y a l p e h t k c e h C s e k a r B Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play Steering Check that the handlebar can be turned smoothly and have no excessive play Front forks and rear shock absorber Check that t...

Страница 27: ...y changing their tightening position Tighten the locknuts THROTTLE CABLE ADJUSTMENT 1 Check Throttle grip free play a Out of specification m Adjust Throttle grip free play a 3 5 mm 2 Adjust Throttle grip free play Throttle grip free play adjustment steps Slide the adjuster cover Turn the adjuster until the specified free play is obtained Tighten the locknut NOTE Before adjusting the throttle cable...

Страница 28: ...e end 3 Install Screw throttle grip cap T R 4 Nm 0 4 m kg AIR FILTER REPLACE NOTE Proper air filter maintenance is the biggest key to preventing premature engine wear and damage CAUTION Never run the engine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove Screw ...

Страница 29: ...ngine warm it up for several minutes and then turn off the engine and wait for five minutes 2 Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine 3 Remove Oil tank cap ENGINE OIL LEVEL INSPECTION Fitting Screw ...

Страница 30: ... once again NOTE Wait a few minutes until the oil settles before inspecting the oil level Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommended engine oil classi fication API STANDARD API SG or higher grade Designed primarily for motor cycles 4 Inspect Oil level Oil level should be between maximum and minimum marks Oil level...

Страница 31: ...e oil level Oil quantity Total amount 0 9 L Periodic oil change 0 8 L With oil filter replacement 0 85 L OIL PRESSURE INSPECTION 1 Check Oil pressure Checking steps Slightly loosen the oil pressure check bolt Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt If no oil comes out after one minute turn the engine off so it will not seize Check oil passages ...

Страница 32: ... screw by the factory set number of turns Pilot screw 1 5 8 turns out example PILOT SCREW ADJUSTMENT ENGINE IDLING SPEED ADJUSTMENT 1 Start the engine and thoroughly warm it up 2 Attach Inductive tachometer To spark plug lead 3 Adjust Engine idling speed Adjustment steps Adjust the pilot screw Refer to PILOT SCREW ADJUSTMENT section Turn the throttle stop screw until the engine runs at the lowest ...

Страница 33: ...tall the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube tightly to the caliper bleed screw d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever or pedal to ...

Страница 34: ...KE 1 Check Brake lever position A Brake lever position A Standard position Extent of adjustment 100 mm Unavailable REAR BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT 1 Check Brake pedal height A Out of specification m Adjust Brake pedal height A 10 mm 2 Adjust Brake pedal height Pedal height adjustment steps Loosen the locknut Turn the adjusting nut until the pedal height D is within specified height Tig...

Страница 35: ...Remove Bolt 1 and 2 Loosen the Caliper CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 3 and 4 18 Nm 1 8 m kg Install the Caliper Bolt 1 and 2 T R Bolt brake caliper 25 Nm 2 5 m kg Remove Bolt 3 and 4 Replace the Brake pad 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPECTION section 4 Check Brake lever operation A softy or spongy feeling m Bleed br...

Страница 36: ...SPECTION AND REPLACEMENT 1 Inspect Brake pad thickness A Out of specification m Replace as a set 2 Replace Brake pad Brake pad thickness 4 mm Limit 1 0 mm Brake pad replacement steps Remove the Screw 1 and 2 Loosen the Caliper Remove the Nut 3 Reeplace the Brake pad ...

Страница 37: ... BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level m Fill up D Lower level A Front B Rear Use only designated quality brake fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake performance Be sure that water or other cont...

Страница 38: ... 1 Remove Master link clip Joint Drive chain 2 Clean Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the drive chain from the kerosene and dry the drive chain 3 Measure Drive chain length 10 links a Out of specification m Replace Drive chain length 10 links Limit 144 4 mm 4 Check Drive chain stiffness a Clean and oil the drive chain and hold as illustrated Stiff...

Страница 39: ...RIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suitable stand under the engine 2 Check Drive chain slack A Above the seal guard installation bolt Out of specification m Adjust NOTE Before checking or adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tight est point Check and or adjust the drive chain slack with the rear w...

Страница 40: ...tain correct axle alignment NOTE Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear CAUTION Too small drive chain slack will overload the engine and other vital parts keep the slack within the specified limits Tighten the axle nut while pushing down the drive chain T R Axle nut 65 Nm 6 5 m kg Tighten the locknuts T R Locknut 12 Nm 1 2 m FRONT FORK INSPEC...

Страница 41: ...igarettes DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury First aid in case of bodily contact External SKIN Wash with water EYES Flush with water for 15 minutes and get immediate medical attention Internal Drink large quantities of water or milk fol l...

Страница 42: ... charger leads are connected to the battery NOTE Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery ter minal and that they are not shorted A cor roded battery charger lead clip may gener ate heat in the contact area and a weak clip spring may cause spar...

Страница 43: ...ng a fuse Check fuse a Connect the pocket tester to the fuse and check it for continuity Set the pocket tester selector to 7 1 b If the pocket tester indicates d replace the fuse REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action m Grease the pivoting points or repair the pivoting points Damage oil leakage m Replace REAR SHOCK ABSORBER INSPECTION ...

Страница 44: ...m around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Locknut 6 Install Rear frame upper Rear frame lower Stiffer m Increase the spring preload Turn the adjuster in Softer m Decrease the spring preload Turn the adjuster out Spri...

Страница 45: ...ps off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 130 kPa 1 3 kgf cm SPOKES INSPECTION AND TIGHTENING 1 Inspect Spokes Bend damage m Replace Loose spoke m Retighten 2 Tighten Spokes NOTE Be sure to retighten these spokes before and after break in After a practice or a race c...

Страница 46: ...ng stem Grasp the bottom of the forks and gen tly rock the fork assembly back and forth Free play m Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action m Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps Remove the number plate Remove the handlebar and handlebar upper bracket Loosen the steering ring nut using the...

Страница 47: ... ring nut one turn Retighten the steering ring nut using the steering nut wrench Avoid over tightening Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings Install the upper bracket washer steer ing stem nut handlebar handlebar upper holder CAUTION First tighten the bolts on the front side of the handlebar ho...

Страница 48: ...any hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap D Use a wire gauge or thickness gauge Out of specification m Regap 4 Clean the plug with a spark plug cleaner if necessary Spark plug gap 0 6 0 7 mm 5 Tighten Spark plug NOTE Before installing a spark plug clean the gas ket surface and plug surface...

Страница 49: ...iming Checking steps Start the engine and let it warm up Let the engine run at the specified speed Engine speed 1 400 1 600 r min Visually check the stationary pointer D is within the firing range E on the rotor Incorrect firing range m Check rotor and pickup assembly 3 Install Timing mark accessing screw ...

Страница 50: ...AT 4 LEFT FENDER PLATE 5 RIGHT FENDER PLATE 6 TAIL FENDER 7 FUEL TANK 8 FUEL CAP 9 PET COCK Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 1 1 1 1 1 1 ENGINE SEAT FUEL TANK AND SIDE COVERS 2 5 3 6 1 4 7 8 9 SEAT FUEL TANK AND SIDE COVERS ...

Страница 51: ...t Remove SEAT FUEL TANK AND SIDE COVERS Bolt for Tank Cover Right Tank Cover Seat Bolt Bolt for Fuel Tank Fuel Tank Screw for Tank Cover and Seat Left Tank Cover Screw for Fender plate Left Fender plate Right Fender plate Screw for Fender plate Seat ...

Страница 52: ... BOLT 2 HOOP 3 RUBBER MAT 4 NUT M6 14 5 EXHAUST MUFFLER 6 EXHAUST PIPE SEAL Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 2 1 1 5 3 2 4 6 1 NEW EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER ...

Страница 53: ...ct Gasket Damage Replace ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1 Install Gasket Exhaust muffler Nut exhaust pipe NOTE First temporarily tighten the Nut ķ exhaust pipe then tighten the bolt ĸ T R 15 Nm 1 5 m kg 2 Install Washer Bolt silencer T R 25 Nm 2 5 m kg m ...

Страница 54: ...R CLAMP 2 AIR FITER 3 CRBURETOR 4 GASKET HEAT INSULATING CRBURETOR 5 O RING 6 INLET PIPE 7 O RING 8 GASKET Remove the parts in the order listed For installation reverse the removal procedure CRBURETOR AIR FITER CRBURETOR AIR FITER 1 1 1 2 1 1 1 1 NEW NEW NEW ...

Страница 55: ... AIR THROTTLE 8 O RING 9 ADJUSTING SCREW AIR THROTTLE Remove the parts in the order listed For installation reverse the removal procedure 10 SPRING ADJUSTING SCREW 11 O RING 12 WASHER 13 ADJUSTING SCREW SPRING 14 IDLE FOAM JET 15 MAIN JET OIL 16 MAIN JET FOAM 17 MAIN MEASURING HOLE 18 IDLE JET 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 NEW NEW CARBURETOR DISASSEMBLY ...

Страница 56: ...der listed For installation reverse the removal procedure 19 FLOAT COMP 20 NEEDLE VALVE CARBURETOR FLOAT 21 HOOK NEEDLE VALVE 22 FLOAT PIN 23 GASKET FLOAT CHAMBER 24 DRAIN SCREW 25 O RING 27 SCREW UNIT FLOAT CHAMPER 28 PIPE CLIP 29 HOSE 1 1 1 1 1 1 3 1 1 1 NEW NEW CARBURETOR DISASSEMBLY ...

Страница 57: ... Jet Main Measuring Hole and Main Nozzi Main Jet Drain Screw Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire Needle valve 1 Inspect Needle valve Valve seat Grooved wear b Replace Dust c Clean Jet needle 1 Inspect Jet needle Bends wear Replace Clip groove Free play exists wear Replace Clip positi...

Страница 58: ...GUAGE OIL LEVER 6 KICK STARTER 7 SPARK PLUG CAP 8 ENGINE SKID PLATE Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 1 1 1 1 1 1 1 1 1 2 SPROCKET REPLACEMENT 1 12 2 3 4 6 7 13 13 10 11 9 9 SIDE STAND 10 RIGHT FOOT PAGS 11 LEFT FOOT PEGS 12 BRACKET FOR PEDAL 13 AXLE SPROCKET REPLACEMENT 8 5 ...

Страница 59: ...3 Cylinder cover L Gasket 4 Timing driven sprocket 5 Valve cover O ring 6 Valve cover O ring 7 Cylinder cover 8 Gasket cylinder cover 9 Cylinder head Remove the parts in the order listed For installation reverse the removal procedure 10 Gasket cylinder head 11 Rectangle ring 1 1 1 1 1 1 1 1 1 1 1 NEW NEW NEW NEW NEW NEW ...

Страница 60: ...h the stationary pointer b on the crankcase cov er a Turn the primary pulley counterclockwise b When the piston is at TDC on the compres sion stroke align the I mark c on the cam shaft sprocket with the mark d on the cylin der head 3 Loosen Bolt 1 1 Remove Long Bolt A 4 Remove Bolt 2 Nut B ...

Страница 61: ...Chain Tensioner Push Road NOTE To prevent the timing chain from falling into the crankcase fasten it with a wire a While holding the generator rotor bolt with a wrench remove the bolt Chain Tensioner Push Road Assembly 5 Remove Chain Tensioner ...

Страница 62: ...park plug threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 03 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure the warpage c If the limited is exceeded resurface the cylin der head as follows d Place a 400 600 grit wet abrasive ...

Страница 63: ...1 Check tappet cover camshaft sprocket cover O ring Damage wear Replace the defective part s INSTALLING THE CYLINDER HEAD 1 Install dowel pins 1 O ring New 2 gasket New 3 2 Install cylinder head Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages Cylinder head nut and bolt M7 1 4 15Nm M...

Страница 64: ... b on the genera tor rotor cover Be sure to keep the timing chain as tight as pos sible 2 Install timing chain onto the camshaft sprocket camshaft sprocket onto the camshaft The notch a on the camshaft should face to wards the intake side of the engine Align the camshaft marks a with the edge of the cylinder head as shown Do not turn the crankshaft when installing the camshaft to avoid damage or i...

Страница 65: ... SHAFT 8 VALVE COTTER 9 PETAINER VALVE SPRING Remove the parts in the order listed For installation reverse the removal procedure 1 1 2 2 2 2 1 4 2 2 2 2 1 1 10 VALVE INNER SPRING 11 VALVE OUTER SPRING 12 VALVE STEM SEAL 13 INTAKE VALVE 14 EXHAUST VALVE CAMSHAFT VALVES AND VALVE SPRINGS CAMSHAFT VALVES AND VALVE SPRINGS ４３６８９７１２５１０１１１２１３１４ NEW NEW ...

Страница 66: ...knuts 1 adjusting screws 2 2 Remove 3 Remove camshaft 1 intake rocker arm shaft exhaust rocker arm shaft intake rocker arm exhaust rocker arm CHECKING THE CAMSHAFTS 1 Check camshaft bushings Damage wear Replace camshaft lobes Blue discoloration pitting scratches Replace the camshaft 3 4 4 3 ...

Страница 67: ...plies to all of the rocker arms and rocker arm shafts 1 Check rocker arm Damage wear Replace 2 Check rocker arm shaft Blue discoloration excessive wear pit ting scratches Replace or check the lu brication system 3 Check camshaft lobe Excessive wear Replace the camshaft 4 Measure rocker arm inside diameter Out of specification Replace Rocker arm inside diameter 10 000 10 015 mm Limit 10 1 mm 5 Meas...

Страница 68: ...5 mm INSTALLING THE CAMSHAFT AND ROCK ER ARMS 1 Lubricate rocker arm shaft Recommended lubricant Molybdenum disulfide oil 2 Install exhaust rocker arm exhaust rocker arm shaft Make sure that the exhaust rocker arm shaft is completely pushed into the cylinder head 3 Install intake rocker arm intake rocker arm shaft 1 Insert the camshaft into the hole in the cylinder head and the intake rocker arm s...

Страница 69: ... Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 2 Remove valve cotters 1 Remove the valve cotters by compressing the valve springs with the valve spring compressor 2 and attachment 3 3 Remove upper spring seat 1 valv...

Страница 70: ... clear ance Intake 0 015 0 042 mm Limit 0 08 mm Exhaust 0 030 0 057 mm Limit 0 10 mm 2 Replace valve guide To ease valve guide removal and installation and to maintain the correct fit heat the cylinder head to 100 C in an oven a Remove the valve guide with a valve guide remover 1 b Install the new valve guide with a valve guide installer 2 and valve guide remover 1 c After installing the valve gui...

Страница 71: ...valve stem runout Out of specification Replace the valve When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the oil seal Valve stem runout Limit 0 03 mm CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wea...

Страница 72: ...e seat After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve f...

Страница 73: ... and lap the valve seat CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spring Valve spring free length intake and exhaust Inner spring 33 78 mm Limit 32 5 mm Outer spring 35 55 mm Limit 34 0 mm 2 Measure compressed spring force a Out of specification Replace the valve spring b Instal...

Страница 74: ...ant Molybdenum disulfide oil 3 Install valve 1 oil seal 2 valve springs 3 upper spring seat 4 into the cylinder head Install the valve springs with the larger pitch a facing up 4 Install valve cotters 1 Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and attachment 3 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a sof...

Страница 75: ...DE ROLLER 3 CYLINDER BLOCK 4 GASKET CYLINDER BLOCK 5 DOWEL PIN 6 RECTANGLE RING 7 CIRCLIP PISTON PIN 8 PISTON PIN 9 PISTON Remove the parts in the order listed For installation reverse the removal procedure 5 3 2 6 1 4 CYLINDER AND PISTON 7 NEW NEW 7 8 1 1 1 1 1 1 1 2 1 1 1 NEW NEW 9 10 PISTON RING ...

Страница 76: ...ush up the other side of the ring CHECKING THE CYLINDER AND PISTON 1 Check piston wall cylinder wall Vertical scratches Rebore or replace the cylinder and replace the piston and piston rings as a set 2 Measure piston to cylinder clearance a Measure cylinder bore C with the cylinder bore gauge Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find th...

Страница 77: ...th the following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 025 0 05 mm f If out of specification rebore or replace the cylinder and replace the piston and piston rings as a set CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set Before measuring the piston ...

Страница 78: ...xces sive replace all three piston rings Piston ring end gap Top ring 0 10 0 25 mm Limit 0 60 mm 2nd ring 0 15 0 30 mm Limit 0 60 mm Oil ring 0 2 0 5 mm CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 13 ...

Страница 79: ... the piston rings so that the manufacturer s marks or numbers face up 2 Install piston 1 piston pin 2 piston pin clip 3 Apply engine oil onto the poston pin Make sure that the mark IN on the piston points towards the intake side of the cylinder Before installing the piston pin clip cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase 3 Install gasket 1 d...

Страница 80: ...Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 6 Install cylinder 1 While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity ...

Страница 81: ...RESSURE PLATE 9 OIL SEAL Remove the parts in the order listed For installation reverse the removal procedure CLUTCH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 ˠ ˡ ˢ ˣ ７８ 10 11 ９ 12 13 14 15 16 18 19 20 21 22 17 23 24 25 26 27 28 10 OIL SEAL 11 R CRANK CASE COVER 12 GASKET R CRANK CASE COVER 13 CLUTCH PUSH ROD 14 OIL TUBE 15 OIL THIMBLE SPRING 16 OIL THIMBLE 17 BEARING 18 CLUTCH END COVER NEW NEW NEW...

Страница 82: ...lation reverse the removal procedure CLUTCH 1 1 1 1 1 1 1 1 1 1 19 GASKET END COVER 20 NUT 21 WASHER 22 THURST WASHER 23 CLUTCH ASSY 24 DRIVER GEAR 25 SLEEVE 26 BUSH 27 CIRCLIP 28 DRIVEN GEAR CAM 1 2 ˠ ˡ ˢ ˣ ７８ 10 11 ９ 12 13 14 15 16 18 19 20 21 22 17 23 24 25 26 27 28 NEW NEW NEW NEW NEW NEW ...

Страница 83: ...TER SLEEVE 5 DRIVE PLATE 6 CLUTCH CUSHION SPRING 7 CLUTCH SPRING 8 CLUTCH OUTER CASE 4 34 CLUTCH Order Job Part name Q ty Remarks Remove the parts in the order listed For installation reverse the removal procedure CLUTCH 1 3 3 1 1 1 1 1 1 １２３４３５６ 8 7 ２２３ ...

Страница 84: ...fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set Measure the friction plate at four places Friction plate thickness 2 85 2 95 mm Limit 2 7 mm CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace th...

Страница 85: ...a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free length 20 5 mm Limit 19 5 mm CHECKING THE CLUTCH OUTER CASE 1 Check clutch outer case dogs Damage pitting wear Deburr the clutch outer case dogs or replace it Pitting on the clutch housing dogs will cause er ratic clutch operation CHECKING THE CLUTCH CENTER SLEEVE 1 Check clutch ce...

Страница 86: ...upper plate and a friction plate with the recommended lubricant Recommended lubricant Engine oil INSTALLING THE CLUTCH ASSY 1 Install put the clutch spring into the clutch outer case put the drive plate into the clutch outer case 3 Install friction plates upper plates 4 Install pressure plate and install clutch circlip ...

Страница 87: ...l thim ble spring Oil thimble spring free length 17 5 mm INSTALLING THE CLUTCH 1 Install clutch assy 1 thrust washer make sure the OUT SIDE mark on the washer is upturned Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss 2 Tighten clutch boss nut 5 While holding the clutch boss with the universal clutch holder tighten the clutch boss nut 3 Bend t...

Страница 88: ...TCH NOTE 6 Nm 0 6 m kg 4 Install oil tube 1 oil thimble spring 2 oil thimble 3 screw ķ ĺ 5 Check clutch assy Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss ...

Страница 89: ...4 40 Order Job Part name Q ty Remarks Remove the parts in the order listed For installation reverse the removal procedure OIL PUMP 1 1 1 1 OIL PUMP 2 OIL FILTER SCREEN 3 GEAR OIL PUMP 1 2 NEW 3 ...

Страница 90: ...of oil pump Remove the gasket of oil pump and check the state Replace if worn or if reuse if questionable 1 Remove Screw gear of oil pump 3 Check Remove the oil pump and inspect oil way for smoothness clean oil way as necessary Check whether the gear is worn ...

Страница 91: ... MOTOR 8 DRIVE SPROCKET STARTING MOTOR 9 STARTING MOTOR DRIVE CHAIN Remove the parts in the order listed For installation reverse the removal procedure 10 OIL SEAL 19 30 5 11 OIL SEAL 12 CHAIN PROTECT PLATE 13 CHAIN GUIDE PLATE 14 WOODRUFF KEY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 MAGNETO AND STARTER GEAR 1 3 5 2 4 10 9 7 8 12 6 11 MAGNETO AND STARTER GEAR 13 NEW NEW NEW NEW 14 ...

Страница 92: ...1 while holding the rotor with a sheave holder 2 Do not allow the sheave holder to touch the projection on the rotor 2 Remove generator rotor 1 woodruff key CHECKING THE STARTER CLUTCH 1 Check 1 starter clutch drive gear 2 starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Remove circlip 1 bolt ...

Страница 93: ...b it should turn freely If the starter clutch gear does not turn freely the starter clutch is faulty and must be re placed 3 Inspect dowel pins 1 compression springs 2 spring caps 3 Wear Damage Replace 4 Inspect starter wheel gear contacting surface Pitting Wear Damage Replace INSTALLING THE STARTER CLUTCH 1 Install starter clutch assembly 1 2 Unloosen the starter clutch assembly by us ing the cen...

Страница 94: ... portion of the crankshaft and the rotor hub When installing the rotor make sure the wood ruff key is properly seated in the key way of the crankshaft and turning the starter wheel gear clockwise 4 Tighten generator rotor 2 Tighten the bolt while holding the generator ro tor with the sheave holder 2 Install starting motor drive chain drive gear cirlip bolt chain protect plate ...

Страница 95: ...H ROD 8 CHAIN TENSIONER PUSH ROD 9 TIGHTENING ROD HEAD Remove the parts in the order listed For installation reverse the removal procedure 10 TIMING CHAIN 11 TIGHTENING ARM SHAFT 12 TIGHTENING ARM 13 TIGHTENING IDLER WHEEL SET 14 OIL PUMP DRIVE SPROCKET 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CAM CHAIN TENSIOR CAM CHAIN TENSIOR 1 4 3 2 5 6 7 8 9 11 12 13 14 10 NEW NEW ...

Страница 96: ... chain tensior roller of cam chain tensior 2 cam chain 3 2 Check aluminium washer Pitting Wear Damage Replace INSTALLING THE CAM CHAIN TENSIOR 1 Install bolt of cam chain tensior 1 spring of chain tensior push rod Pitting Wear Damage Replace CAM CHAIN TENSIOR ...

Страница 97: ...R BODY ASSY 6 TENSION SPRING GEARSHIFT LEVER 7 STOP PLATE 8 BOLT M8 11 9 CIRCLIP 16 Remove the parts in the order listed For installation reverse the removal procedure 10 SPRING 11 SPRING SHAFE SPRING BASE 1 1 1 1 1 1 1 1 1 1 1 CRANKSHAFT AND GEARSHIFT ARM CRANKSHAFT AND GEARSHIFT ARM 13 13 14 14 15 16 17 17 17 18 19 20 21 22 23 24 25 6 11 10 12 1 2 5 8 7 4 3 10 11 9 ...

Страница 98: ... BOLT M6 60 21 BREATHER TUBE C100 2 Remove the parts in the order listed For installation reverse the removal procedure 22 LEFT CRANKCASE 23 GASKET CRANKCASE 24 RIGHT CRANKCASE 25 TIE IN BREATHER TUBE 1 2 2 1 1 3 1 1 1 1 1 1 1 1 CRANKSHAFT AND GEARSHIFT ARM CRANKSHAFT AND GEARSHIFT ARM 13 13 14 14 15 16 17 17 17 18 19 20 21 22 23 24 25 6 11 10 12 1 2 5 8 7 4 3 10 11 9 12 CONTACT GEAR INDICATION ...

Страница 99: ...4 50 CRANKSHAFT AND GEARSHIFT ARM DISASSEMBLING THE CRANKCASE 1 Gearshift arm bolt of locating plate 2 Remove cirlip Remove bolt of locating plate spring spring seat ...

Страница 100: ...asing numerical or der refer to the numbers in the illustration The numbers embossed on the crankcase in dicate the crankcase tightening sequence 2 Remove right crankcase Set the left crankcase half under then put in the flat head screw driver to the separating slit First check that the shift drum segment s teeth and the drive axle circlip are properly positioned then remove the right crank case D...

Страница 101: ...E SPROCKET 2 BEARING 6205 3 BEARING 6205 4 PIN 5 ROLLER BEARING 6 JOINT RED 7 LEFT CRANKSHAFT 8 RIGHT CRANKSHAFT Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 1 1 1 1 1 CRANKSHAFT CRANKSHAFT 1 2 3 1 4 6 5 7 8 ...

Страница 102: ...on Replace the big end bearing crankshaft pin or connecting rod Big end axial clearance 0 15 0 35 mm Limit 0 6 mm 3 Measure crankshaft width Out of specification Replace the crank shaft Crankshaft width 40 15 40 20 mm 4 Check crankshaft sprocket 1 Damage wear Replace the crankshaft bearing 2 Cracks damage wear Replace the crankshaft 5 Check crankshaft journal Scratches wear Replace the crankshaft ...

Страница 103: ... SPROCKET AND TIMING CHAIN GUIDES 1 Check timing chain Damage stiffness Replace the timing chain and camshaft sprocket as a set 2 Check camshaft sprocket More than 1 4 tooth a wear Replace the camshaft sprocket and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check timing chain guide exhaust side timing chain guide intake side timing chain guide top s...

Страница 104: ... apply en gine oil onto each bearing ASSEMBLING THE CRANKCASE 1 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 2 Apply sealant onto the crankcase mating surfaces Do not allow any sealant to come into contact with the oil gallery a 3 Install dowel pins right crankcase 4 Tighten crankcase right half Tighten the screws in decreasing numerical or der see numbers on the ...

Страница 105: ...emove the parts in the order listed For installation reverse the removal procedure 10 SPRING SHAFE 11 BEARING 12 PIN 13 PIN 14 PIN 14 1 PRING CLIP 15 GEAR FORK 16 GEAR FORK 17 DRUM 1 1 1 1 1 1 1 1 1 1 1 2 3 2 2 1 1 1 TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS 1 2 3 4 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 20 22 21 23 24 14 1 19 ...

Страница 106: ...e removal procedure 18 MAINSHAFT 19 COUNTERSHAFT 20 BEARING 6203 21 BEARING 6201 22 BEARING 6001 23 BEARING 6203 24 OIL SEAL 17X29X5 1 1 1 1 1 1 1 TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS 1 2 3 4 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 20 22 21 23 24 14 1 19 TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS ...

Страница 107: ...ar indication 2 1 Loosen screw 1 Remove them at same the time 3 Remove drive axle assembly 1 main axle assembly 2 gearshift drum assy 3 Remove clip gearshift drum 1 pin gearshift drum 2 4 Gearshift drum assy dissembly TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS ...

Страница 108: ...related components Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork CHECKING THE SHIFT DRUM 1 Check shift drum grooves Damage scratches wear Replace the shift drum shift drum segment Damage wear Replace TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS ...

Страница 109: ...he drive axle Drive axle runout limit 0 02 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement Incorrect Reassemble the transmission axle assemblies 5 Check transmission gear movement Rough movement Replace the defective part s 6 Check circlips...

Страница 110: ...k shift cam operation Unsmoothy operation Repair Check the transmission and shift forks for smooth operation by turning the shift cam with your hand Put them into the crankcase at same the time main axle 1 drive axle 2 gearshift drum assy 3 TRANSMISSION DEVICE SHIFT DRUM GEAR FORKS ...

Страница 111: ...AXLE 2 FRONT RIM AXLE 3 FRONT TIRE 4 COLLAR FR WHEEL 5 OIL SEAL 6 BEARING 7 FRONT BRAKE DISK Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 2 2 2 1 FRONT WHEEL FRONT WHEEL AND REAR WHEEL 2 4 5 6 3 7 6 5 4 NEW NEW 1 ...

Страница 112: ...installation reverse the removal procedure 1 1 2 1 3 1 2 2 1 NEW REAR WHEEL 4 10 2 9 8 5 3 9 8 5 3 1 1 NUT FRONT WHEEL AXLE 2 FRONT RIM AXLE 3 CHAIN PULLER 4 REAR WHEEL 5 COLLAR RE WHEEL 6 DRIVEN SPROKET 7 OIL SEAL 8 BEARING 9 FRONT BRAKE DISK FRONT WHEEL AND REAR WHEEL NEW 6 7 5 ...

Страница 113: ...g if necessary 1 Remove Bearing NOTE Remove the bearing using a general bearing puller INSPECTION Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 2 0 mm Lateral 2 0 mm ...

Страница 114: ...eel axle bending limit 0 5 mm Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc 2 Measure Brake disc thickness b Out of limit Replace Brake disc deﬂection limit Rear Limit 0 15 mm Brake disc thickness Front 3 0 mm Limit 2 5 mm Rear 3 0 mm Limit 2 5 mm FRONT WHEEL A...

Страница 115: ... of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install Brake disc Bolt brake disc NOTE Tighten the bolts in stage using a crisscross pattern 3 Install Collar NOTE Apply the lithium soap base grease on the oil seal lip 4 Install Wheel NOTE ...

Страница 116: ...5 6 FRONT WHEEL AND REAR WHEEL 5 Install Wheel axle NOTE Apply the lithium soap base grease on the wheel axle 6 Install Nut wheel axle T R 50Nm 5 m kg ...

Страница 117: ...outward Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward ACHTUNG CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc Bolt brake disc NOTE Tighten the bolts in stage using a crisscros...

Страница 118: ...nstall Left Collar NOTE Apply the lithium soap base grease on the oil seal lip 5 Install Right Collar 7 Install Drive chain NOTE Push the wheel forward and install the drive chain Washer rear wheel sprocket Nut rear wheel sprocket 6 Install Wheel NOTE Install the brake disc between the brake pads correctly NOTE Apply the lithium soap base grease on the oil seal lip ...

Страница 119: ...chain slack A Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAP TER 3 Drive chain slack 30 40 mm 10 Tighten Reft drive chain puller Locknut T R 65 Nm 6 5 m kg T R 12 Nm 1 2 m kg 7 Install Left drive chain puller Wheel axle NOTE Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle Nut wheel axle ...

Страница 120: ...he order listed For installation reverse the removal procedure 1 2 1 1 1 2 1 FR CALIPER ASSY 2 UNION BOLT 3 FR BRAKE HOSE 4 BRAKE LEVER 5 BRAKE MASTER CYLINDER BRACKET 6 BRAKE MASTER CYLINDER FRONT BRAKE AND REAR BRAKE FRONT BRAKE NEW NEW NEW 1 NEW 2 3 4 2 5 6 ...

Страница 121: ... parts in the order listed For installation reverse the removal procedure 2 1 1 1 1 1 UNION BOLT 2 REAR CALIPER ASSY 3 REAR BRAKE HOSE 4 REAR MASTER CYLINDER ASSY 5 REAR BRAKE PEDAL FRONT BRAKE AND REAR BRAKE REAR BRAKE 4 NEW NEW NEW NEW 2 1 3 1 4 5 ...

Страница 122: ... the transparent hose to the bleed screw and place a suitable con tainer under its end 3 Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal ACHTUNG CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately NOTE Do not remove the diaphragm ...

Страница 123: ... piece of rag into the brake caliper to lock one brake caliper Carefully force the piston out of the brake caliper cylinder with compressed air Brake caliper piston and spring plate 1 Remove Piston Brake caliper Pad support Brake caliper ACHTUNG CAUTION Never attempt to take out the piston INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface b Wear scratches Replace maste...

Страница 124: ...AR WHEEL 2 Inspect Diaphragm Crack damage Replace 3 Inspect Brake master cylinder piston Brake master cylinder cup Wear damage score marks Replace brake master cylinder kit Brake hose 1 Inspect Brake hose Crack damage Replace ...

Страница 125: ...iper ASSEMBLY AND INSTALLATION All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Front braker caliper 1 Install Pad support Brake pad Pad pin Bolt front brake caliper WARNING ...

Страница 126: ...5 16 FRONT WHEEL AND REAR WHEEL 2 Install Brake caliper Rear braker caliper 1 Install Pad support Brake pad Pad pin Right spacer rear wheel Nut rear wheel ...

Страница 127: ...stalled as shown direction Wrong instal lation cause improper brake performance 3 Install Spring To brake master cylinder piston NOTE Install the spring at the smaller dia side 4 Install Front Brake master cylinder kit Circlip Brake master cylinder boot To brake master cylinder Rear Brake master cylinder kit Push rod Brake master cylinder boot To brake master cylinder NOTE Apply the brake fluid on...

Страница 128: ...he lower side T R 9 Nm 0 9 m kg 2 Install Brake lever Bolt brake lever NOTE Apply the lithium soap base grease on the brake lever sliding surface bolt and contacting surface of the brake master cylinder piston Rear brake master cylinder 1 Install Copper washer Brake hose Union bolt Always use new copper washers ACHTUNG CAUTION Install the brake hose so that its pipe por tion directs as shown and l...

Страница 129: ...e 1 Install Union bolt Copper washer T R 25 Nm 2 5 m kg 2 Install Brake master cylinder Bolt brake master cylinder T R 9 Nm 0 9 m kg 3 Install Spring Brake pedal Pin Washer Cotter pin Brake hose Always use new copper washers ACHTUNG CAUTION After installing brake hose should be instal led as shown direction wrong installation case brake hose broken WARNING ...

Страница 130: ... 2 5 m kg Rear brake hose 1 Install Copper washer Brake hose Union bolt Always use new copper washers T R 25 Nm 2 5 m kg Brake hose Brake caliper Swing arm 2 Install Brake holder ACHTUNG CAUTION After installing brake hose should be instal led as shown direction wrong installation case brake hose broken WARNING WARNING ...

Страница 131: ... to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock ACHTUNG CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Recommended brake fluid DOT 3 or DOT 4 2 Air bleed Brake system Refer to BRAKE SYSTEM AIR BLEEDING sec...

Страница 132: ...ke master cylinder cap Bolt brake master cylinder cap ACHTUNG CAUTION After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper T R 2 Nm 0 2 m kg T R 2 Nm 0 2 m kg ...

Страница 133: ...Remove the parts in the order listed For installation reverse the removal procedure 1 1 1 1 1 1 NUT STEERING UPPER M22 2 WASHER STEEL 3 STEERING STEM LOCK NUT 4 BEARING ASSY 5 TRIPLE CLAMP STEERING STEM ASSY STREERING STREERING 6 5 5 4 3 2 ...

Страница 134: ...rt name Q ty Remarks Remove the parts in the order listed For installation reverse the removal procedure 1 1 2 4 1 1 FRONT NUMBER PLATE 2 FRONT FENDER 3 SCREW 4 SCREW 5 FRONT FORK ASSY FRONT FORK FRONT FORK 5 4 6 6 2 3 ...

Страница 135: ...nch bolts upper bracket yet 2 Tighten Front fork 4 Tighten Pinch bolt upper bracket Pinch bolt lower bracket ACHTUNG CAUTION Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction 5 Install Brake hose holder Bolt brake hose holder T R 15 Nm 1 5 m kg T R 15 Nm 1 5 m kg T R 9 Nm 0 9 m kg ...

Страница 136: ... the steering stem so that it may not fall down Lower bearing 1 Remove Lower bearing Use the floor chisel ACHTUNG CAUTION Take care not to damage the steering shaft thread Ball race 1 Remove Ball race Remove the ball race using long rod and the hammer INSPECTION Steering stem 1 Inspect Steering stem Bend damage Replace WARNING ...

Страница 137: ...h in their operation in the ball races replace bearings and ball races as a set ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Ball race Upper bearing Ball race cover NOTE Apply the lithium soap base grease on the bearing and ball race cover lip 3 Install Lower bracket NOTE Apply...

Страница 138: ...to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install Lower Upper bracket NOTE Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts upper bracket yet 7 Install Washer Steering stem nut T R 70 Nm 7 0 m kg 8 After tightening the nut check the steer ing for smooth movement If not adjust the steering by loosening the s...

Страница 139: ...ING 9 Tighten Pinch bolt upper bracket Pinch bolt lower bracket ACHTUNG CAUTION Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction T R 15 Nm 1 5 m kg T R 15 Nm 1 5 m kg ...

Страница 140: ... 1 1 1 1 4 2 1 2 1 1 CROSS BAR COVER 2 CROSS BAR FOAM 3 GRIP R 4 5 THROTTLE CABLE 6 GRIP L 7 START SWITCH ASSY 8 CLUTCH LEVER ASSY 9 CLUTCH CABLE ASSY HANDLEBAR HANDLEBAR ３４ 1 ６７５８９ 10 11 12 13 14 ２ THROTTLE HOUSEING 10 SCREW WITH NUTM8X80 11 RISER SET FOR HANDLEBAR 12 HANDLEBAR 13 RISER SET FOR HANDLEBAR 14 UPPER TRIPLECLAMP ...

Страница 141: ... hose Keep the brake master cylinder cap side horizontal to prevent air from coming in Grip 1 Remove Grip NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose INSPECTION Handlebar 1 Inspect Handlebar Bends cracks damage Replace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar WARNING ...

Страница 142: ...front side of the handlebar upper holder and then tighten the bolts on the rear side 2 Install Left grip Apply the adhesive to the handlebar NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface b with a lacquer thinner T R 25 Nm 2 5 m kg 3 Install Right grip Collar Apply the adhesive on the tube guide NOTE Before applying the adhesive wipe off grease or oil on the tube...

Страница 143: ... guide NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 6 Install Throttle cable cap Screw throttle cable cap WARNING After tightening the screws check that the throttle grip moves smoothly If it does not retighten the bolts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 7 Install Grip cap cover Cover throttle cable cap ...

Страница 144: ...ylinder bracket and then tighten the bolt on the lower side 9 Install Engine stop switch Bolt clutch lever holder Screw Engine start button T R 9 Nm 0 9 m kg T R 9 Nm 0 9 m kg T R 4 Nm 0 4 m kg 10 Install NOTE Apply the lithium soap base grease on the clutch cable end 11 Adjust Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 Hot starter lever free play Clutch lever holde...

Страница 145: ... SHOCK 2 NUT 3 WSHER 4 5 BUSHING 6 NEEDLE BEARING 7 MIDDLE AXLE BOLT 8 REAR SWING ARM ASSY 9 CLIP NEEDLE BEARING 10 CHAIN GUARD 11 REAR FORK DUST COVER 12 BOLT 13 WSHER 14 CHAIN ROLLER 15 COLLAR 16 CHAIN GUIDE BRACKET 17 LT CHAIN GUIDE BRACKET set SWINGARM AND REAR SHOCK ABSORBER SWINGARM AND REAR SHOCK ABSORBER 1 11 10 7 8 17 16 9 3 4 5 6 6 5 4 3 2 15 14 13 12 ...

Страница 146: ...he swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm REMOVING THE DRIVE CHAIN 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a...

Страница 147: ...B a Check the tightening torque of the pivot shaft nut Pivot shaft nut 50 Nm 5 0 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0 mm d Check the swingarm vertical movement B by moving the swingarm up and down If swin...

Страница 148: ...ks Replace the rear shock absorber assembly spring Damage wear Replace the rear shock absorber assembly bolts Bends damage wear Replace CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft spacer bearings Recommended cleaning solvent Kerosine WAR...

Страница 149: ... 144 4 mm While measuring the 10 link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 11 as shown Perform this measurement at two or three dif ferent places 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosine and remove any remain...

Страница 150: ...e chain and be low the swingarm 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains 6 Check drive sprocket rear wheel sprocket More than 1 4 tooth a wear drive chain sprockets as a set Bent teeth Replace the drive chain sprockets as a set b Correct 1 Drive chain roller 2 Drive chain sprocket INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Insta...

Страница 151: ...K in chapter 3 Drive chain slack 30 50 mm INSTALLING THE DRIVE CHAIN 1 Lubricate drive chain master link New Recommended lubricant Engine oil or chain lubricant suitable for non O ring chains 2 Install master link 1 master link plate 2 3 Install master link clip 1 The closed end of the master link clip must face in the direction of drive chain rotation Never install a new drive chain onto worn dri...

Страница 152: ...ARM CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swin garm or cause an accident Therefore keep the drive chain slack within the specified limits ...

Страница 153: ...rter Solenoid 3 Rectifier Regulator 4 DWWHU 5 CDI magneto 6 Spark plug 7 Ignition coil 8 CDI unit WIRING DIAGRAM s p u d f o o p D s p u d f o o p D o p j u j o h J m j p D p u f o h b N J E D y p C Rectifier Starter Solenoid y e K h c t i w S ON OFF Starter Switch Battery Engine Mount Bolt A 0 1 e s u F Starter 7 4 5 3 2 6 ...

Страница 154: ...Use the following special tools in this inspection Spark gap test Clean or replace spark plug Check entire ignition system for connection couplers leads and ignition coil Repair or replace e c a l p e R h c t i w s p o t s e n i g n e k c e h C e c a l p e R l i o c y r a m i r P l i o c n o i t i n g i k c e h C R l i o c y r a d n o c e S eplace e c a l p e R l i o c p u k c i P o t e n g a m I ...

Страница 155: ...UPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cyl inder head cover ENGINE START STOP SWITCH INSPECTION 1 Inspect Engine stop switch conduct No continuous while being pushed Rep...

Страница 156: ... Inspect Engine start switch conduct No continuous while being pushed Replace Continuous while being freed Replace Tester lead Red Yellow lead 4 Tester lead Black lead 5 B 5 R Y 4 Tester selec tor position PUSH IN Ω 1 FREE ...

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