DAELIM Roadwin R Service Manual

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HEAD OFFICE(FACTORY)

#58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA

TEL: (82-55) 239-7000 / FAX: (82-55) 239-7520

OVERSEAS SALES OFFICE(FACTORY)

13-5,SEONGSU 1-GA,2DONG, SEONGDONG-GU, SEOUL, KOREA

TEL: (82-2) 3408-2634 / FAX: (82-2) 467-9997

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Page 1 HEAD OFFICE(FACTORY) #58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL: (82-55) 239-7000 / FAX: (82-55) 239-7520 OVERSEAS SALES OFFICE(FACTORY) 13-5,SEONGSU 1-GA,2DONG, SEONGDONG-GU, SEOUL, KOREA TEL: (82-2) 3408-2634 / FAX: (82-2) 467-9997...
Page 2 SERVICE MANUAL 2007. 01 PRINTED C C O O P P Y Y P P R R O O H H I I B B I I T T 2007. 01 PUBLICATION...
Page 3 HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for GENERAL INFORMATION the VJF125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the INSPECTIONS / ADJUSTMENTS vehicle, carry out regular inspections according to the maintenance schedule (Section 2).
Page 5: General Information
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
Page 6 GENERAL INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
Page 7 GENERAL INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball be performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
Page 8 GENERAL INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
Page 9 GENERAL INFORMATION CAUTION WHEN WIRING Each cord must be connected depending on its color. When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
Page 10 GENERAL INFORMATION Turn off the main switch before connecting/dis- When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
Page 11 GENERAL INFORMATION Insert the connector until the vinyl cover is fully When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. The opening of the vinyl cover must face at the ground Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
Page 12 GENERAL INFORMATION In case that the wire harness is contacted with the end or The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness is not pressed by the parts.
Page 13 GENERAL INFORMATION MODEL IDENTIFICATION FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER ENGINE SERIAL NUMBER...
Page 14 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 2,025mm OVERALL WIDTH 764mm OVERALL HEIGHT 1,180mm DIMENSIONS WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 139mm DRY WEIGHT 162kgf CURB WEIGHT 292kgf TYPE Double Cradle FRONT SUSPENSION / STROKE Telescopic / 130mm REAR SUSPENSION / STROKE Swingarm / 28mm FRONT TIRE SIZE (TYPE)
Page 15 GENERAL INFORMATION ITEM SPECIFICATIONS CLUTCH TYPE Multiplate Wet Clutch / 5 TRANSMISSION TYPE Constant Mesh GEAR RATIO 1st 3.200(37/12 T) DRIVE TRAIN GEAR RATIO 2.143(32/17 T) GEAR RATIO 1.438(29/21 T) GEAR RATIO 1.095(23/21 T) GEAR RATIO 0.923(24/26 T) GEARSHIFT PATTERN Left foot operated return system Down 1-N-2-3-4-5 Up IGNITION TYPE...
Page 16 GENERAL INFORMATION TORQUE VALUES ENGINE TORQUE THREAD DIA Q’TY REFERENCE ITEM (mm) kgf.m,(N.m) CAM HOLDER BOLT(SHBOLT) 1.0~1.2 Apply Engine Oil M6 1.0 CYLINDER HEAD SPECIAL SOCKET NUT 3.5~4.5 Apply Engine Oil M10 1.25 CYLINDER HEAD COVER BOLT 0.8~1.2 M6 1.0 CAM CHAIN TENSIONER PIVOT BOLT 0.8~1.2 M6 1.0...
Page 17 GENERAL INFORMATION FRAME THREAD DIA TORQUE Q’TY ITEM REFERENCE (mm) kgf.m,(N,m) REAR CALIPER BRACKET BOLT 2.8~3.4 M8 1.25 REAR MASTER CYLINDER HOLDER SOCKET BOLT M6 1.0 1.0~1.4 FRONT AXLE NUT 5.5~6.5 M14 1.5 U- NUT FRONT BRAKE DISK BOLT M8 1.25 4.0~4.5 BRAKE OIL BOLT (FRONT/REAR) M10 1.25...
Page 18 GENERAL INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious vehicle part damage may result if instruction accident may result if instructions are not are not followed.
Page 19 GENERAL INFORMATION TOOLS SPECIAL COMMON DESCRIPTION REF. SEC. DESCRIPTION REF. SEC. CLUTCH CENTER HOLDER WRENCH, 8 9mm ACG ROTOR PULLER ADJUSTING WRENCH, B VALVE GUIDE DRIVER LOCK NUT WRENCH, 20 24mm VALVE GUIDE REAMER EXTENSION BAR 8, 14 UNIVERSAL BEARING PULLER FLY WHEEL HOLDER 8, 9 BEARING REMOVER SET...
Page 20 GENERAL INFORMATION WIRING DIAGRAM ST.-HAZ. SW. THROTTLE CABLE FR. BRAKE HOSE ‡“» »Œ 1.5 » Œ ‚ﬁ ST.-HAZ. SW. CORD CLUTCH CABLE BATTERY EARTH CABLE ST.-MAG SW.,RR. STOP SW., POSITION LIGHT ST.-MAG. BATTERY CABLE(+) SIDE STAND SW. HARNESS COVER HEAD LIGHT ST.-MOTOR CABLE ST.-MAG.
Page 21 GENERAL INFORMATION WIRE HARNESS NOISE SUPPRESSOR CAP FUEL INJECTOR O2 SENSOR COUPLER IG. COIL EARTH MAP & AT SENSOR (MAPAT) HIGH TENSION CORD IDLE SPEED ACTUATOR ST.-HAZ. SW.,COMB.& LOCK SW., WINKER SW.. ∞·º ± (ISA) THROTTLE POSITION SENSOR (TPS) ST.-MAG. BATTERY CABLE(+) WATER TEMPERATURE SENSOR THROTTLE CABLE CORD...
Page 22 GENERAL INFORMATION WIRE CLIP ST.-MAG. BATTERY CABLE(+) HARNESS COVER ST.-MAG. SW. WIRE BATTERY EARTH CABLE ST.-MAG. BATTERY CABLE(+) ST.-MAG. SW. ASS'Y. ST.-MOTOR CABLE BATTERY EARTH CABLE SIDE STAND SW. CORD RR. STOP SW. CORD RESERVE TANK RR. BRAKE HOSE RR. BRAKE HOSE GUIDE RR.
Page 23 GENERAL INFORMATION ECU COMP. SPARE FUSE(30A,15A) FUSE BOX WINKER RELAY BATTERY EARTH CABLE ST.-MAG.BATTERY CORD(+) BATT. BAND WIRE CLIP R/L.RR.WINKER CORD WIRE HARNESS FAN MOTOR RELAY BATTERY(12V 10AH MF.) ECU COMP. COUPLER FUEL PUMP RELAY ST.-MAG.BATTERY CABLE(+) ECU COMP. EARTH CORD DETAIL OF FUSE BOX PART DETAIL OF BATTER PART REG.
Page 24 MEMO...
Page 25 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION BRAKE SYSTEM 2-11 MAINTENANCE SCHEDULE BRAKE STOP SWITCH 2-12 FUEL LINE (FUEL TUBE) HEADLIGHT AIM 2-12 THROTTLE GRIP OPERATION CLUTCH SYSTEM 2-12 AIR CLEANER SIDE STAND 2-13 SPARK PLUG SUSPENSION 2-14 VALVE CLEARANCE BOLTS, NUTS, FASTENERS 2-14 CYLINDER COMPRESSION PRESSURE WHEEL/TIRE...
Page 26 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG 1.1 kgf-m( 11N.m) CYLINDER HEAD COVER BOLT 1.0 kgf-m( 10N.m) AC GENERATOR CAP 0.6 kgf-m( 6N.m) CRANKSHAFT HOLE CAP 0.8 kgf-m( 8N.m) AIR CLEANER CASE COVER SCREW 0.43kgf-m( 4.3N.m) REAR AXLE NUT 8.8kgf-m(88N.m) DRIVE SPROCKET BOLT 1.2kgf-m(12N.m) DRIVEN SPROCKET NUT...
Page 27: Maintenance Schedule
INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Perform the Self Inspections Before Operation at each scheduled maintenance period. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart.
Page 28 INSPECTIONS / ADJUSTMENTS FUEL LINE (FUEL TUBE) Check the fuel tube for deterioration, damage or leakage. Replace it if necessary. FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE...
Page 29: Air Cleaner
INSPECTIONS / ADJUSTMENTS AIR CLEANER SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS Remove the seat. ( 13-2) Loosen the 4 screws, remove the air cleaner housing cover. AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER...
Page 30: Valve Clearance
INSPECTIONS / ADJUSTMENTS VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold. (below 35° C/95°F) Remove the cylinder head cover. Remove the A.C generator cap and crankcase hole cap. Rotate the flywheel counterclockwise to align the "T" mark with the index mark on the left crankcase cover.
Page 31: Cylinder Compression Pressure
INSPECTIONS / ADJUSTMENTS The type of shim is 33 The clearance of shim is 1,500mm to 2,300mm with 0.025mm clearance. Demanded thickness of shim :A Recorded clearance of the valve lifter : B Specified clearance of the valve lifter : C (In :0.15mm / Ex : 0.20mm) Removed thickness of the shim : D how to calculate : A = (B-C)+D...
Page 32: Drive Chain
INSPECTIONS / ADJUSTMENTS DRIVE CHAIN Because there is a danger which fingers get jammed in the drive chain, never inspect or adjust it while the engine is running. DRIVE CHAIN SLACK ADJUSTMENT Turn off the ignition switch, support the motorcycle on its main stand, and shift the transmission into neutral.
Page 33: Drive Chain Inspection
INSPECTIONS / ADJUSTMENTS DRIVE CHAIN INSPECTION Lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying WIPE AND DRY fully. Because an extremely lubricated oil splash while the chain moves round, clean it with a piece of GEAR OIL(#80-90) cloth.
Page 34: Drive Chain Slider
INSPECTIONS / ADJUSTMENTS DRIVE CHAIN SLIDER WEAR Inspect the drive chain slider for excessive wear or INDICATOR damage. If it is worn to the wear indicator, replace the drive chain slider. BRAKE FLUID FR. BRAKE FLUID FR. BRAKE FLUID FR. BRAKE FLUID FR.
Page 35: Rear Brake Pads
INSPECTIONS / ADJUSTMENTS REAR BRAKE PADS Check the brake pads for wear. WEAR INDICATOR Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 16-7 for brake pad replacement. BRAKE SYSTEM Check to see if there is a crack and damage in the front and rear brake hose.
Page 36: Brake Pedal Height Adjustment
INSPECTIONS / ADJUSTMENTS BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. After adjustment, tighten the lock nut securely. The adjustment faulty of height may caused that the brake runs in state of operation. After adjusting the brake pedal height, inspect the operation of rear brake light switch and brake pedal, and adjust them if necessary.
Page 37: Side Stand
INSPECTIONS / ADJUSTMENTS Minor adjustments are made using the upper adjuster at the clutch lever. LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...
Page 38: Front Suspension
INSPECTIONS / ADJUSTMENTS SUSPENSION Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle's safety and operation efficiency. FRONT SUSPENSION Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.
Page 39 INSPECTIONS / ADJUSTMENTS WHEEL/TIRE Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE (kpa) ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY...
Page 40: Coolant Level Inspection
INSPECTIONS / ADJUSTMENTS COOLANT LEVEL INSPECTION Erect the main stand prior to beginning work. Check the coolant level and the reserve tank. The level should be between the “UPPER” and “LOWER” level lines. Fill the coolant to the reserve tank up to the “F” (upper level).
Page 41 3. LUBRICATION SERVICE INFORMATION OIL FILTER ELEMENT CHANGE TROUBLESHOOTING OIL PUMP ENGINE OIL LEVEL INSPECTION LUBRICATION POINTS ENGINE OIL CHANGE SERVICE INFORMATION GENERAL SAFETY The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.
Page 42 LUBRICATION TROUBLESHOOTING Engine oil level too low Oil consumption naturally. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal. Oil contamination Oil or filter not changed regularly. Faulty head gasket. Worn piston rings. Low or no oil pressure Clogged oil orifice.
Page 43: Engine Oil Level Inspection
LUBRICATION ENGINE OIL LEVEL INSPECTION OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE...
Page 44: Oil Pump
LUBRICATION OIL FILTER ELEMENT CHANGE Drain the engine oil. ( 3-3) Loosen the 3 flange bolts securing the oil filter cover bolt, filter cover, the oil filter element and oil filter spring. Change the oil filter element with a new one. Check if the oil filter seal is in good condition, if necessary, replace it with new one.
Page 45 LUBRICATION INSPECTION Install the inner and outer rotors into the oil pump body. Measure the pump body clearance. SERVICE LIMIT : 0.25mm Measure the rotor end clearance. SERVICE LIMIT : 0.20mm ASSEMBLY Clean all parts with fresh cleaning oil. Install the lnner and outer rotor to the pump body. After installing, check the oil pump to operate smothly INSTALLATION...
Page 46: Lubrication Points
LUBRICATION LUBRICATION POINTS Use general grease...
Page 47 MEMO...
Page 48 FUEL SYSTEM...
Page 49: Fuel System
4. FUEL SYSTEM SERVICE INFORMATION FUEL TANK TROUBLESHOOTING AIR CLEANER CASE SERVICE INFORMATION GENERAL SAFETY Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Exhaust gas contains poisonous substance.
Page 50 FUEL SYSTEM FULE TANK SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS REMOVAL Do not smoke or allow flames or sparks in the work area because gasoline is extremely flammable.
Page 51 FUEL SYSTEM AIR CLEANER CASE AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER REMOVAL Remove the main seat. Remove the fuel tank.
Page 52 MEMO...
Page 53 EMS(Engine Management System) 5. EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS 2. THE COMPONENT PARTS OF THE EMS 3.TERMINAL ARRANGEMENT OF THE ECU 4. WIRING DIAGRAM OF THE ECU 5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - SELF DIAGNOSTIC FUNCTION - FAIL SAFE FUNCTION - HOW TO CHECK THE FAULT CODE - HOW TO SHOW THE FAULT CODE...
Page 54: Caution When Repairing The Ems Parts
EMS(Engine Management System) 1.CAUTION WHEN REPAIRING THE EMS PARTS. If the fuse is short-circuited, find out the cause and repair, replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts, because these parts may be damaged by the impact of the drop.
Page 55: The Component Parts Of The Ems
EMS(Engine Management System) 2.THE COMPONENT PARTS OF THE EMS EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM. 1) INTAKE SYSTEM As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc.
Page 56: Terminal Arrangement Of The Ecu
EMS(Engine Management System) 3. TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO. 5,6,7,8,11,14,15,16,36,38 were not connected. Terminal arrangement is based on the ECU. 4. WIRING DIAGRAM OF THE ECU...
Page 57 EMS(Engine Management System) 5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp) SELF-DIAGNOSTIC FUNCTION The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL (malfunction indicator lamp).
Page 58 EMS(Engine Management System) FAIL-SAFE FUNCTION If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible. INTAKE : MIL on/off INTAKE...
Page 59 EMS(Engine Management System) HOW TO CHECK THE FAULT CODE There are two methods of checking the Fault codes. 1) Use the MIL in the Speedometer. 2) The diagnostic Tool. First) Use the MIL in the Speedometer(refer to how to read the fault codes and Fault codes table and diagnostic methods for each part) Second) The diagnostic tool (refer to scan user’s manual.) Turn off the ignition key...
Page 60 EMS(Engine Management System) HOW TO SHOW THE FAULT CODE There are two methods to show the Fault codes. First, the methods to show in engine operation In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the light on/off function of MIL in order for driver to acknowledge defect.
Page 61 EMS(Engine Management System) FAULT CODES TABLE No failure Injection valve failure(IV) Idle speed actuator failure (ISA) Electrical fuel pump failure (EFP) Intake Manifold absolute pressure signal failure (IMP) Throttle position signal failure (TPS) O2 sensor heater output failure (LSH) Lambda signal failure (VLS) Engine temperature signal failure (TENG) Breathing air temperature signal failure (TBA)
Page 62 EMS(Engine Management System) HOW TO REMOVE THE FAULT CODE Remove the fault codes in two ways; First) Full warm up 1. Starting the engine. - The MIL blinks continuously because the ECU memorized the fault code yet. 2. Full warm up the engine (keep idling five minutes) 3.
Page 63 EMS(Engine Management System) 6.INJECTOR INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR...
Page 64 EMS(Engine Management System) CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit 40 : INJECTOR control 39 : FUEL PUMP control INJECTOR FUEL PUMP RELAY Coupler terminal is based on wire harness. 5-12...
Page 65 EMS(Engine Management System) CHECKING PROCEDURE 1) Turn off the ignition key. 2) Check to see if the injector coupler has come loose or the wire is peeling off. If there is no problem, measured the resistance of injector. 3)Disassemble the injector coupler and measure the resistance between injector terminals. The resistance of injector : 14.5±0.7[ ], 20 Remarks : measuring unit for resistance : resistance ‘...
Page 66 EMS(Engine Management System) 7. MAPAT(Manifold Air pressure MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR...
Page 67 EMS(Engine Management System) Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit Fault code number is displayed by MIL The Fault code of intake pressure sensor The Fault code of intake temperature sensor Checking circuit MAPAT 3 : Intake pressure sensor ground 3 : Inhalation pressure 26 : 5V voltage sensor GROUND...
Page 68 EMS(Engine Management System) CHECKING OF THE INTAKE PRESSURE SENSOR 1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler 2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 ) 3) Turn on the ignition key.
Page 69 EMS(Engine Management System) CHECKING OF INTAKE TEMPERATURE SENSOR 1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND) Remarks : Measuring value for resistance : Resistance[ The Voltage of air pressure;...
Page 70 EMS(Engine Management System) 8.TPS(THROTTLE POSITION SENSOR) It is Located on the right side of throttle body CAUTION The key is off before disassembly. Remove LH.side cowl TPS coupler Remove TPS screw 2EA Replace the TPS 5-18...
Page 71 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number is displayed by MIL Checking circuit The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key . 2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of TPS.
Page 72 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ 7) If not problem, measure the resistance of TPS.
Page 73 EMS(Engine Management System) 9.ETS(ENGINE TEMPERATURE SENSOR) It is located on the left-hand side of cylinder head. CAUTION The key is off, before disassembly. ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR...
Page 74 EMS(Engine Management System) 1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) Fault code number is displayed by MIL CHECKING CIRCUIT 4 : SENSOR GROUND 20 : ETS Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key . 2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad.
Page 75 EMS(Engine Management System) 6-1) If the measured value is not normal, Replace the ETS with the new one, recheck. If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if the ECU coupler is a bad contact ( No.4, No.
Page 76 EMS(Engine Management System) 10.ISA(IDLE SPEED ACTUATOR) ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR It is located upwards on the throttle body CAUTION The key is off, before disassembly.
Page 77 EMS(Engine Management System) 1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT. Showing of defects codes by MIL CHECKING CIRCUIT 33 : ISA CONTROL 39:FUEL PUMP FUEL PUMP RELAY Coupler terminal is based on the side of the wire-harness CHECK PROCEDURE 1) Turn off ignition key . 2) Check to see if the ISA(Throttle Position Sensor) coupler is loose, or bad.If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of ISA, measure the resistance...
Page 78 EMS(Engine Management System) CHECK PROCEDURE 5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck. 6) If resistance and continuty is normal, connect the coupler of ISA. 7) Turn on ignition key 8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : 10~14[V]...
Page 79 EMS(Engine Management System) 11.O2(Oxygen) SENSOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR O2 SENSOR CONNECTOR It is located on the exhaust pipe...
Page 80 EMS(Engine Management System) 1) CHECKING OF OXYGEN(O ) SENSOR CIRCUIT Fault code number is displayed by MIL Fault code number is displayed by MIL of the oxygen(O )sensor lambda signal. CHECKING CIRCUIT OXYGEN SENSOR 2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER Coupler terminal is based on the side of Wire-Harness.
Page 81 EMS(Engine Management System) CHECKING FOR A FAULT CODE BY OXYGEN(O )SENSOR HEATER If the voltage value is abnormal, Check to see if the ECU coupler is loose or if there is bad contact. Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been broken or have short- circuited.
Page 82 EMS(Engine Management System) 12.CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT Fault code number is displayed by MIL CHECKING CIRCUIT TACHOMETER 32 : ESS(ENGINE SPEED SIGNAL) Coupler terminal is based on the side of Wire-Harness. CHECK PROCEDURE 1) Turn off the ignition key . 2) Check the ESS coupler is loose, or bad.
Page 83 EMS(Engine Management System) 13.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT Fault code number is displayed by MIL CHECKING CIRCUIT 24 : MALFUNCTION INDICATOR LAMP OUTPUT MALFUNCTION INDICATOR LAMP(MIL) CHECK PROCEDURE 1) Turn off ignition key. 2) Check the ESS coupler is loose, or bad. If there is no problem.
Page 84 EMS(Engine Management System) 14.ECU(ELECTRONIC CONTROL UNIT) SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT SEAT It is located inside a pillion seat CAUTION The key is off before disassembly. Remove Main seat The pillion seat Flange bolt 4EA ECU GROUND WIRE ECU GROUND WIRE...
Page 85 EMS(Engine Management System) 15.CPS(CRANK POSITION SENSOR) It is located inside a LH.crank case cover CAUTION GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH GEAR SWITCH...
Page 86: Fuel Pump
EMS(Engine Management System) 16.FUEL PUMP It is Located inside a fuel tank CAUTION The key is off before disassembly. Remove Fuel pump screw 4EA Remove Fuel pump CAUTION Do not push the fuel pump base under the fuel tank when the fuel tank is stored. Always replace the packing when the fuel pump is removed.
Page 87 EMS(Engine Management System) 16.FUEL PUMP The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump) 5-35...
Page 88 EMS(Engine Management System) CHECKING OF THE FUEL LEVEL GAUGE. Remove the fuel level gauge (19-10) Measure the resistance between terminals. The FLOAT position Terminals resistance [ ] F : 192[mm] 15[ ] 1/2 : 138[mm] 20[ ] E : 74[mm] 15[ ] The float position is based on the tank bottom plate after assemble.
Page 89: Throttle Body
EMS(Engine Management System) 17.THROTTLE BODY INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY...
Page 90 EMS(Engine Management System) DISASSEMBLY THE THROTTLE BODY INSULATOR DISCONNECT: - Injector cap bolt - Injector and injector cap at the same time from the insulator - Injector and injector cap. CHECKING CHECK: - O-ring - Inner side of insulator - Inner side of injector INJECTOR INJECTOR INJECTOR...
Page 91 EMS(Engine Management System) Assemble the insulator into the throttle body. Torque: 1.0 kgf m INSTALLATION OF INSULATOR AND THROTTLE BODY Installation of insulator and throttle body is the reverse order of removal Check the o-ring when the insulator become assembly. Assemble the insulator gasket.
Page 92 EMS(Engine Management System) ADJUSTMENT OF THROTTLE ADJUST SCREW THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK THE COUPLER TO CHECK...
Page 93: How To Use Scan
EMS(Engine Management System) 18.HOW TO USE SCAN WHEN THE ECU IS INITIALIZED The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn on the lgnition key. Press the power button of the diagnostic tool. Press the enter button in the initial screen.
Page 94 EMS(Engine Management System) Press the enter button when it is ready When the ECU was initialized. turn off the lgnition key and then turn on the ignition key. 5-42...
Page 95 EMS(Engine Management System) WHEN THE ‘ISA PWM’ ADJUSTING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the button at the vehicle diagnostic screen.
Page 96 EMS(Engine Management System) WHEN THE IGNITION TIMING IS CHECK The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the enter button on the vehicle diagnosis screen.
Page 97 EMS(Engine Management System) WHEN THE ENGINE RPM IS CHECK The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the enter button on the vehicle diagnosis screen.
Page 98 COOLING SYSTEM...
Page 99: Radiator Installation
6. COOLING SYSTEM SERVICE INFORMATION RADIATOR DISASSEMBLY STROUBLESHOOTING CHECK THERMOSTATIC SWITCH COOLANT RADIATOR INSTALLATION COOLING SYSTEM INSPECTION 6-3 WATER PUMP COOLING SYSTEM TEST TERMOSENSOR 6-10 RADIATOR THERMOSTATIC 6-10 SERVICE INFORMATION Do not remove the radiator cap if the coolant temperature is over 100°C. It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding.
Page 100 COOLING SYSTEM TROUBLESHOOTING Engine temperature too high Faulty temperature gauge or thermo sensor Air in cooling system Faulty thermostat stuck (Thermostat stuck closed) Passages blocked in radiator, hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck (Thermostat stuck open) Faulty fan motor switch...
Page 101: Coolant Inspection
COOLING SYSTEM COOLANT COOLANT INSPECTION RADIATOR Radiator coolant mixes the distilled water. WATER Standard consistenly : 30~50% Coolant mixes the light water and radiator liquid COOLANT about 5°C of tolerance inrespect to the minimum temperature. RADIATOR COOLANT MIXTURE CHART (ANTICORROSIVE AND ANTIFREEZE) When the whole capacity of coolant is 2000cc Radiator coolant is toxic.
Page 102 COOLING SYSTEM COOLING SYSTEM TEST RADIATOR CAP Install the redicator cap onto the radiator tester. Press it with specified pressure and it must keep RADIATOR TESTER the pressure for at least six seconds. (SALE AT A MARKET) Apply water to the cap sealing surface before the test.
Page 103 COOLING SYSTEM Loosen the hose band and disconnect the upper hose and lower hose from the radiator. Disconnect the thermostatic switch wire coupler. Disconnect thefan motor wire coupler. Remove 2 bolts and 1 nut on the radiator. RADIATOR DISASSEMBLY Remove 3 bolts and than remove the fan/shround from the radiator.
Page 104 COOLING SYSTEM CHECK THERMOSTATIC SWITCH REMOVAL When coolant temperature lower then 83~87 thermostatic switch OFF. When coolant temperature over 88~92 thermostatic switch ON. Install the fan shroud on the radiator with the 3 bolts. RADIATOR INSTALLATION Intall the radiaator on the radiator bracket with the 2 bolts and 1 nut.
Page 105 COOLING SYSTEM Connect the overflow tube and secure with the tube clamp. Fill the radiator with coolant. Connect the vent tube to the radiator filler. After installation, check for coolant leaks. Install the RH/LH side cowl and center cowl. WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical...
Page 106 COOLING SYSTEM Remove the 3 bolts and the water pump cover. Remove the water pump impeller. The impeller has left hand threads. Inspect the mechanical (water) seal and seal washer for wear or damage. The mechanical seal and seal washer change with the set.
Page 107 COOLING SYSTEM Check the water pump shaft. Check the water pump body and O-ring for damage and wear. MECHANICAL SEAL REPLACEMENT Water pump assembly from the inside. Drive in a newmechanical seal using a mechanical seal driver. Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal.
Page 108 COOLING SYSTEM THERMOSENSOR REMOVAL Remove RH.side cowl. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. INSPECTION Soak the theromosensor in the beaker(fill the beaker with water) Heats up the beaker. Measure the resistance. Temperature( ) Resistance( ) INSTALLATION THERMOSENSOR Apply a sealant to the themosensor threads and install it into the thermostat housing.
Page 109 COOLING SYSTEM INSPECTION THERMOSTAT Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation. THERMOMETER Technical data Begins to open 80 2 Full-open Valve lift 3.5~4.5mm Do not let the thermostat touch the pan as it will give a false reading.
Page 110 ENGINE REMOVAL/INSTALLATION...
Page 111 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE INSTALLATION ENGINE REMOVAL SERVICE INFORMATION GENERAL SAFETY Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. Attach tape to the frame to protect it during the engine removal or installation.
Page 112 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil. ( 3-1) Remove the muffler. ( 13-4) Remove the noise suppressor cap. Remove the battery ground cable and clutch cable. Remove the throttlebody from the throttlebody. Remove the RH. side cowl and LH.side cowl. RADIATOR CAP RADIATOR CAP RADIATOR CAP...
Page 113: Engine Installation
ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. Carefully align mounting points with the jack to prevent damage from mounting bolt threads and wire harness and cables. Be careful not to damage any part of the frame and bolt nuts.
Page 114 CLUTCH/GEARSHIFT...
Page 115 8. CLUTCH / GEARSHIFT SERVICE INFORMATION GEARSHIFT SPINDLE TROUBLESHOOTING CLUTCH INSTALLATION R. CRANKCASE COVER PRIMARY DRIVE GEAR 8-10 CLUTCH R. CRANKCASE COVER INSTALLATION 8-11 SERVICE INFORMATION GENERAL SAFETY The clutch, gearshift spindle can be serviced with the engine in the frame. If the shift fork, drum and transmission require service, remove the engine and separate the crankcase.
Page 116 CLUTCH/GEARSHIFT TROUBLESHOOTING Clutch working problem can be solved by adjusting a cable free play. Clutch leverworking is too hard Damaged, clogged or sticking clutch cable Damaged lifter mechanism Damaged clutch lifter plate bearing Incorrect wiring of clutch cable When gripping the clutch tightly, the vehicle moves Too big clutch lever free play Clutch plate warpage Clutch lock nut loose...
Page 117 CLUTCH/GEARSHIFT R. CRANKCASE COVER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER...
Page 118: Clutch Removal
CLUTCH/GEARSHIFT Apply the grease to the new O-ring, and install it to HOLE HOLE HOLE HOLE HOLE the clutch lever. HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE HOLE Install the clutch lever spring into the hole of the clutch lever ends.
Page 119 CLUTCH/GEARSHIFT Remove the lock washer. Remove the clutch center, disk, plate and pressure LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER LOCK WASHER plate.
Page 120 CLUTCH/GEARSHIFT Measure the clutch spring free length; replace the springs if the measurement is not within the service limit. SERVICE LIMIT : 34.2mm If the motorcycle has been used for a long time, the clutch springs free lingth will be shorten, because the clutch springs are compressed while the clutch is disengaged.
Page 121 CLUTCH/GEARSHIFT GEAR SHIFT SPINDLE HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT HEX BOLT REMOVAL Loosen the hex bolt and remove the gear change arm.
Page 122 CLUTCH/GEARSHIFT INSTALLATION COLLAR Install the collar, spring, drum stopper and bolt. Tighten the bolt. TORQUE : 1.2kgf m(12N m) SPRING DRUM STOPPER Press the drum stopper, and install the gear shift cam, aligning the roller with the gear shift cam hole.
Page 123 CLUTCH/GEARSHIFT CLUTCH INSTALLATION Coat the clutch outer guide with clean engine oil. Install the trust washer and outer guide into the main shaft. Install the clutch outer and spline washer. CLUTCH CENTER PRESSURE PLATE Install the clutch inner ass’y. DISKS Coat the clutch and plate disk.
Page 124: Primary Drive Gear
CLUTCH/GEARSHIFT Install the lock nut by pressing clutch center into the clutch center holder. TORQUE : 6.5kgf m (65N m) TOOLS : CLUTCH CENTER HOLDER LOCK NUT WRENCH EXTENSION BAR Install the bearing. PRIMARY DRIVE GEAR REMOVAL Remove the R. crankcase cover. Hold the flywheel using a flywheel holder, and remove the primary drive gear lock nut.
Page 125 CLUTCH/GEARSHIFT INSTALLATION Install the woodruff key into the key groove of the crankshaft. Align the primary drive gear key groove with the crankshaft key and install the gear. Install the lock washer. Coat the nut with clean engine oil, and temporarily tighten the lock nut.
Page 126 CLUTCH/GEARSHIFT Install the right crankcase cover, aligning the spline of the crank shaft and with the spline of the oil pump shaft. If any difficulty is encountered in joining the crank shaft spline to the oil pump shaft spline, remove the crankshaft hole cap, then install the right crank case cover while turning the crankshaft to the right slowly.
Page 127 MEMO...
Page 128 A.C GENERATOR / STARTER CLUTCH...
Page 129 9. A.C GENERATOR / STARTER CLUTCH SERVICE INFORMATION A.C GENERATOR INSTALLATION A.C GENERATOR REMOVAL STARTER CLUTCH SERVICE INFORMATION GENERAL SAFETY This section covers removal and installation of the A.C. generator. Refer to section 16 for inspection of the A.C. generator. The A.C.
Page 130 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR REMOVAL L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L. REAR COVER L.
Page 131 A.C GENERATOR / STARTER CLUTCH Remove the starter reduction gear shaft and starter STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR...
Page 132 A.C GENERATOR / STARTER CLUTCH After installing the ACG rotor puller on the rotor, remove the rotor. TOOL : ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER ACG ROTOR PULLER...
Page 133 A.C GENERATOR / STARTER CLUTCH STARTER IDLE GEAR INSPECTION Inspect the wear and damage of starter ldle gear. Measure the gear inside diameter. SERVICE LIMIT : 10.100mm STARTER IDLE GEAR Measure the gear shaft outside diameter. SERVICE LIMIT : 9.970mm REDUCTION GEAR INSPECTION Inspect the wear and damage of reduction gear.
Page 134 A.C GENERATOR / STARTER CLUTCH Install the starter idle gear and starter idle gear shaft. Install the new gasket and dowel pins. Install the L. crankcase cove and tighten the bolts to the specified torque. TORQUE : 1.1kgf m(11N m) Install the starter gear and shaft.
Page 135 A.C GENERATOR / STARTER CLUTCH Connect the A.C generator wire coupler and gear change wire coupler. Install the wire clamp. Install the L. rear cover. Install the gear change arm a ligning its slit with the punch mark on the gearshift spindle. Install and tighten the pinch bolt to the specified torque.
Page 136 A.C GENERATOR / STARTER CLUTCH Check the starter driven gear for damage or wear. Measure the starter driven gear I.D. and O.D. SERVICE LIMIT : O.D. : 39.607mm I.D. : 22.100mm INSTALLTION Check the one-way clutch for wear or damage. Install the one-way clutch flange into the clutch outer.
Page 137 MEMO...
Page 138 CYLINDER HEAD / VALVES 10-0...
Page 139: Valve Guides
10. CYLINDER HEAD / VALVES SERVICE INFORMATION 10-1 VALVES 10-7 TROUBLESHOOTING 10-2 VALVE GUIDES 10-7 CAMSHAFT 10-3 VALVE SEATS 10-8 CYLINDER HEAD 10-5 CYLINDER HEAD ASSEMBLY 10-11 VALVE SPRINGS 10-6 CAMSHAFT ASSEMBLY 10-13 SERVICE INFORMATION GENERAL SAFETY The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed from the frame to maintain the cylinder head.
Page 140 CYLINDER HEAD / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 20 (23mm) EX 30 (20mm) IN 45 (24.5mm) EX 45 (24.5mm) IN 70 (22mm) EX 70 (22mm) CUTTER HOLDER 5mm TROUBLESHOOTING Enging top-end problems useally affect engine performance.
Page 141 CYLINDER HEAD / VALVES CAMSHAFT REMOVAL Remove the noise suppressor cap assembly from the spark plug. Remove the side cowl. Remove the fuel tank. Remove the cylinder head cover bolts and cover. Remove the AC generator cap and crank shaft hole cap out of the left crankcase cover.
Page 142 CYLINDER HEAD / VALVES Check the cam lobes of the camshaft for wear or damage. Measure the height of the cam lobe. SERVICE LIMIT : IN : 37.110 mm EX: 36.870 mm Take precautions not to allow the cam chain to drop into the crankcase.
Page 143: Cylinder Head Disassembly
CYLINDER HEAD / VALVES CYLINDER HEAD DISASSEMBLY Loosen the pivot bolt and remove the cam chain tensioner. Remove the throttle body insulator. Remove the spark plug cover and spark plug from the cylinder head. Remove the valve spring cotter, retainer, spring, and valve.
Page 144 CYLINDER HEAD / VALVES INTERVAL BETWEEN VALVE STEM AND VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal wear. Insert the valves in their original positions in the valve guid and check each valve moves up and down smothly, without binding.
Page 145 CYLINDER HEAD / VALVES Using a torch to heat the cylinder head may cause warping. Wear insulated gloves to avoid burns when handling the heated cylinder head. Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. TOOL : VALVE GUIDE DRIVER Avoid damaging the head when driving the valve guide out.
Page 146 CYLINDER HEAD / VALVES Valve faces and stem tips cannot be ground. If a valve face or stem tip is rough, worn unevenly, or contacts the seat improperly, the valve must be replaced. Measure the valve seat width. STANDARD VALUE : 0.7~0.9 mm SERVICE LIMIT : 1.3 mm VALVE SEAT VALVE SEAT...
Page 147 CYLINDER HEAD / VALVES Using a 70 degree cutter, remove the bottom of the old seat. OLD SEAT WIDTH Using a 45 degree cutter, cut the seat to the proper width. VALVE SEAT WIDTH : 0.9~1.1mm SEAT WIDTH Apply a light coating of Prussian Blue to each valve face.
Page 148 CYLINDER HEAD / VALVES After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. Do not excessively press and turn the valve to set it as it may cause damage. Gently tap and set the valve. The seat surface may become worn on one side if the valve is set in the same position.
Page 149: Cylinder Head Installation
CYLINDER HEAD / VALVES Tap the valve stems gently with a soft hammer to firmly seat the cotters. Take necessary precautions not to damage the valve. Install the cam chain tensioner, and assemble pivot bolts. TORQUE : 1.0 kgf m (10N m) Install the spark plug.
Page 150 CYLINDER HEAD / VALVES After checking the comshaft for damage, put it to the cylinder head. Slowly rotate the crankshaft counterclockwise, and align the T mark of the flywheel with the index mark of the LH. crankcase cover. Take precautions not to allow the cam chain to drop into the camshaft timing gear while turning the camshaft.
Page 151 CYLINDER HEAD / VALVES Assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. Tighten the tensioner mounting bolts to the specified torque. TORQUE : 1.2 kgf m (12N m) Install the O-ring and sealing screw to the tensioner lifer.
Page 152 CYLINDER / PISTON 11-0...
Page 153 11. CYLINDER / PISTON SERVICE INFORMATION 11-1 PISTON / PISTON RING 11-3 TROUBLESHOOTING 11-1 CYLINDER INSTALLATION 11-6 CYLINDER REMOVAL 11-2 SERVICE INFORMATION GENERAL SAFETY Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins.
Page 154 CYLINDER / PISTON CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL CYLINDER REMOVAL...
Page 155 CYLINDER / PISTON WARPAGE INSPECTION RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER RULER Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded.
Page 156 CYLINDER / PISTON Insert the piston ring squarely into the bottom of the FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE cylinder, check the piston ring clearance. FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE...
Page 157 CYLINDER / PISTON PISTON / CYLINDER ASSEMBLY TOP RIDNG PISTON RING ASSEMBLY SECOND RING Clean the piston ring assembly ring groove of the piston with oil. Carefully install the piston rings onto the piston with the markings facing up. MARK Be careful not to damage the piston and rings during assembly.
Page 158 CYLINDER / PISTON CYLINDER INSTALLATION Install a new cylinder gasket and dowel pins. Coat the cylinder wall with clean engine oil and lubricate the piston rings and install the cylinder. Be careful not to damage the piston rings. Be careful not to drop the cam chain into the crankcase.
Page 159 MEMO...
Page 160 CRANKCASE/TRANSMISSION/CRANKSHAFT 12-0...
Page 161 12. CRANKCASE/TRANSMISSION/CRANKSHAFT SERVICE INFORMATION 12-1 CRANKCASE BEARING 12-7 TROUBLESHOOTING 12-2 CRANKSHAFT INSTALLATION 12-8 CRANKCASE DISASSEMBLY 12-3 TRANSMISSION ASSEMBLY 12-9 TRANSMISSION DISASSEMBLY 12-4 CRANKCASE ASSEMBLY 12-10 CRANKSHAFT 12-6 SERVICE INFORMATION GENERAL SAFETY To service the transmission, crank shaft and kick starter, the crankcase should be disassembled. Before disassembling the crankcase, the following parts must be removed.
Page 162 CRANKCASE/TRANSMISSION/CRANKSHAFT Unit: mm ITEM STANDARD VALUE SERVICE LIMIT CONNECTING ROD BIG END SIDE 0.050~0.300 0.600 CLEARANCE CONNECTING ROD BID END CRANKSHAFT 0~0.008 0.050 VERTICAL DIRECTION CLEARANCE RIGHT 0.100 CRANKSHAFT RUNOUT LEFT 0.100 TORQUE VALUES MAIN SHAFT BEARING SETTING PLATE 1.2kgf m(12N m) CRANKCASE BOLT 1.1kgf m(11N m) TOOLS...
Page 163: Crankcase Disassembly
CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKCASE DISASSEMBLY The engine must be separated from the frame. section 6) Refer to the service information for removal of necessary parts before disassembling the crankcase. Remove the gear change switch. Remove the 6mm bolt from the right crankcase. Remove the cam chain.
Page 164 CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION DISASSEMBLY SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT...
Page 165 CRANKCASE/TRANSMISSION/CRANKSHAFT Check the shift drum for wear or damage. Check the shift drum guide groove for partial wear or damage. Measure the main shaft and counter shaft outside diameter. SERVICE LIMIT : M3, M5 : 19.930mm C1 : 16.440mm C2 : 19.940mm C4 : 19.930mm Check the gear for hole, projection part in gear, shift groove, gear wear, and damage.
Page 166 CRANKCASE/TRANSMISSION/CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT REMOVAL Remove the transmission. ( 12-4) Remove the crankshaft from the left crankcase using a crankshaft separating tool. Remove the remaining bearings in the left crankcase with a driver handle and outer driver.
Page 167 CRANKCASE/TRANSMISSION/CRANKSHAFT Measure the connecting rod radial clearance in both X and Y directions. Replace the crankshaft if the service limit is exceeded. SERVICE LIMIT : 0.050 mm CRANKCASE BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING...
Page 168: Crankshaft Installation
CRANKCASE/TRANSMISSION/CRANKSHAFT RH. Crank Case Remove the main shaft bearing set plate. BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE BEARING SET PLATE...
Page 169: Transmission Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT TRANSMISSION ASSEMBLY C-1 GEAR COUNTER TRANSMISSION SHAFT C-3 GEAR C-4 GEAR C-5 GEAR C-2 GEAR DRIVE SPROCKET MAIN SHAFT M-3 GEAR M-4 GEAR M-5 GEAR M-2 GEAR Apply the gear and gear bush with clean engine oil COUNTER SHAFT and install the main shaft and counter shaft.
Page 170: Crankcase Assembly
CRANKCASE/TRANSMISSION/CRANKSHAFT Check the marks on the shift forks. - L. fork : “L” mark LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK LEFT FORK...
Page 171 CRANKCASE/TRANSMISSION/CRANKSHAFT Make sure that there is no gap between the mating surfaces of the right and left crankcase. Tighten the left crankcase bolts in a crisscross pattern in 2-3 steps. TORQUE : 1.1kgf m(11N m) Tighten the right crankcase bolt to the specified torque.
Page 172 CRANKCASE/TRANSMISSION/CRANKSHAFT Install the cam chain. Install the disassembled parts (Install in the reverse order of removal) Install the engine on the frame. ( Section 7) MEMO 12-12...
Page 173 MEMO...
Page 174 EXTERNAL PARTS 13-0...
Page 175 13. EXTERNAL PARTS SERVICE INFORMATION 13-1 REAR FENDER 13-3 TROUBLESHOOTING 13-1 REAR WHEEL MUDGUARD 13-3 SEAT/SIDE COVER 13-2 MUFFLER/EXHAUST PIPE 13-4 REAR SEAT (PILLION SEAT) 13-2 FRONT FENDER 13-5 REAR COWL 13-3 SERVICE INFORMATION GENERAL SAFETY Beware of the muffler after driving or engine stop, as it is still hot to be burnt especiiallt never children touch on it. This section covers removal and installation of the seat and exhaust muffler.
Page 176 EXTERNAL PARTS SIDE COVER / SEAT SIDE COVER REMOVAL Remove the seat (see above). Remove the R/L. side cover mounting bolts, then remove the R/L. side covers. Remove the side cover hook from the grommet of the frame, by pulling the side cover forward. SEAT REMOVAL Insert the ignition key into the seat lock.
Page 177: Rear Cowl
EXTERNAL PARTS REAR COWL Remove the R/L. side cover. the center cover. the pillion seat. the two flange bolts and two special bolts. the rear fender mounting body cover clips. Carefully spread the bottom of both sides of the rear cowl, then remove it. Installation is in the reverse order of removal.
Page 178 EXTERNAL PARTS MUFFLER/EXHAUST PIPE Do not service the exhaust system while it is hot. REMOVAL Remove the exhaust pipe to muffler mounting bolts. Remove the muffler mounting bolt/nut and washer, then remove the muffler. Remove the exhaust pipe flange gasket. Remove the exhaust pipe joint cap nuts.
Page 179: Front Fender
EXTERNAL PARTS INSTALLATION Install the removed parts in the reverse order of removal. Check the protrusion of the exhaust pipe stud bolt. Install the new exhaust pipe gasket onto the exhaust ports of the cylinder head. Install the new gasket onto the exhaust pipe. FRONT FENDER Remove the wire grommat from the front fender.
Page 180 FRONT WHEEL/FRONT FORK/STEERING 14-0...
Page 181 14. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION 14-1 FRONT WHEEL 14-7 TROUBLESHOOTING 14-2 FRONT FORK 14-12 HANDLEBARS 14-3 STEERING STEM 14-20 SERVICE INFORMATION GENERAL SAFETY A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk with a brake degreasing agent.
Page 182 FRONT WHEEL/FRONT FORK/STEERING TOOLS BALL RACE DRIVER STEERING STEM DRIVER FORK SEAL DRIVER STEERING STEM SOCKET EXTENSION BAR DRIVER FORK SEAL DRIVER BODY LOCK NUT WRENCH BEARING REMOVER SHAFT REMOVER HEAD ATTACHMENT PILOT TROUBLESHOOTING Hard steering Soft suspension Steering bearing adjustment nut too tight Weak springs Damaged, worn steering head bearing Oil level too low...
Page 183: Handle Bars
FRONT WHEEL/FRONT FORK/STEERING HANDLE BARS HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP...
Page 184 FRONT WHEEL/FRONT FORK/STEERING Remove the screws and left handlebar switch housing. Remove the socket bolt and left handle weight cap. Remove the left handle grip and choke lever from the handlebar. Loosen the clutch lever bracket holder bolts. Loosen the handle pipe pinch bolt. Remove the handlebars from the front forks.
Page 185 Install the winker switch housing aligning its locating pin with the hole in the handlebar. Tighten the forward screw first, then the rear screw. Apply DAELIM Bond A to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip.
Page 186 FRONT WHEEL/FRONT FORK/STEERING Insert the throttle pipe to the handle bar THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE Connect the throttle cable to the throttle pipe.
Page 187: Front Wheel
FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL REMOVAL Support the motorcycle securely and raise the front wheel off the ground using a safety stand or a hoist. Remove the brake hose clamp bolt. Remove the monting bolts and brake caliper. BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER...
Page 188 FRONT WHEEL/FRONT FORK/STEERING BEARING INSPECTION Turn the inner race of each bearing with finger. Bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub.
Page 189 FRONT WHEEL/FRONT FORK/STEERING WHEEL BEARING REPLACEMENT Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing.
Page 190 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. WHEEL SIDE COLLAR FR. CASTING WHEEL RADIAL BALL BEARING FR. WHEEL AXLE GEAR BOX RETAINER OIL SEAL DUST SEAL SPEEDOMETER GEAR RADIAL BALL BEARING FR. DISTANCE COLLAR FR. TIRE LH. FR. BRAKE DISK SPEEDOMETER GEAR BOX ASSEMBLY Install the brake disk on the wheel hub.
Page 191 FRONT WHEEL/FRONT FORK/STEERING Align the wheel hub tangs with the slots of the gear box retainer, and assemble the speedometer gear box seal. Apply grease to the dust seal rim. SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX...
Page 192: Front Fork
FRONT WHEEL/FRONT FORK/STEERING Install the brake caliper and tighten the new mounting FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS bolts to the specified torque.
Page 193 FRONT WHEEL/FRONT FORK/STEERING DESASSEMBLY Remove the fork pipe bolt from the fork. If the bolt is completely loosened, the fork pipe bolt may spring out by the force for the spring. Remove the fork spring, and expand and release the fork pipe several times to drain fork oil. Wrap the bottom case with a piece of cloth, and remove the socket bolt.
Page 194 FRONT WHEEL/FRONT FORK/STEERING Remove the oil seal stopper ring. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING Pull the fork pipe out until you feel resistance from the slider bushing.
Page 195 FRONT WHEEL/FRONT FORK/STEERING Check components for damage or abnormal wear. BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE Replace defective parts with new ones.
Page 196 FRONT WHEEL/FRONT FORK/STEERING ASSEMBLY FR. FORK BOLT DUST SEAL FORK PIPE FR. FORK SPRING OIL SEAL STOPPER RING SEAT PIPE OIL SEAL BACK UP RING GUIDE BUSH RH. BOTTOM CASE REBOUND SPRING LH. FR. FORK ASSEMBLY OIL LOCK PIECE Before assembly, wash all parts with a clean oil and wipe them dry.
Page 197 FRONT WHEEL/FRONT FORK/STEERING Wrap the bottom case with a piece of cloth, and fix it to the vise. STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING STOPPER RING...
Page 198 FRONT WHEEL/FRONT FORK/STEERING Pour the specified amount of automatic transmission fluid(ATF) into the fork pipe. CAPACITY : 265 2.5cc Slowly press the fork tube 2-3 times to discharge air. FORK OIL FORK OIL Install the fork spring to the fork pipe. Install the spring with the smaller pitch side facing downward.
Page 199 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE FORK TOP BRIDGE...
Page 200 FRONT WHEEL/FRONT FORK/STEERING STEERING STEM BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY...
Page 201 FRONT WHEEL/FRONT FORK/STEERING RACE REPLACEMENT Replace the cone reces and ball races in pairs. Remove the ball races from the steering head using the ball race dirver. TOOL : BALL RACE DRIVER Install the new ball races into the head pipe using the driver and attachment.
Page 202 FRONT WHEEL/FRONT FORK/STEERING INSTALLATION STEERING HEAD TOP THREAD TOP CONE RACE STEEL BALLS STEEL BALL RACE STEEL BALL RACE STEEL BALLS BOTTOM CONE RACE DUST SEAL WASHER STEERING STEM FR. BRAKE HOSE STAY Install the steel ball. Apply grease to top and bottom ball races and cone races.
Page 203 FRONT WHEEL/FRONT FORK/STEERING Install the top bridge, washer and steering stem nut. Temporarily install the R/L front forks, then tighten the steering stem nut to the specified torque. TORQUE : 7.4 kgf m (74N m) Install the following: - Front fork ( 14-12) - Handlebar ( 14-3) Install the front brake hose stay and tighten the mounting bolts.
Page 204 CYLINDER HEAD / VALVES 10-0...
Page 205 REAR WHEEL/REAR SUSPENSION 15-0...
Page 206 15. REAR WHEEL/REAR SUSPENSION SERVICE INFORMATION 15-1 REAR CUSHION 15-7 TROUBLESHOOTING 15-2 SWINGARM 15-9 REAR WHEEL 15-3 SERVICE INFORMATION GENERAL SAFETY If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.
Page 207 REAR WHEEL/REAR SUSPENSION TROUBLESHOOTING Wobble or vibration in motorcycle Bent rim Worn rear wheel bearing Damaged tire Axle not tightened properly Insufficient air in tire Worn rear fork bush Soft suspension Weak spring Improper rear cushion adjust Incorrect rear damper Hard suspension Improper rear cushion adjust Bent damper rod...
Page 208 REAR WHEEL/REAR SUSPENSION REAR WHEEL AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT REMOVAL Erect the motorcycle using a safety stand or hoist, raise the rear wheel off the ground.
Page 209 REAR WHEEL/REAR SUSPENSION Wheel bearing Turn the inner race of each bearing with finger. Bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Replace the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub.
Page 210 REAR WHEEL/REAR SUSPENSION Check the damper rubber for deterioration or damage. Replace it if necessary. DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER DAMPER RUBBER...
Page 211 REAR WHEEL/REAR SUSPENSION Install the dust seal after applying the grease. If the damper rubber was removed, install the damper rubber. Make the part in protection ring face the outside, and connect the final driven sprocket. SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING...
Page 212 REAR WHEEL/REAR SUSPENSION Install the axle nut temporary. By tightening the chain adjust nut, adjust the drive chaim slack. ( 2-8) Tighten the axle nut to the specified torque. TORQUE : 8.8 kgf m ( 88 N m) REAR CUSHION REMOVAL Raise and support the motorcycle with main stand.
Page 213 REAR WHEEL/REAR SUSPENSION BUSHING REPLACEMENT Remove the pivot collar and dust seals. Press out the bushing out of the rear cushion lower mount using the special tools. PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR PIVOT COLLAR...
Page 214 REAR WHEEL/REAR SUSPENSION INSTALLATION UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT UPPER FLANGE BOLT...
Page 215 REAR WHEEL/REAR SUSPENSION Remove the U-nut and swingarm pivot bolt and then remove the swingarm from the frame. U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT U-NUT DISASSEMBLY/INSPECTION Remove the two screws and chain slider. Check the chain slider for wear or damage.
Page 216 REAR WHEEL/REAR SUSPENSION ASSEMBLY RR. FORK END CAP CHAIN ADJUSTER CHAIN ADJUSTER LOCK NUT RR. SWING ARM DUST SEAL CAP BUSH BEARING BEARING O-RING CHAIN CHAIN SLIDER PIVOT DISTANCE CENTER COLLAR SWING ARM PIVOT BOLT Apply grease to the center collar, bearing and bushes. Install the center collar, bearings and bushes to the swingarm.
Page 217 REAR WHEEL/REAR SUSPENSION INSTALLATION Apply thin coat of grease to the swingarm pivot bolt surface. Install the swingarm into the frame, then install the pivot bolt from the left side. Install the U-nut. Hold the pivot bolt using a special tool, tighten the U- nut to the specified torque using the same tool.
Page 218 MEMO...
Page 219 HYDRAULIC BRAKE FRONT : REAR : 16-0...
Page 220 16. HYDRAULIC BRAKE FRONT MASTER CYLINEDR 16-9 SERVICE INFORMATION 16-1 REAR MASTER CYLINDER 16-13 TROUBLESHOOTING 16-2 FRONT BRAKE CALIPER 16-18 BRAKE FLUID REPLACEMENT/ AIR BLEEDING 16-3 REAR BRAKE CALIPER 16-20 BRAKE PAD/DISK 16-6 BRAKE PEDAL 16-23 SERVICE INFORMATION GENERAL SAFETY Don't put in dust or water when filling the reservoir.
Page 221 HYDRAULIC BRAKE TORQUE VALUES BRAKE CALIPER BRACKET BOLT 3.0 f m ( 30N m) BRAKE CALIPER BLEEDER VALVE 0.6 f m ( 6N m) BRAKE CALIPER HANGER PIN 2.3 f m ( 23N m) BRAKE CALIPER PIN BOLT 1.8 f m ( 18N m) BRAKE PAD PIN BOLT 1.8 f m ( 18N m) BRAKE OIL BOLT...
Page 222: Brake Fluid Replacement
HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP AIR BLEEDING Do not allow foreign material to enter the system when filling the reservoir.
Page 223 HYDRAULIC BRAKE Connect a bleeder hose to the caliper bleeder valve. BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE Loosen the bleeder valve and pump the brake lever or pedal.
Page 224 HYDRAULIC BRAKE BRAKE BLEEDING <When the brake bleeder is not available> Connect a clear bleeder hose to the bleeder valve. Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the master cylinder and lever or pedal resistance is felt.
Page 225 HYDRAULIC BRAKE BRAKE PAD/DISK FRONT BRAKE PAD REPLACEMENT When replacing brake pads, replace whole set. Do not remove the brake hose when replacing brake pads. Remove the brake hose clamp from the front fork. Remove the pin plug using the L. wrench. Loosen the hanger pin.
Page 226 HYDRAULIC BRAKE Make sure the brake pad spring is in place. HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS...
Page 227 HYDRAULIC BRAKE Remove the rear caliper bracket bolts and brake HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS caliper.
Page 228: Front Master Cylinder
HYDRAULIC BRAKE BRAKE DISK INSPECTION Visually inspect the brake disk for damage or crack. Measure the brake disk thickness with a micrometer. SERVICE LIMIT : FRONT: 3.0mm REAR : 3.0mm Replace the brake disk if the smallest measurement is less than the service limit. Measure the brake disk runout with a dial indicator.
Page 229 HYDRAULIC BRAKE DISASSEMBLY BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT Remove the handle lever bolt/nut and RH. handle lever assembly. HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER...
Page 230 HYDRAULIC BRAKE INSPECTION Check the piston for abnormal scratches. Check the primary cup and secondary cup for fatigue or damage. Measure the master cylinder piston O. D. SERVICE LIMIT : 12.645mm Check the master cylinder for abnormal scratches. Measure the master cylinder I.D. SERVICE LIMIT : 12.755mm ASSEMBLY MASTER CYLINDER CAP...
Page 231 HYDRAULIC BRAKE Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER Dip the piston in brake fluid.
Page 232: Rear Master Cylinder
HYDRAULIC BRAKE Install the RH. handle lever assembly, tighten the bolt. Hold the bolt and tighten the nut. BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER HANDLE LEVER...
Page 233 HYDRAULIC BRAKE Loosen the rear master cylinder mounting socket bolts. Remove the main step holder socket bolts and main step bar assembly. Unhook the stop switch spring from the brake pedal spring. Remove and discard the brake pedal joint cotter pin. Remove the joint pin C.
Page 234 HYDRAULIC BRAKE Remove the brake rod joint, master piston and spring. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER Clean the inside of the cylinder with brake fluid.
Page 235 HYDRAULIC BRAKE ASSEMBLY TUBE JOINT PIPE O-RING RR. RESERVOIR ASSEMBLY MASTER CYLINDER SPRING SECONDARY CUP RR. PISTON PRIMARY CUP INTERNAL CIR CLIP BOOT BRAKE ROD BRAKE ROD JOINT JOINT PIN C Coat all parts with clean brake fluid before assembly. MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
Page 236 HYDRAULIC BRAKE Apply brake fluid to a new O-ring and install it onto TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE...
Page 237: Front Brake Caliper
HYDRAULIC BRAKE Install the brake hose with the oil bolt and new washers. Tighten the oil bolt to the specified torque. TORQUE : 3.4 kgf m (34 N m) Install and tighten the rear reservoir mounting bolt. Fill the reservoir to the upper level and bleed the brake system.
Page 238 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other damage. Measure the caliper cylinder I. D. SERVICE LIMIT : 25.42mm Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston O. D. SERVICE LIMIT : 25.27mm ASSEMBLY CALIPER BRACKET PISTONS...
Page 239: Rear Brake Caliper
HYDRAULIC BRAKE Coat the new piston seals with clean brake fluid. Coat the new dust seals with silicone grease. PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL...
Page 240 HYDRAULIC BRAKE Remove the rear caliper bracket bolts and the brake pads. ( 16-6) CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER Pivot the caliper up and remove it. BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS...
Page 241 HYDRAULIC BRAKE INSPECTION Check the caliper cylider for scoring or other damage. Measure the caliper cylinder I. D. SERVICE LIMIT : 25.070mm Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston O. D. SERVICE LIMIT : 24.870mm ASSEMBLY CALIPER BRACKET PIN BOLT...
Page 242: Brake Pedal
HYDRAULIC BRAKE Apply the boot with silicone grease. BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT BOOT Install the boot into the groove of the caliper body. Install the pad spring into the caliper body. Install the caliper pin bolt and caliper bracket into the caliper body.
Page 243 HYDRAULIC BRAKE INSTALLATION Apply grease to the sliding surface of the brake pedal. Assemble the brake pedal, washer and external cir-clip. Hook the brake pedal spring. Connect the brake pedal to the brake rod joint. Install the joint pin C and secure it with a new cotter pin. Hook the stop switch spring to the brake pedal spring.
Page 244 MEMO...
Page 245 BATTERY/CHARGING SYSTEM ß /„Ø MAIN SWITCH ( 30A) BATTERY „Ł ¯˝ ‚ﬁ ( 15A) ”˛ ˙ˇ B..Black Y..Yellow G..Green R..Red W..White Lg..Light green 17-0...
Page 246 17. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 17-1 REGULATOR/RECTIFIER 17-5 TROUBLESHOOTING 17-2 A.C. GENERATOR CHARGING COIL INSPECTION 17-6 BATTERY 17-3 CHARGING SYSTEM INSPECTION 17-4 SERVICE INFORMATION Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.
Page 247 BATTERY/CHARGING SYSTEM TROUBLESHOOTING No power (Key turned on) Low power (Engine running) Dead battery. Battery undercharged. - Low fluid level. Battery is failing. - Low specific gravity. Charging system failure. - Charging system failure. Intermittent power Disconnected battery cable. Main fuse burned out. Loose battery connection.
Page 248: Voltage Inspection
BATTERY/CHARGING SYSTEM BATTERY TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL REMOVAL/INSTALLATION Remove the seat. ( 13-2) TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL...
Page 249 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECITION Turn the ignition switch off and disconnect the negative battery cable from the battery. Connect an ampere meter between negative (-) terminal and ground cable. With the ignition switch off, check for current leakage. LEAK CURRENT : Not to exceed 1mA TOOL : DIGITAL TESTER When measuring current using a tester, set it to a high...
Page 250 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER HARNESS SIDE CIRCUIT INSPECTION Remove the seat. ( 13-2) Remove the LH.
Page 251 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION Disconnect the regulator/rectifier 2P,3P coupler. Remove the regulator/rectifier unit mounting bolts and regulator/rectifier. Install the reguator/rectifier unit in the reverse order of removal. A.C. GENERATOR CHARGING COIL INSPECTION Remove the seat. ( 13-2) Remove the LH. side cover. ( 13-2) Disconnect the A.C generator cord coupler.
Page 252 MEMO...
Page 253 IGNITION SYSTEM BATTERY FUSE BOX REGULATOR/RECTIFIER IGNITION COIL AC GENERATOR 18-0...
Page 254 18. IGNITION SYSTEM SERVICE INFORMATION 18-1 IGNITION COIL INSPECTION 18-4 TROUBLESHOOTING 18-2 SIDE STAND SWITCH 18-5 PULSE GENERATOR INSPECTION 18-3 SERVICE INFORMATION GENERAL SAFETY Inspect the ignition system in proper sequence based on the troubleshooting. Dropping or giving a shock to the ECU unit causes a trouble. There should be battery voltage with the ignition and engine stop switched ON.
Page 255 IGNITION SYSTEM TROUBLESHOOTING No spark at plug. (TOOL : PVA MUITI TESTER) UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. Battery is undercharged 3. The sample timing of the tester and measured pulse were not Low peak voltage.
Page 256 IGNITION SYSTEM Inspection Items INSPECTION ITEM Check the battery voltage between main switch wire (black) and ground wire when the ignition is MAIN SWITCH Check the resistance of coil (between blue / yellow and green) is within the specified range. CRANK POSITION SENSOR ( 80~150 20 )
Page 257: Ignition Coil Inspection
IGNITION SYSTEM IGNITION COIL INSPECTION Disconnect the primary wire . Since the resistance value of the primary coil is small, it is too diffcult to judgment even if the problem happen from the short circuit. Measure the resistance between the two terminals of the ignition primary coil.
Page 258 IGNITION SYSTEM SIDE STAND SWITCH REMOVAL Remove the RH side covver. Remove the side stand switch couper connected with main wire harness Remove the side stand switch mounting screws and remove the cord clamp and side stand switch. INSPECTION Check the following terminals. ITEM TERMINALS COLOR STANDARD...
Page 259 ELECTRIC STARTER STARTER STARTER MAGNETIC SWITCH B(CABLE) SWITCH STARTER FUSE MOTOR Lg/R SIDE STAND SWITCH B(CABLE) MAIN SWITCH FUSE GEAR POSITION SWITCH B..Black NEUTRAL BATTERY Y..Yellow LAMP (12A 10AH) G..Green R..Red W..White Lg/R Lg..Light green 19-0...
Page 260 19. ELECTRIC STARTER SERVICE INFORMATION 19-1 STARTER MOTOR 19-3 TROUBLESHOOTING 19-2 STARTER MAGNETIC SWITCH 19-9 SERVICE INFORMATION GENERAL SAFETY Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing serious injury. The starter motor can be maintained without removing the engine from the vehicle. A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current.
Page 261 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn. Check for a blown out main fuse before servicing. Make sure the battery is fully charged and in good condition. Connect the starter motor (+) terminal to the With the ignition switch ON , check for a battery positive terminal.
Page 262 ELECTRIC STARTER STARTER MOTOR BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS REMOVAL With the ignition switch turned to "OFF", remove the negative cable at the battery before servicing the starter motor. Remove the rubber cap.
Page 263 ELECTRIC STARTER Remove the following : - Rear cover assembly - Seal ring - Washers - Armature INSPECTION Check the bushing in the rear cover for wear or damage. Check the oil seal and bushing in the front cover for wear or damage.
Page 264 ELECTRIC STARTER Check for continuity between pairs of commutator bars. There should be continuity. Check for continuity between each commtator bar and armature shaft. There should be no continuity. Check for continuity between the insulated brush and cable terminal. There should be continuity. Check for continuity between the cable terminal and the case.
Page 265 ELECTRIC STARTER Remove the following: - Washer nut - Washer - O-ring - Terminal setting bush - Brush holder Inspect the brushes for damage and measure the brush length. SERVICE LIMIT : 5 mm ASSEMBLY MOTOR CASE SEAL RING ARMATURE FRONT COVER BRUSH HOLDER SHIM...
Page 266 ELECTRIC STARTER Install the following : - New O-ring - Insulators - Washer - Washer nut Install the brushes into the brush holder. Install the brush holder into the motor case, aligning the holder tab with the motor case groove. Install the armature in the motor case, while pushing in the brushes into the brush holder.
Page 267 ELECTRIC STARTER Install the cir-clip and washers onto the armature shaft. Install a new seal ring onto the motor case. Apply grease to the bushing in the front cover. Install the lock washer onto the front cover. Install the front cover, aligning its mark with the motor case mark.
Page 268: Operation Inspection
ELECTRIC STARTER STARTER MAGNETIC SWITCH REMOVAL Remove the seat. ( 13-2) Remove the RH. side cover. (13-2) Disconnect the battery wire cable from the starter magnetic switch terminal. Disconnect the starter motor cable from the starter magnetic switch terrminal. Disconnect the Yellow/Red and Green/Yellow connector from the wire harness.
Page 269 ELECTRIC STARTER CONTINUITY INSPECTION Disconnect the wire connector of the magnetic switch. Connect the positive wire to the yellow/red wire terminal and the negative wire to the green/yellow wire terminal. There should be continuity. INSTALLATION Install in the reverse order of removal. 19-10...
Page 270 MEMO...
Page 271 LIGHTS/METER/SWITCHES 20-0...
Page 272 20. LIGHTS/METER/SWITCHES SERVICE INFORMATION 20-1 HANDLEBAR SWITCHES 20-8 TROUBLESHOOTING 20-2 FRONT/REAR STOP SWITCH 20-9 HEADLIGHT 20-3 NEUTRAL SWITCH 20-9 FRONT/REAR WINKER 20-4 HORN 20-9 STOP/TAIL LIGHT 20-4 WINKER RELAY 20-10 COMBINATION METER 20-5 FUEL UNIT 20-10 MAIN SWITCH 20-7 SERVICE INFORMATION GENERAL SAFETY Connect the same color wires together.
Page 273: Bulb Replacement
LIGHTS/METER/SWITCHES HEADLIGHT BULB REPLACEMENT Headlight bulbs become very hot while the headlight is ON, and remain hot for a while after they are turned OFF. Be sure to turn the ignition switch OFF and let the bulb cool down before replacement.
Page 274 LIGHTS/METER/SWITCHES FRONT/REAR WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER FRONT WINKER...
Page 275 LIGHTS/METER/SWITCHES COMBINATION METER REMOVAL Loosen the speedometer cable nut and remove the cable from the meter. Remove the headlight ( 20-3) Disconnect the combination meter connector. Remove the combination meter mounting socket bolts COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER...
Page 276 LIGHTS/METER/SWITCHES MAIN SWITCH INSPECTION Remove the key cover. Remove the main seat Remove the fuel tank Remove the main switcs coupler Check for continuity between the wire terminals of the main switch connector in each switch position. Continuity should exist between the color coded wires as follows: MAIN SWITCH BAT1...
Page 277: Lighting Switch
LIGHTS/METER/SWITCHES HANDLEBAR SWITCHES LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH Disconnect the handlebar switch connectors. Check for continuity between the wire terminals of the handlebar switch connector.
Page 278 LIGHTS/METER/SWITCHES FRONT/REAR STOP SWITCH FRONT Disconnect the front stop switch connectors and check for continuity between the terminals. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released. REAR Remove the seat ( 13-2) Remove the RH.
Page 279 LIGHTS/METER/SWITCHES GEAR CHANGE SWITCH Remove the seat. (13-2) Remove the LH. side cover. (13-2) Disconnect the neutral switch connector from the switch. Shift the transmission into neutral and check for continuity between the green/white wire terminal and ground. There should be continuity with the transmission is in neutral, and no continuity when the transmission is into gear.
Page 280 LIGHTS/METER/SWITCHES FUEL UNIT Remove the seat. ( 13-2) Remove the fuel filter cap. Remove the fuel tank cover. ( 4-2) Discounect the LH. side cover. ( 13-2) Remove the unit set cap and remove the fuel unit from the fuel tank. Be careful not to damage the wire.
Page 281 MEMO...
Page 282 21. TROUBLESHOOTING ENGINE WON’T START OR IS HARD TO START 21-1 POOR HANDLING 22-4 ENGINE LACKS POWER 21-2 POOR FRONT/REAR SUSPENSION PERFORMANCE 22-5 POOR PERFORMANCE (AT LOW AND IDLE SPEED) 21-3 FUEL GAUGE 22-5 POOR PERFORMANCE (AT HIGH SPEED) 21-4 ENGINE WON’T START OR IS HARD TO START INSPECTION CAUSE OF TROUBLE...
Page 283 TROUBLESHOOTING ENGINE LACKS POWER INSPECTION CAUSE OF TROUBLE 1. Check tire pressure. Pressure low Punctured tire. Faulty tire valve. Pressure normal 2. Raise wheels off ground and Wheel don’t rotate Dragged brake. rotate by hands. freely Worn or damaged wheel bearings. Lacked wheel bearings lubrication.
Page 284 TROUBLESHOOTING INSPECTION CAUSE OF TROUBLE 9. Check the spark plug. Lean fuel mixture. Contaminated or discolored Using spark plug with on incorrect heat Not contaminated or not range. discolored. 10. Check oil level. Level low or high Oil level too high. Oil level too low.
Page 285 TROUBLESHOOTING POOR PERFORMANCE(AT HIGH SPEED) INSPECTION CAUSE OF TROUBLE 1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment. valve clearance. Faulty ECU unit. Faulty pulse generator. Correct. 2. Disconnect fuel tube at Fuel flows No fuel to fuel tank. carburetor.
Page 286: Fuel Gauge
TROUBLESHOOTING POOR FRONT/REAR SUSPENSION PERFORMANCE INSPECTION CAUSE OF TROUBLE Cushion spring weak. 1. Suspension excessively soft. Overloaded. Damper oil leaks. 2. Suspension excessively hard. Fork pipe or cushion rod bent. 3. Noise from the suspension. Sliders stuck. Cushion stopper rubber damaged. FUEL GAUGE GAUGE READING INACCURATE (IGNITION SWTICH ON) INSPECTION...
Page 287 TROUBLESHOOTING GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES. (IGNITION SWTICH ON) INSPECTION CAUSE OF TROUBLE Fuse cut. 1. Operate the turn signal to check the Signal continuously Battery weak or totally discharged. battery circuit. operates dim or does not Ignition switch damaged or shorted. operate at all.
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Page 292 22. WIRING DIAGRAM...
Page 293 WIRING DIAGRAM 22-1...

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