KYMCO Zing 125 Service Manual
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KYMCO Zing 125 Service Manual

KYMCO Zing 125 Service Manual

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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Zing
125/150.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the inspection/ adjustment
procedures, safety rules and service
information for each part, starting from
periodic maintenance.
Sections 3 and 4 state the servicing
procedures and cautions for the removal
and installation of lubrication and fuel
systems.
Sections 5 through 19 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

CLUTCH/CAMSHAFT
CRANKCASE/CRANKSHAFT/TRANS-
MISSION SYSTEM/STARTER SPINDLE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

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  • Page 1: Table Of Contents

    PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing INSPECTION/ADJUSTMENT procedures for the KYMCO Zing 125/150. LUBRICATION SYSTEM FUEL SYSTEM Section 1 contains the precautions for all operations stated in this manual. Read ENGINE REMOVAL/INSTALLATION...

  • Page 2: General Information

    . GENERAL INFORMATION ENGINE SERIAL NUMBER....1- 0 LUBRICATION POINTS ....... 1-13 SPECIFICATIONS........1- 2 CABLE & HARNESS ROUTING.... 1-14 SERVICE PRECAUTIONS ....1- 3 WIRING DIAGRAM ......1-16 TORQUE VALUES.......1-11 TROUBLESHOOTING ......1-17 SPECIAL TOOLS .........1-12 ENGINE SERIAL NUMBER ZING 150 Location of Engine Serial Number...

  • Page 3: Specifications

    . GENERAL INFORMATION SPECIFICATIONS Motorcycle name & Model No. RT30AU Motorcycle name Zing 150 Air cleaner type Sponge type Overall length (mm) 2183 Fuel capacity 14.0 liter Overall width (mm) Type Overall height (mm) 1162 Piston dia. (mm) Wheel base (mm) 1460 φ25 equivalent Venturi dia.(mm)
  • Page 4 . GENERAL INFORMATION SPECIFICATIONS Motorcycle name & Model No. RF25AA Air cleaner type Sponge type Motorcycle name Zing 125 Fuel capacity 14.0 liter Overall length (mm) 2183 Type Overall width (mm) Piston dia. (mm) φ25 equivalent Overall height (mm) 1162 Venturi dia.(mm)

  • Page 5: Service Precautions

    . GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. Use genuine parts and lubricants. When servicing the motorcycle, be sure to use special tools for removal and installation.
  • Page 6 . GENERAL INFORMATION Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
  • Page 7 . GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 8 . GENERAL INFORMATION The connector shall be inserted completely. If the double connector has a lock, Snapping! lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 9 . GENERAL INFORMATION After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. When fixing the wire harnesses, do not make it contact the parts which will No Contact !
  • Page 10 . GENERAL INFORMATION Route harnesses so they are neither Do not pull pulled tight nor have excessive slack. too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 11 . GENERAL INFORMATION After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. Do you understand When a testing device is used, make sure the instrument? Is...
  • Page 12 . GENERAL INFORMATION Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication. Grease : Use special tool.

  • Page 13: Torque Values

    . GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45～0.6 5mm screw 0.35～0.5 6mm bolt, nut 0.8～1.2 6mm nut, SH bolt 0.7～1.1 8mm bolt, nut 1.8～2.0 6mm flange bolt, nut 1.0～1.4 10mm bolt, nut 3.0～4.0 8mm flange bolt, nut 2.0～3.0...

  • Page 14: Special Tools

    . GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Valve adjuster 780614 Valve guide driver Valve guide reamer Valve spring compressor attachment IN valve seat cuter EX valve seat cutter IN valve seat cutter EX valve seat cutter Valve seat cutter clip, 5.5mm Clutch holder Generator stator puller...

  • Page 15: Lubrication Points

    . GENERAL INFORMATION LUBRICATION POINTS Engine Oil Clutch Cable Grease Throttle Cable Grease Speedometer Cable Front Brake Fluid Tube 1-13...

  • Page 16: Cable & Harness Routing

    . GENERAL INFORMATION CABLE & HARNESS ROUTING A.C. Generator Wire Connector Wire Harness Fuel Filter CDI Unit Handlebar Switch Connectors Ignition Coil Secondary Air Reed Valve Taillight Wire Fuel Tube Ignition Switch Connector 1-14...
  • Page 17 . GENERAL INFORMATION Battery Positive Negative Cable Starter Relay Cable A.C.V. A.C.V. Vacuum Tube Fuse Box Starter Motor Wire Winker CDI Unit Accelerating Pump Purge Control Vacuum Tube A.I.C.V. Throttle Cable Cable Valve Ignition Coil Wire Oil Cooler Secondary Air Clutch Cable Charcoal Canister Cleaner...

  • Page 18: Wiring Diagram

    . GENERAL INFORMATION WIRING DIAGRAM 1-16...

  • Page 19: Troubleshooting

    . GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Symptom Inspection/Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches Clogged fuel filter...
  • Page 20 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty pulser coil Check carburetor pilot screw adjustment Mixture too lean (turn screw in) Correctly adjusted Incorrectly adjusted Mixture too rich (turn screw out) Check carburetor gasket...
  • Page 21 . GENERAL INFORMATION POOR PERFORMANCE (ENGINE LACKS POWER) Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Poor fuel flow (Restricted) Clogged fuel tank cap breather hole Engine speed Engine speed does not Clogged exhaust muffler increases increase sufficiently Carburetor fuel level too low...
  • Page 22 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Correct Incorrect Worn valve seat Check fuel filter for fuel supply Empty fuel tank Fuel flows freely Fuel flow restricted...
  • Page 23 . GENERAL INFORMATION POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty coil Normal Resistance too high...
  • Page 24 . GENERAL INFORMATION NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty old spark plug Check spark plug cap and ignition coil wire for looseness Loose Not loose...

  • Page 25: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 MAINTENANCE SCHEDULE-------------------------------------------- 2- 2 FUEL LINE/FILTER-------------------------------------------------------- 2- 3 THROTTLE OPERATION------------------------------------------------- 2- 3 AIR CLEANER -------------------------------------------------------------- 2- 4 SPARK PLUG---------------------------------------------------------------- 2- 4 VALVE CLEARANCE ----------------------------------------------------- 2- 5 CARBURETOR IDLE SPEED -------------------------------------------- 2- 5 IGNITION TIMING--------------------------------------------------------- 2- 6 CYLINDER COMPRESSION --------------------------------------------- 2- 6 ENGINE OIL ----------------------------------------------------------------- 2- 7...

  • Page 26: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT SERVICE INFORMATION GENERAL ！ WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions.

  • Page 27: Maintenance Schedule

    • In the interest of safety, we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas.

  • Page 28: Fuel Line/Filter

    . INSPECTION/ADJUSTMENT FUEL LINE/FILTER Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area. Fuel Line Fuel Filter THROTTLE OPERATION Check for smooth throttle grip movement in all steering positions.

  • Page 29: Air Cleaner

    . INSPECTION/ADJUSTMENT Element Screen AIR CLEANER AIR CLEANER REPLACEMENT Remove the right side cover. Remove the two screws attaching the emission control system. Remove the air cleaner case cover screws and the cover. Remove the air cleaner screen and element. Check the element and replace it with a new one if it is excessively dirty or damaged.

  • Page 30: Valve Clearance

    . INSPECTION/ADJUSTMENT Bolts Bolts VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the right and left side covers. Remove the cylinder head cover protector.. Remove the cylinder head cover. “T” Mark Rotate the generator flywheel to locate the camshaft on the top dead center (TDC) and align the “T”...

  • Page 31: Ignition Timing

    . INSPECTION/ADJUSTMENT IGNITION TIMING ＊ • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system. Remove the ignition timing eye hole cap on the left crankcase cover. Eye Hole Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the index mark on the left crankcase cover aligns with the...

  • Page 32: Engine Oil

    . INSPECTION/ADJUSTMENT ENGINE OIL ＊ When checking the oil level, place the motorcycle on its main stand on level ground for oil level check. After the engine is stopped for 10 minutes, check if the oil level is between the upper and lower limits through the wash window.

  • Page 33: Brake Shoe/Brake Adjustment

    . INSPECTION/ADJUSTMENT BRAKE SHOE Inspect the front brake linings for wear. BRAKE LEVER/PEDAL Measure the front brake lever free play. Free Play: 10～20mm Measure the rear brake pedal free play. Free Play: 10～20mm Adjusting Nut Lock Nut CLUTCH Measure the clutch lever free play. Free Play: 10～20mm When minor adjustment is required, adjust by turning the adjusting nut on the clutch...

  • Page 34: Suspension

    . INSPECTION/ADJUSTMENT SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. REAR Check the action of the rear shock absorber by compressing it several times.

  • Page 35: Steering Handlebar

    . INSPECTION/ADJUSTMENT Check the front and rear axle nuts for looseness. If the axle nuts are loose, tighten them to the specified torques. Torques: Front : 5.5～7.0kg-m Rear : 6.0～8.0kg-m Front Axle Nut STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation.

  • Page 36: Lubrication System

    . LUBRICATION SYSTEM LUBRICATION SYSTEM...
  • Page 37 . LUBRICATION SYSTEM SERVICE INFORMATION..... 3-1 OIL PUMP/OIL FILTER ROTOR ....3-3 TROUBLESHOOTING......3-1 OIL COOLER REMOVAL/INSTALLATION... 3-5 ENGINE OIL/OIL FILTER SCREEN..3-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • The service and maintenance of this section can be performed with the engine installed in the frame.
  • Page 38 . LUBRICATION SYSTEM Upper Limit ENGINE OIL/OIL FILTER OIL LEVEL ＊ ＊ ＊ ＊ • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
  • Page 39 . LUBRICATION SYSTEM OIL PUMP/OIL FILTER ROTOR REMOVAL 1. Remove the kick lever. 2. Disconnect the clutch cable. 3. Remove the right crankcase cover bolts and right crankcase cover. 4. Check the cover gasket, oil seal and O-ring for oil leaks or damage. Replace with new ones if necessary.
  • Page 40 . LUBRICATION SYSTEM Screw DISASSEMBLY Remove the pump cover attaching screw. Feeler Gauge INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.20mm Outer Rotor Outer Rotor Oil Pump Body Inner Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm Feeler Gauge Measure the rotor end-to-pump body clearance.
  • Page 41 . LUBRICATION SYSTEM Inner Rotor Outer Rotor ASSEMBLY Install the outer rotor and inner rotor into the pump body. Insert the pump shaft. ＊ ＊ ＊ ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.

  • Page 42: Fuel System

    . FUEL SYSTEM...
  • Page 43 . FUEL SYSTEM SERVICE INFORMATION .......4-1 CARBURETOR INSTALLATION ..4- 8 TROUBLESHOOTING......4-2 THROTTLE VALVE ASSEMBLY ..4- 8 THROTTLE VALVE DISASSEMBLY..4-3 AIR CUT-OFF VALVE......4- 9 CARBURETOR REMOVAL.....4-3 FUEL TANK..........4-10 FLOAT/FLOAT VALVE/JETS/ AIR CLEANER REMOVAL....4-11 ACCELERATING PUMP ......4-4 FLOAT LEVEL INSPECTION ....4-7 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous.

  • Page 44: Troubleshooting

    . FUEL SYSTEM TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel • Faulty ignition system • No spark at plug •...

  • Page 45: Throttle Valve Disassembly

    . FUEL SYSTEM Throttle Cable Carburetor Cap THROTTLE VALVE DISASSEMBLY Remove the right side cover. Remove the carburetor cap. Pull out the throttle valve. Right side cover Throttle Cable Disconnect the throttle valve and remove the spring from the carburetor cap. Needle Retainer Pry off the needle retainer and remove the jet needle.

  • Page 46: Float/Float Valve/Jets/ Accelerating Pump

    . FUEL SYSTEM Loosen the air cleaner connector band screw. Remove the two carburetor lock nuts. Remove the carburetor Lock Nut Screw CARBURETOR DISASSEMBLY FLOAT/FLOAT VALVE/JETS/ ACCELERATING PUMP Float/Float Valve Disassembly Remove the three float chamber attaching screws and remove the float chamber. Screws Float Remove the float pin, float and float valve.
  • Page 47 . FUEL SYSTEM Throttle Stop Screw Main Jet/Jets/Pilot Screw/Throttle Stop Screw Removal Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the pilot screw and throttle stop screw. Main Jet Slow Jet Throttle Stop Screw CAUTIONS ! ＊...
  • Page 48 . FUEL SYSTEM Inlet Hole Inlet Ball Check Valve Steel Ball Accelerating Pump Check Valve Removal Fuel Inlet Ball Check Valve Removal Remove the check valve nut. Take out the spring and steel ball. ＊ ＊ ＊ ＊ When removing, be careful not to drop the tiny spring.

  • Page 49: Float Level Inspection

    . FUEL SYSTEM Throttle Stop Screw Slow Jet/Main Jet Installation Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and pilot screw. ＊ ＊ ＊ ＊ • When installing the pilot screw, return it to the original position as noted during removal •...

  • Page 50: Carburetor Installation

    . FUEL SYSTEM Screws Accelerating Pump Installation First install the accelerating pump diaphragm. Install the spring. Install the accelerating pump cover and tighten the three screws. ＊ ＊ ＊ ＊ When installing the diaphragm, be sure to position it correctly. Accelerating Pump Cover CARBURETOR INSTALLATION Install the carburetor onto the intake...

  • Page 51: Air Cut-Off Valve

    . FUEL SYSTEM Adjusting Nut Lock Nut Install the throttle valve into the carburetor body. ＊ ＊ ＊ ＊ Align the groove in the throttle valve with the throttle stop screw on the carburetor body. Connect the throttle cable. Throttle Cable Tighten the carburetor cap.

  • Page 52: Fuel Tank

    . FUEL SYSTEM Check Valve Groove INSPECTION Inspect the check valve for proper operation. Inspect the air cut-off valve diaphragm and O-ring for deterioration or damage. Replace with new ones if necessary. Clean each air passage with compressed air. Diaphragm O-ring INSTALLATION First install the diaphragm and O-ring onto...

  • Page 53: Air Cleaner Removal

    . FUEL SYSTEM Bolts AIR CLEANER REMOVAL Remove the right side cover. Remove the two bolts attaching the emission control system. Remove the rear carrier. (Refer to 4-10.) Remove the seat. (Refer to 4-10.) Remove the two air cleaner case attaching bolts.

  • Page 54: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION...
  • Page 55 5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION .......................5-1 ENGINE REMOVAL .........................5-2 ENGINE INSTALLATION ......................5-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • A engine stand or floor jack is required to support and maneuver the engine. • The following parts can be serviced with the engine installed in the frame: ...
  • Page 56 . ENGINE REMOVAL/INSTALLATION Exhaust Muffler Clutch Cable Joint ENGINE REMOVAL Remove the right and left decorative covers under the fuel tank. Remove the carburetor. (Refer to 4-3.) Disconnect the clutch cable. Disconnect the oil cooler oil pipes. Remove the crankcase breather. Disconnect the secondary air reed valve inlet pipe.
  • Page 57 5. ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION Install the engine in the reverse order of removal. Install the engine to its original position with a jack or other adjustable support. ＊ ＊ ＊ ＊ • When installing the engine, do not damage the bolt thread and route the wires and cables properly.

  • Page 58: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES...
  • Page 59 6. CYLINDER HEAD/VALVES SERVICE INFORMATION......6-1 VALVE GUIDE REPLACEMENT...6- 6 TROUBLESHOOTING......6-3 VALVE SEAT INSPECTION & REFACING ..6- 7 ROCKER ARM SET REMOVAL....6-4 CYLINDER HEAD ASSEMBLY .....6- 9 CYLINDER HEAD REMOVAL ....6-4 CYLINDER HEAD INSTALLATION..6-10 CYLINDER HEAD DISASSEMBLY ..6-5 SERVICE INFORMATION GENERAL INSTRUCTIONS •...
  • Page 60 . CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head cover bolt 0.8～1.2kg-m Cylinder head lock nut 2.3～2.8kg-m Cam follower bolt 1.5～2.0kg-m Valve arm bolt 1.5～2.0kg-m SPECIAL TOOLS Valve spring compressor Valve seat cutter, 24.5mm 45° IN/EX Valve seat cutter, 25mm Plane cutter 37.5° IN Valve seat cutter, 22mm Plane cutter 37.5°...

  • Page 61: Troubleshooting

    6. CYLINDER HEAD/VALVES TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low • Worn or broken valve stem or valve guide •...

  • Page 62: Rocker Arm Set Removal

    . CYLINDER HEAD/VALVES Bolts Bolts CYLINDER HEAD COVER REMOVAL Remove the secondary air reed valve. (Refer to 19-19.) Remove the four bolts attaching the cylinder cover protector to remove the protector. Remove the three cylinder head cover bolts. Remove the cylinder head cover. Inspect the cylinder head cover O-ring for wear or damage and replace if necessary.

  • Page 63: Cylinder Head Disassembly

    6. CYLINDER HEAD/VALVES CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, washers and valve stem seals using a valve spring compressor. ＊ ＊ ＊ ＊ • Be sure to compress the valve springs with a valve spring compressor. •...

  • Page 64: Valve Guide Replacement

    . CYLINDER HEAD/VALVES VALVE /VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: 5.27mm replace if below 5.27mm replace if below Ream the guides to remove any carbon build-up using a valve guide reamer.

  • Page 65: Valve Seat Inspection & Refacing

    6. CYLINDER HEAD/VALVES Apply engine oil to new O-rings and install them to new valve guides. Then, drive in new valve guides. ＊ ＊ ＊ ＊ • Be careful not to damage the cylinder head mating surface. • Check for damage after driving in the new valve guides.
  • Page 66 . CYLINDER HEAD/VALVES VALVE SEAT GRINDING Remove any roughness or irregularities from Roughness the seat using a 45° cutter. ＊ ＊ ＊ ＊ Be careful not to grind too much. Use a 37.5° cutter to remove the upper existing valve seat material. Old Seat Width Use a 63.5°...

  • Page 67: Cylinder Head Assembly

    6. CYLINDER HEAD/VALVES Inspect the valve seat contact area. If the contact area is too high on the valve, Contact too High the seat must be lowered using a 37.5° cutter. If the contact area is too low on the valve, the seat must be raised using a 63.5°...

  • Page 68: Cylinder Head Installation

    . CYLINDER HEAD/VALVES Plastic Hammer Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters. ＊ ＊ ＊ ＊ Be careful not to damage the valves. Dowel Pins CYLINDER HEAD INSTALLATION Install the dowel pins and a new gasket onto the cylinder.
  • Page 69 6. CYLINDER HEAD/VALVES VALVE CLEARANCE ADJUSTMENT Adjust the valve clearance. ( Refer to 2-6. ) Feeler Gauge O-ring Cylinder Head Cover Install a new cylinder head cover O-ring onto the cylinder head cover. Install the cylinder head cover and cylinder head cover protector.

  • Page 70: Cylinder/Piston

    . CYLINDER/PISTON...

  • Page 71: Service Information General Instructions

    . CYLINDER/PISTON SERVICE INFORMATION .......7-1 CAM FOLLOWER REMOVAL ....7-2 TROUBLESHOOTING......7-1 PISTON REMOVAL.........7-2 CYLINDER REMOVAL......7-2 CYLINDER INSTALLATION....7-7 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. Unit: mm SPECIFICATIONS Standard...
  • Page 72 . CYLINDER/PISTON Dowel Pins CYLINDER REMOVAL Remove the cylinder head. ( Refer to 6-5. ) Remove the dowel pins. Remove the two bolts attaching the cylinder. Remove the cylinder. Bolts CAM FOLLOWER REMOVAL Remove the cam follower shaft. Remove the cam follower and 12mm washer (wave washer).
  • Page 73 . CYLINDER/PISTON INSPECTION Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ ＊ ＊ ＊ Take care not to damage or break the piston rings during removal. Remove carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 74 . CYLINDER/PISTON Measure the piston pin O.D. Service Limit: 14.99mm replace if below Measure the piston O.D. ＊ ＊ ＊ ＊ Take measurement at 10mm from the bottom and 90° to the piston pin hole. Service Limit: 150cc: 61.8mm replace if below 125cc: 56.35mm replace if below CYLINDER INSPECTION Inspect the cylinder bore for wear, scratches...
  • Page 75 . CYLINDER/PISTON Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.032mm replace if over Check the cam follower contact face for wear or peeling of electroplated coating. Measure the cam follower shaft I.D.
  • Page 76 . CYLINDER/PISTON Measure the cam follower shaft O.D. Service Limit: 11.95mm replace if below Check the push bar for bending and steel balls for wear or dropping. Measure the push bar length. Service Limit: 141mm replace if below Faulty (IN/EX) PISTON INSTALLATION Piston Ring Installation First install the third ring side rail onto the...
  • Page 77 . CYLINDER/PISTON Shop Towel Remove any gasket material from the crankcase surface. ＊ ＊ ＊ ＊ Place a shop towel in the crankcase to prevent foreign matters from falling into the crankcase. Gasket “IN” Mark Install the piston, piston pin and a new piston pin clip.

  • Page 78: Starter Motor/Generator/ Left Crankcase Cover/Starter

    8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT...
  • Page 79 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT SERVICE INFORMATION .......8-1 CAMSHAFT REMOVAL......8-4 TROUBLESHOOTING......8-1 CAMSHAFT INSTALLATION....8-5 STARTER MOTOR ........8-2 STARTER GEAR INSTALLATION....8-5 LEFT CRANKCASE COVER REMOVAL..8-2 GENERATOR INSTALLATION ....8-5 GENERATOR REMOVAL......8-2 LEFT CRANKCASE COVER INSTALLATION...8-6 STARTER CLUTCH REMOVAL .....8-3 STARTER MOTOR INSTALLATION ..8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS •...
  • Page 80 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT STARTER MOTOR REMOVAL Remove the two starter motor mounting bolts and the motor. Inspect the starter motor O-ring for damage or deterioration. Inspect the starter motor pinion for wear or damage. Mounting Bolts O-ring Cover Bolts...
  • Page 81 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT Bolt Reduction Pinion STARTER CLUTCH REMOVAL Remove the bolt attaching the starter gear set plate. Remove the starter gear. Set Plate Starter Gear INSPECTION Measure the starter gear shaft I.D. Service Limit: 22.062mm replace if over Starter Gear Measure the starter gear shaft O.D.
  • Page 82 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT Camshaft CAMSHAFT REMOVAL Remove the camshaft set piece. Remove the spring, camshaft, washer and cam. Inspect the camshaft O-ring for wear or damage. Cam Gear Set Piece Measure the cam lobe height. Service Limit: 32.628mm replace if below Measure the cam gear shaft hole I.D..
  • Page 83 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT Remove the push rod holder bolt. Remove the push rod holder. Check the bearing push rod for proper operation. Check the bearing push rod and O-ring for wear or damage. Push the rod into Installation holder Install the bearing push rod by pressing it in...
  • Page 84 8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT Groove LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover and tighten the eight bolts. (Refer to 8-2.) Torque: 0.8～1.2kg-m Bolts Install the reduction gear, shaft and washers. Then install the reduction gear cover and tighten the three bolts.

  • Page 85: Clutch/Gear Shift Mechanism

    . CLUTCH/GEAR SHIFT MECHANISM Clutch Outer Assembly Clutch Pressure Plate Clutch Plate Friction Disk Clutch Spring Clutch Center Clutch Lifter Clutch Lifter Guide Pin...
  • Page 86 . CLUTCH/GEAR SHIFT MECHANISM SERVICE INFORMATION ....................9-1 TROUBLESHOOTING ......................9-2 RIGHT CRANKCASE COVER REMOVAL ................. 9-3 CLUTCH REMOVAL ......................9-3 RIGHT CRANKCASE COVER INSTALLATION ..............9-9 SERVICE INFORMATION GENERAL INSTRUCTIONS • The clutch and gear shift mechanism can be serviced in the frame. •...
  • Page 87 . CLUTCH/GEAR SHIFT MECHANISM TROUBLESHOOTING Clutch slips during acceleration Clutch won’t operate; motorcycle moves moves slowly • No free play • Worn friction disk • Excessive free play • Weak spring • Bent clutch plate Clutch won’t operate Too much pressure on clutch lever •...
  • Page 88 . CLUTCH/GEAR SHIFT MECHANISM Clutch Cable Bolt RIGHT CRANKCASE COVER REMOVAL Drain the engine oil. Remove the kick lever. Disconnect the clutch cable. Remove the right crankcase cover attaching bolts and right crankcase cover. Remove the clutch lever and bearing. Kick Lever Screws Guide Pin...
  • Page 89 . CLUTCH/GEAR SHIFT MECHANISM Clutch Center Remove the 20mm circlip using a pair of pliers and then remove the clutch center, clutch friction disks and plates. ＊ ＊ ＊ ＊ • When removing the circlip, do not expand it excessively to avoid deformation. •...
  • Page 90 . CLUTCH/GEAR SHIFT MECHANISM Vernier Caliper CLUTCH FRICTION DISK Measure each clutch friction disk thickness. Service Limit: 2.5mm Clutch Friction Disk CLUTCH PLATE Measure each clutch plate bending using a feeler gauge. Service Limit: 0.20mm Clutch Plate Feeler Gauge CLUTCH OUTER/OUTER GUIDE Inspect the clutch outer groove for scratches caused by the friction disks.
  • Page 91 . CLUTCH/GEAR SHIFT MECHANISM Remove the stopper and spring. Remove the gear shift cam bolt. Remove the gear shift cam and set pin. Spring Gear Shift Cam Stopper Looseness Wear Inspection Inspect the gear shift cam stopper for wear or looseness and replace if necessary.
  • Page 92 . CLUTCH/GEAR SHIFT MECHANISM Gear Shift Cam Stopper Installation Install the gear shift cam stopper and spring. Tighten the 6mm lock bolt. Torque: 0.8～1.2kg-m Spring Install the set pin into the transmission drum hole. Install the gear shift cam, aligning the pin hole in the gear shift cam with the set pin.
  • Page 93 . CLUTCH/GEAR SHIFT MECHANISM Clutch Outer Drive Gear Install the clutch outer drive gear onto the crankshaft. Install the oil pump drive gear onto the crankshaft. Install oil pump driven gear and chain. Chain Driven Gear Install the clutch outer and thrust washer. ＊...
  • Page 94 . CLUTCH/GEAR SHIFT MECHANISM Square Nut Install the oil filter rotor. Install the washer and tighten the square nut. Torque: 4.0～5.0kg-m ＊ ＊ ＊ ＊ Install the washer with the mark “OUTSIDE” facing up. Install the special flange gasket onto the balance shaft driven gear with the flange facing down and then loosely install the square nut (left hand threads).

  • Page 95: Front Wheel/Suspension/ Steering

    . FRONT WHEEL/SUSPENSION/ STEERING 11-0...
  • Page 96 . FRONT WHEEL/SUSPENSION/ STEERING SERVICE INFORMATION..... 11-1 FRONT WHEEL........11- 6 TROUBLESHOOTING......11-2 FRONT FORK .........11-10 HANDLEBAR.......... 11-3 STEERING STEM........11-14 SERVICE INFORMATION GENERAL INSTRUCTIONS SPECIFICATIONS Item Standard (mm) Service Limit (mm) Front axle shaft runout  Axial Front wheel rim runout Radial Front fork spring free length Front fork tube runout...

  • Page 97: Troubleshooting

    . FRONT WHEEL/SUSPENSION/ STEERING TROUBLESHOOTING Hard steering • Insufficient tire pressure • Excessively tightened steering stem nut • Damaged steering stem bearings • Damaged steering bearing races Steers to one side or does not track straight • Uneven front shock absorbers •...

  • Page 98: Handlebar

    . FRONT WHEEL/SUSPENSION/ STEERING Throttle Cover HANDLEBAR REMOVAL Remove the two throttle cover screws and the throttle cover. Screws Throttle Pipe Disconnect the throttle cable from the throttle grip and then remove the throttle pipe from the handlebar. Master Cylinder Throttle Cable Remove the two master cylinder holder bolts and the master cylinder.
  • Page 99 . FRONT WHEEL/SUSPENSION/ STEERING Remove the two handlebar lock nuts to remove the handlebar. Lock Nuts INSTALLATION Install the handlebar in the reverse order of removal. Torque: 0.8～1.2kg-m Hole When installing the right and left handlebar switch housings, align the pin on the housing with the hole in the handlebar.
  • Page 100 . FRONT WHEEL/SUSPENSION/ STEERING Clean Surface THROTTLE PIPE INSTALLATION Clean the handlebar surface and install the throttle pipe. Check the throttle grip for proper operation. Throttle Pipe Connect the throttle cable to the throttle grip. Apply grease to the throttle cable. Install the throttle cover by aligning the pin on the cover with the hole in the handlebar and then tighten the two screws.

  • Page 101: Front Wheel

    . FRONT WHEEL/SUSPENSION/ STEERING FRONT WHEEL REMOVAL Place a jack or other adjustable support under the engine to raise the front wheel off the ground. Remove the speedometer cable set screw and disconnect the speedometer cable. Remove the front axle nut and pull out the axle.
  • Page 102 . FRONT WHEEL/SUSPENSION/ STEERING Tabs DISASSEMBLY Remove the speedometer gearbox and dust seal from the left side of the wheel. Dust Seal Speedometer Cable Remove the axle collar from the right side of the wheel. Axle Collar Nuts Remove the dust seal. Remove the five nuts and the brake disk.
  • Page 103 . FRONT WHEEL/SUSPENSION/ STEERING Bearing Driver Handle ASSEMBLY Pack all bearing cavities with grease. First drive in the right bearing and then install the distance collar. Finally, drive in the left bearing. Attachment, 37x40mm Install the brake disk and tighten the five nuts.
  • Page 104 . FRONT WHEEL/SUSPENSION/ STEERING Install the axle collar to the right side of the wheel. Axle Collar Groove INSTALLATION Install the front wheel onto the front fork, aligning the tab on the front fork with the groove in the speedometer gearbox. Front Axle Nut Insert the axle shaft and tighten the axle nut.

  • Page 105: Front Fork

    . FRONT WHEEL/SUSPENSION/ STEERING Upper Fork Bridge Bolts FRONT FORK REMOVAL Remove the front wheel. (Refer to 11-6.) Remove the four front fender bolts and the front fender. Remove the front brake caliper. Loosen the upper and lower fork bridge bolts and the bolts attaching the front right and left turn signal lights.
  • Page 106 . FRONT WHEEL/SUSPENSION/ STEERING Oil Seal Remove the dust seal and snap ring. Take out the oil seal and circlip. ＊ ＊ ＊ ＊ • Do not damage the bottom tube when taking out the oil seal and circlip. • Be sure to replace the removed oil seal and circlip with new ones during assembly.
  • Page 107 . FRONT WHEEL/SUSPENSION/ STEERING ASSEMBLY Before assembly, clean the removed parts with high flash or non-flammable solvent. Oil Stopper Install the return spring and piston into the front fork tube and then install oil stopper to the piston end. Install the front fork tube into the bottom tube.
  • Page 108 . FRONT WHEEL/SUSPENSION/ STEERING 6mm Socket Spanner Place shop towels under the bottom tube and set it in a vise. Apply locking agent to the socket head bolt and then install it into the piston. Tighten the socket head bolt using the socket spanner.

  • Page 109: Steering Stem

    . FRONT WHEEL/SUSPENSION/ STEERING Bolts INSTALLATION Install the front fork tubes into the upper and lower fork bridges and the front right and left turn signal light holders. Install and tighten the attaching bolts. Front Fender Front Fender Installation Install the front fender between the front fork tubes, then install and tighten the four bolts.
  • Page 110 . FRONT WHEEL/SUSPENSION/ STEERING Ball Race Remover Remove the top and bottom ball races. Bearing Driver Handle BALL RACE INSTALLATION Drive the top and bottom ball races into the steering head using a bearing driver. Attachment, 37x40mm Attachment, 37x40mm BOTTOM CONE RACE REPLACEMENT Drive out the bottom cone race.
  • Page 111 . FRONT WHEEL/SUSPENSION/ STEERING Top Cone Race Steel Balls Apply grease to the top and bottom ball races and steel balls. Install 21 steel balls each on the top and bottom ball races. Install the steering stem into the steering pipe and then install the top cone race and the bearing adjusting nut.

  • Page 112: Rear Wheel/Brake/Suspension

    . REAR WHEEL/BRAKE/SUSPENSION 12-0...
  • Page 113 . REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION ..... 12-1 REAR BRAKE ........12-4 TROUBLESHOOTING ......12-2 REAR SHOCK ABSORBER ....12-8 REAR WHEEL ......... 12-3 REAR FORK ...........12-9 SERVICE INFORMATION GENERAL INSTRUCTIONS • When installing the drive chain joint clip, the cutout of the clip should be opposite to the rotating direction.
  • Page 114 . REAR WHEEL/BRAKE/SUSPENSION TROUBLESHOOTING Rear wheel wobbling Poor brake performance • Bent rim • Improperly adjusted brake • Worn rear wheel bearing • Worn brake linings • Loose or broken wheel spoke wires • Contaminated or damaged brake linings • Faulty tire •...
  • Page 115 . REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Remove the rear axle nut. Remove the rear brake adjusting nut. Rear Axle Nut Rear Brake Adjusting Nut Remove the rear brake panel fixing arm bolt. Remove the bushing. Remove the rear brake panel. Remove the drive chain.
  • Page 116 . REAR WHEEL/BRAKE/SUSPENSION Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand. Axial Radial Check the drive chain gear teeth for wear or damage. Replace the drive chain gear if necessary. Replace Good ＊...
  • Page 117 . REAR WHEEL/BRAKE/SUSPENSION Drive Handle ASSEMBLY Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ ＊ ＊ ＊ • Drive in the bearings squarely. • Install the bearings with the sealed end facing out.
  • Page 118 . REAR WHEEL/BRAKE/SUSPENSION Measure the brake drum I.D. Service Limit: 131mm replace if over Cotter Pin Brake Shoes DISASSEMBLY Remove the cotter pin, washer and brake shoes. Washer Brake Arm Remove the brake arm bolt to remove the brake arm. Remove the oil seal.
  • Page 119 . REAR WHEEL/BRAKE/SUSPENSION Brake Cam Grease Apply grease to the brake cam and anchor pin, then install the brake cam to the brake panel. Brake Panel Apply engine oil to the oil seal and install it to the brake cam. Oil Seal Install the brake arm onto the brake cam, aligning the punch mark on the cam with the...
  • Page 120 . REAR WHEEL/BRAKE/SUSPENSION Screws Upper Mount Nut REAR SHOCK ABSORBER REMOVAL Remove the two screws attaching the left shock absorber outer cover and remove the outer cover. Remove the left shock absorber upper mount nut and washer and then press down the motorcycle to pull out the shock absorber.
  • Page 121 . REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly. ＊ ＊ ＊ ＊ • Apply locking agent to the lock nut threads and tighten the lock nut. • Install the shock absorber spring with closely wound coils facing up.
  • Page 122 . REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the rear fork in the reverse order of removal. Tighten the rear fork pivot nut. Torque: 5.5～6.5kg-m After the rear fork is installed, install the following parts: Rear shock absorber (Refer to 12-8) Rear wheel ( Refer to 12-3.) Rear brake adjustment (Refer to 2-9.

  • Page 123: Hydraulic Brake

    . HYDRAULIC BRAKE 2.5～3.5kg-m 2.4～3.0kg-m 13-0...
  • Page 124 . HYDRAULIC BRAKE SERVICE INFORMATION ....13-1 BRAKE PAD/DISK........13-4 TROUBLESHOOTING ......13-2 BRAKE MASTER CYLINDER....13-5 BRAKE FLUID CHANGE/AIR BLEED..13-3 BRAKE CALIPER ........13-8 SERVICE INFORMATION GENERAL INSTRUCTIONS • Drain the brake fluid from the hydraulic brake system before disassembly. • Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir with brake fluid.
  • Page 125 . HYDRAULIC BRAKE TROUBLESHOOTING Loose brake lever • Air in hydraulic brake system • Brake fluid level too low • Hydraulic brake system leakage Tight brake lever • Seized piston • Clogged hydraulic brake system • Smooth or worn brake pad Hard braking •...
  • Page 126 . HYDRAULIC BRAKE Screws BRAKE FLUID CHANGE/AIR BLEED Place the motorcycle on its main stand on level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap. ＊ ＊ ＊ ＊ Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid.
  • Page 127 . HYDRAULIC BRAKE Bolts BRAKE PAD/DISK BRAKE PAD REPLACEMENT Remove the two bolts attaching the brake caliper holder. ＊ ＊ ＊ ＊ The brake pads can be replaced without removing the brake fluid tube. Remove the brake caliper. Pin Bolts Remove the brake pad pin bolt caps and then remove the pad pin bolts and brake pads.
  • Page 128 . HYDRAULIC BRAKE BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0mm Measure the brake disk runout. Service Limit: 0.3mm Fluid Tube Bolt BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic brake system. ＊ ＊ ＊ ＊ Do not splash brake fluid onto any rubber, plastic and coated parts.
  • Page 129 . HYDRAULIC BRAKE DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Pliers Master Cylinder Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid.
  • Page 130 . HYDRAULIC BRAKE ASSEMBLY Before assembly, apply brake fluid to all removed parts. Install the spring together with the 1st rubber cup. ＊ ＊ ＊ ＊ • During assembly, the master cylinder, main piston and spring must be installed as a unit without exchange. •...
  • Page 131 . HYDRAULIC BRAKE BRAKE CALIPER REMOVAL Remove the brake caliper and brake pad springs. Place a clean container under the brake caliper and disconnect the brake fluid tube from the brake caliper. ＊ ＊ ＊ ＊ Be careful not to splash brake fluid on any coated surfaces.
  • Page 132 . HYDRAULIC BRAKE INSPECTION Check each piston for scratches or wear. Measure each piston O.D. with a micrometer gauge. Service Limit: 25.30mm replace if below Check each caliper and caliper cylinder for scratches or wear and measure the caliper cylinder I.D. Service Limit: 25.45mm replace if over ASSEMBLY Clean all removed parts.
  • Page 133 . HYDRAULIC BRAKE INSTALLATION Install the brake caliper onto the right front fork and tighten the bolts. Torque: 2.4～3.0kg-m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 2.4～3.0kg-m Add the recommended brake fluid into the brake reservoir and bleed air from the brake system.

  • Page 134: Rear Carrier/Rear Fender/ Exhaust Muffler

    . REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER 14-0...
  • Page 135 . REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER SERVICE INFORMATION......14-1 REAR FENDER........14-2 REAR CARRIER ........14-2 EXHAUST MUFFLER......14-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • The exhaust muffler must be removed when it is cold to avoid burns. • When installing the exhaust muffler, first tighten the exhaust muffler joint lock nuts and then tighten the exhaust muffler hanger lock bolt.
  • Page 136 . REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER REAR CARRIER REMOVAL Remove the two lock bolts on each side of the rear carrier. Remove the rear carrier and two collars. Rear Carrier Lock Bolts INSTALLATION Install the rear carrier in the reverse order of removal.
  • Page 137 . REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER EXHAUST MUFFLER REMOVAL ＊ ＊ ＊ ＊ The exhaust muffler must be removed when it is cold to avoid burns. Remove the two exhaust muffler joint lock nuts. Remove the two socket head bolts attaching the rear foot rest.

  • Page 138: Ignition System

    . IGNITION SYSTEM Ignition Coil CDI Unit Spark Plug Ignition Switch Pulser Coil A.C. Generator Exciter Coil Ignition Spark Switch Plug A.C. Generator C.D.I. Unit Pulser Coil Ignition Coil 15-0...
  • Page 139 . IGNITION SYSTEM SERVICE INFORMATION ...... 15-1 CDI UNIT ..........15-4 TROUBLESHOOTING ......15-2 PULSER COIL........15-5 IGNITION COIL........15-3 EXCITER COIL........15-5 SERVICE INFORMATION GENERAL INSTRUCTIONS • Inspect the ignition system according to the sequence specified in the Troubleshooting 15-2. • The ignition system has an electrical auto aligner in the CDI unit, so the ignition timing is not adjustable.
  • Page 140 . IGNITION SYSTEM TROUBLESHOOTING Engine stalls immediately after it starts • Weak spark • Improper ignition timing • Faulty CDI unit No spark at plug • Faulty ignition switch • Poorly connected, broken or shorted wire −Between pulser coil, CDI unit and ignition coil −Between exciter coil and CDI unit −Between CDI unit and ignition coil −Between CDI unit and ignition switch...
  • Page 141 . IGNITION SYSTEM IGNITION COIL CONTINUITY TEST Remove the left decorative cover under the fuel tank. Disconnect the ignition coil black/yellow wire coupler and measure the resistance between the ignition coil primary wire terminals. Resistance: 0.2～0.3Ω Remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and the primary coil terminal.
  • Page 142 . IGNITION SYSTEM CDI Coupler CDI UNIT REMOVAL Remove the left side cover. Disconnect the CDI coupler and remove the CDI unit. CDI Unit E2 (Green) SW (Black/White) EXT (Black/Red) INSPECTION Measure the resistance between the CDI unit terminals. Replace the CDI unit if the readings are not within the specifications in the table below.
  • Page 143 . IGNITION SYSTEM Ignition Coil CDI Tester Test the CDI unit using the CDI tester. ＊ ＊ ＊ ＊ Operate the CDI tester by following the manufacturer‘s instructions. Spark Window Connect the special connector to the CDI coupler and CDI tester. Switch Range Good CDI Faulty CDI...

  • Page 144: Charging System

    . CHARGING SYSTEM Regulator/Rectifier Fuse Battery A.C. Generator Ignition Switch A.C. Generator Regulator/Rectifier Battery 16-0...
  • Page 145 . CHARGING SYSTEM SERVICE INFORMATION......16-1 PERFORMANCE TEST......16-4 TROUBLESHOOTING......16-2 A.C. GENERATOR ........16-4 BATTERY..........16-3 REGULATOR/RECTIFIER .....16-5 SERVICE INFORMATION GENERAL INSTRUCTIONS • The battery is a MF battery which needs no refilling of distilled water. • Do not quick charge the battery. Be sure to use a MF battery charger and the battery temperature should not exceed 45℃.
  • Page 146 . CHARGING SYSTEM TROUBLESHOOTING No power • Dead battery • Fuse burned out • Disconnected battery cable • Faulty ignition switch Low power • Weak battery • Loose battery connection (terminal) • Charging system failure • Faulty regulator/rectifier Intermittent power •...
  • Page 147 . CHARGING SYSTEM Terminal (+) Set Plate Terminal (-) Battery BATTERY REMOVAL Remove the left side cover. First disconnect the battery negative cable and then the positive cable. Remove the two battery set plate lock nuts. Remove the battery. When disconnecting the battery positive (+) cable, do not touch the frame with tool;...
  • Page 148 . CHARGING SYSTEM Negative Probe Positive Probe PERFORMANCE TEST Perform this test with a fully charged battery. Start and warm up the engine for 10 minutes. Connect the battery positive cable to the ammeter positive probe and the battery negative cable to the ammeter negative probe.
  • Page 149 . CHARGING SYSTEM Regulator/Rectifier REGULATOR/RECTIFIER REMOVAL Remove the rear carrier and seat. (Refer to 4-10.) Remove the regulator/rectifier lock nut and disconnect the regulator/rectifier wire coupler. Measure the resistances between the regulator/rectifier wire terminals. Replace the regulator/rectifier if the readings are not within the specifications in the table below.

  • Page 150: Starting System

    . STARTING SYSTEM Starter Button Starter Relay Battery Starter Motor Ignition Switch Starter Button Fuse Starter Motor Starter Relay Battery 17-0...
  • Page 151 . STARTING SYSTEM STARTING SYSTEM DIAGRAM ... 17-0 STARTER MOTOR .......17-2 SERVICE INFORMATION ...... 17-1 STARTER RELAY ........17-5 TROUBLESHOOTING ......17-1 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed in the frame. •...
  • Page 152 . STARTING SYSTEM Wire Lock Nut STARTER MOTOR REMOVAL ＊ ＊ ＊ ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 153 . STARTING SYSTEM Wire Terminal STARTER MOTOR HOUSING CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor housing. Also check for the continuity between the wire terminal and each brush. There should be continuity.
  • Page 154 . STARTING SYSTEM Rear Cover Check if the bearing in the rear cover turns freely and has no excessive play. Replace if necessary. Bearing ASSEMBLY First remove the brush springs and then install the brushes onto the brush holders. Insert the commutator into the starter motor housing.
  • Page 155 . STARTING SYSTEM Starter Relay STARTER RELAY INSPECTION Remove the left side cover. Turn the ignition switch ON and the starter relay is normal if you hear a “click” when the starter button is depressed. If there is no click sound: •...

  • Page 156: Lights/Instruments/Switches/Horn

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN SERVICE INFORMATION .......18-0 IGNITION SWITCH........18-2 TROUBLESHOOTING......18-0 STARTER BUTTON/HORN BUTTON/ HEADLIGHT..........18-1 FUEL GAUGE.........18-3 TURN SIGNAL LIGHT ......18-2 HANDLEBAR SWITCHES ....18-4 STOPLIGHT/TAILLIGHT ......18-2 FUEL UNIT ..........18-6 SERVICE INFORMATION GENERAL INSTRUCTIONS • All plastic plugs have locking tabs that must be released before disconnecting. •...

  • Page 157: Headlight

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN Bolt HEADLIGHT REMOVAL Remove the headlight band screw to remove the band. Remove the headlight unit and disconnect the headlight wire coupler. Remove the headlight bulb and bulb socket. Check the bulb for damage and replace with a new one if necessary. INSTALLATION Install the headlight in the reverse order of removal.

  • Page 158: Turn Signal Light

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN Light Shell Bulb TURN SIGNAL LIGHT Remove the two turn signal light shell screws and the bulb. Check the bulb for damage and replace with a new one if necessary. The installation sequence is the reverse of removal. Screws Reflector STOP LIGHT/TAILLIGHT...

  • Page 159: Fuel Gauge

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN STARTER BUTTON Remove the decorative covers under the fuel tank. Disconnect the right switch wire coupler. Check for continuity between the black and yellow/red wires. Color Black Yellow/Red Position FREE ○ ○ ○ ○ ○ ○ ○ ○ PUSH Starter Button Black...

  • Page 160: Handlebar Switches

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN HANDLEBAR SWITCHES FRONT STOP SWITCH Disconnect the front stop switch wire coupler. Check for continuity between the front stop switch wires. Brake lever applied: There is continuity. Brake lever released: There is no continuity. Front Stop Switch Rear Stop Switch Wire REAR STOP SWITCH Remove the right side cover.
  • Page 161 . LIGHTS/INSTRUMENTS/SWITCHES/HORN Green Black/White ENGINE STOP SWITCH Disconnect the engine stop switch wire coupler. Check for continuity between the engine stop switch wires. Color Black/White Green Position ○ ○ ○ ○ ○ ○ ○ ○ Engine Stop Switch Blue/White Black Dimmer Switch DIMMER SWITCH Disconnect the dimmer switch wire coupler.

  • Page 162: Fuel Unit

    . LIGHTS/INSTRUMENTS/SWITCHES/HORN Fuel Unit FUEL UNIT ＊ ＊ ＊ ＊ Keep flames and sparks away from the working area. REMOVAL Remove the seat and fuel tank. (Refer to 4-10.) Remove the four fuel unit attaching nuts. Remove the fuel unit. ＊...

  • Page 163: Evaporative Emission Control System

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EVAPORATIVE EMISSION CONTROL SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ..............19- 1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION ..19- 2 TROUBLESHOOTING................19- 2 SERVICE INFORMATION..............19- 3 EVAPORATIVE EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE ............. 19- 4 MOTORCYCLE ENGINE EVAPORATIVE EMISSION CONTROL SYSTEM TEST ..............

  • Page 164: Schematic Drawing

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SCHEMATIC DRAWING 19-1...

  • Page 165: Evaporative Emission Control System Function

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION FOREWORD: The Evaporative Emission Control System is abbreviated to E.E.C. System. This device collects the fuel vapor from the carburetor and fuel tank and then the fuel vapor is drawn into the engine for re-burning to avoid air pollution caused by the fuel vapor diffused into the air.

  • Page 166: Service Information

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Do not smoke or allow flames or sparks near the working area. • Note the locations of tubes for proper installation. • Replace any damaged tube with a new one. •...
  • Page 167 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM 1. EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE: Service Mileage (KM) Item Inspection 300 1000 3000 5000 7000 9000 11000 ○ Drive belt Belt thickness ○ ○ ○ ○ ○ ○ Drive chain Chain tension & length ○...

  • Page 168: Motorcycle Engine Evaporative Emission Control System Test

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM MOTORCYCLE ENGINE EVAPORATIVE EMISSION CONTROL SYSTEM TEST A. LEAKAGE TEST PIPING DIAGRAM (SIMPLE) Purge Control Valve Fuel Fuel Vapor Tank Vacuum Carburetor Fuel Valve Air Cleaner Engine Fresh Air Charcoal Canister Exhaust Muffler 1. Charcoal Canister Plug (Point Charcoal Leak-proof Rubber Plug (It...

  • Page 169: Purge Control Valve Removal

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM Purge Control Valve PURGE CONTROL VALVE REMOVAL 1. Remove the frame right side cover. 2. Disconnect the purge control valve vacuum tube that goes to the carburetor and the tubes that go to the air cleaner and charcoal canister.
  • Page 170 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM PURGE CONTROL VALVE FLOW INSPECTION 1. Connect a vacuum pump to the purge control valve vacuum tube that goes to the carburetor and apply vacuum Pressure Pump pressure of 45mm/Hg. 2. Connect a pressure pump to the tube that goes to the charcoal canister and apply pressure.

  • Page 171: Charcoal Canister

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM CHARCOAL CANISTER REMOVAL 1. Remove the frame right side cover. 2. Disconnect the charcoal canister tubes that go to the fuel tank and purge control valve. 3. Remove the charcoal canister. To Purge Control To Air Charcoal Valve Canister...
  • Page 172 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM P.C.V. P.C.V. (POSITIVE CRANKCASE VENTILATION) SYSTEM P.C.V. REMOVAL Remove the P.C.V. tubes that go to the air cleaner and crankcase. Remove the P.C.V. To Crankcase To Air Cleaner To Air Cleaner P.C.V. INSPECTION Blow compressed air into the P.C.V. tube that goes to the crankcase.

  • Page 173: Exhaust Emission Related System Inspection

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM Air Cleaner Screen EXHAUST EMISSION RELATED SYSTEM INSPECTION AIR CLEANER CLEANING 1. Remove the frame right side cover and emission control system plate. 2. Remove the air cleaner cover screws and the air cleaner cover. 3.
  • Page 174 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM CARBURETOR ADJUSTMENT 1. Start and warm up the engine for five minutes. Adjust the pilot screw to find the highest idle speed. 2. Turn the throttle stop screw to obtain the specified idle speed of 1600±100rpm. 3.

  • Page 175: Exhaust Emission Test And Adjustment

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION TEST AND ADJUSTMENT 1. Start the engine and warm up for several minutes. (Engine surface temperature 60℃～80℃) 2. Adjust the idle speed to 1600±100 rpm. 3. Connect the emission tester sampling pipe to the exhaust muffler. Standard: CO: 1.2±0.3 max.

  • Page 176: Exhaust Emission Control System

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM DIAGRAM ....19-14 EXHAUST EMISSION CONTROL SYSTEM FUNCTION....19-15 TROUBLESHOOTING................19-15 SERVICE INFORMATION..............19-16 SECONDARY AIR CLEANER............. 19-17 AIR INJECTION CUT-OFF VALVE (A.I.C.V.) ........19-18 REED VALVE..................

  • Page 177: Exhaust Emission Control System Diagram

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM DIAGRAM SECONDARY AIR INJECTION SYSTEM 19-14...

  • Page 178: Exhaust Emission Control System Function

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.

  • Page 179: Service Information

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • During operation, be careful to avoid scalding caused by the exhaust muffler. • Note the locations of tubes for proper installation. • Replace any damaged tube with a new one. •...

  • Page 180: Secondary Air Cleaner

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM Bolt SECONDARY AIR CLEANER REMOVAL 1. Remove the right side cover and disconnect the secondary air cleaner connecting tube. 2. Remove the secondary air cleaner case. Right Side Cover Connecting Tube Secondary Air Cleaner Air Outlet Tube O-ring Element DISASSEMBLY...

  • Page 181: Air Injection Cut-Off Valve (A.i.c.v.)

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM Reed Valve Vacuum Tube AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL 1. Remove the front right decorative cover under the fuel tank. 2. Disconnect all the tubes that go to the air injection cut-off valve. 3. Remove the air injection cut-off valve mounting bolts to remove the air injection cut-off valve.

  • Page 182: Reed Valve

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM Duct Inlet Tube REED VALVE REMOVAL 1. Disconnect the secondary air inlet tube and connector. 2. Remove the two bolts attaching the secondary air exhaust port duct. 3. Remove the two bolts attaching the reed valve unit to remove the reed valve unit.

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