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DAELIM DAYSTAR - Service Manual - Handle Bar

Other manuals for DAYSTAR -: Specification, Owner's Manual

Summary of DAYSTAR -

  • Page 1

    Service manual.

  • Page 2: How to Use This Manual

    How to use this manual this manual explains how to maintain the daystar of the daelim motor co., ltd. Follow the maintenance schedule (section 3) recommen- dations to ensure that the vehicle is in peak operating condition. Section 1 through 3 apply to the whole motorcycle, while sections 4 through 1...

  • Page 3: Service Rules

    1. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. 2. The battery contains sulfuric acid(electrolyte) contact wit...

  • Page 4: General Information

    1-2 general information model identification frame no frame no frame no frame no frame no frame no frame no frame no frame no frame no frame no frame no engine no engine no engine no engine no engine no engine no engine no engine no engine no engine no engine no engine no.

  • Page 5: General Information

    1-3 general information item specifications overall length 2,240mm overall width 860mm overall height 1,140mm dimensions wheel base 1,505mm seat height 720mm ground clearance 135mm dry weight 147.5kgf curb weight 341kgf type double cradle front suspension stroke telescopic fork 140mm rear suspension...

  • Page 6: General Information

    1-4 general information item specifications carburetor type piston valve /24mm(0.94 in) setting mark vl125 b main jet #102 carburetor slow jet #38 pilot screw initial setting 2 1/4 float level 19mm idle speed 1,400±100(rpm) clutch hydraulic, multi-plate transmission type constant mesh transmission p...

  • Page 7: General Information

    1-5 general information item q’ty thread dia torque remark oil filter screen cap 1 36 1.5(15) oil filter relief valve oval screw 1 10 1.2(12) oil filter cover socket bolt 3 6 1.1(11) oil pump mounting bolt 2 6 1.1(11) valve adjusting screw lock nut 4 5 1.1(11) drive sprocket 2 6 1.2(12) engine hange...

  • Page 8: General Information

    1-6 general information torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below. Sh(small head): 6mm bolt of 8mm flange head. Type torque type torque kgf-m n.M kgf-m n.M 1 5mm bolt, nut 0.45~6 4.5~6 5mm screw 0.35~0.5 3.5~5 1 6mm bol...

  • Page 9: General Information

    1-7 general information ! Warning △ safety notices following marks indicate some warnings and caution against some specific service methods. The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. When performing maintenance special grease...

  • Page 10: General Information

    1-8 general information tools special common description reference section description reference section clutch center holder 6 wrench, 8 9mm 3 flywheel puller 7 adjusting wrench, b 3 lock pin puller set 8 float level gauge 4 sliding shaft 8 lock nut wrench, 20 24mm 6 sliding weight 8 extension bar ...

  • Page 11: General Information

    1-9 general information tester, gauge compression gauge digital circuit tester circuit tester inspecion adapter spark adapter 3 16, 17 16, 17 17 17 remark description reference section valve seat cut valve seat cutter 45 valve seat cutter 35 valve seat cutter 35 valve seat cutter 60 cutter holder 5m...

  • Page 12: General Information

    1-10 general information cable & harness routing note the following when routing cables and wire harnesses: ● a loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. ● do not squeeze wires against the weld or its clamp. ● secure wires and wire ha...

  • Page 13: General Information

    1-11 general information r. Front winker cord engine stop switch cord (starter kill switch cord) r. Horn cord horn(low) r. Front winker cord front brake hose r. Rear winker cord winker relay regulator / rectifier starter magnetic cable starter motor cable fuel meter code horn sub harness clutch cabl...

  • Page 14: General Information

    1-12 general information wire harness fuel tube fuel unit cord drain tube tacho meter cord combination cord speedometer cord wire clamp brake hose speedometer cable brake clamp speedometer cable guide cable grommet a.C.G cord fuel tube choke cable high tension cord ignition coil choke cable clutch c...

  • Page 15: Lubrication

    2-1 lubrication service information 1. If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open ...

  • Page 16: Lubrication

    2-2 lubrication troubleshooting low oil pressure ● oil level low ● pressure relief valve stuck open ● plugged oil pick-up screen ● oil pump worm ● external oil leaks high oil pressure ● pressure relief valve stuck closed ● plugged oil filter, gallery, or metering orifice ● in correct oil being used ...

  • Page 17: Lubrication

    2-3 lubrication engine oil level check ● run the engine and allow it to idle for few minutes. Stop the engine and place the motorcycle on its center stand. ● after 2-3 minutes, check the oil level with the filler cap/dipstick. ● do not screw it in when making this check. ● if the oil level is below ...

  • Page 18: Lubrication

    2-4 lubrication engine oil filter element change ● remove the drain plug and drain the oil. (⇨2-3) ● remove the oil filter cover bolt, filter cover, filter element and spring. ● replace the oil filter element with a new oil filter. ● check the operation of the relief valve. ● if the relief valve is ...

  • Page 19: Lubrication

    2-5 lubrication ● measure the rotor end clearance. Service limit : 0.20mm(0.008 in) disassembly / assembly ● remove the inner and outer rotor from pump body. ● remove the setting ring, spacer, oil seal and pump shaft. Clean each parts with cleaning solvent. ● measure the pump side clearance. Service...

  • Page 20: Lubrication

    2-6 lubrication ● remove the oval screw, sealing washer, spring and relief valve from oil filter cover. ● remove the oil filter element from r. Crank case cover. ● blow the oil path way of crank case cover with compressed air, and clean. Torque oil filter cover : 1.1kgf-m(11n.M) oval screw: 1.2kgf-m...

  • Page 21: Lubrication

    2-7 lubrication lubrication points if there is no specific indication of oil, use general grease to lubricate the lubrication parts. Lubricate the other operation parts which are not shown below with oil or grease. Control cable lubrication periodically, disconnect the throttle cables at their upper...

  • Page 22

    Memo.

  • Page 23: Maintenance

    3-1 maintenance service information ● if the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open a...

  • Page 24: Maintenance

    3-2 maintenance torque values spark plug 1.1 kgf-m( 11n.M) cylinder head cover bolt 1.0 kgf-m( 10n.M) valve adjusting nut 1.1 kgf-m( 11n.M) timing hole cap 0.6 kgf-m( 6n.M) crankshaft hole cap 0.8 kgf-m( 8n.M) rear axle nut 8.8kgf-m(88n.M) tools common tool wrench, 8×9 mm adjuster wrench compression...

  • Page 25: Maintenance

    3-3 maintenance ＊ fuel line i i i i 3-4 ＊ fuel filter r r r 3-4 ＊ throttle grip operation i i i 3-4 ＊ carburetor choke i i i 3-5 air cleaner r r r 3-5 note 2 spark plug i r i 3-6 ＊ valve clearance i i i i 3-6 engine oil r r r r 2-3 engine oil filter element r r r r 2-4 ＊ carburetor idles speed i i i...

  • Page 26: Maintenance

    3-4 maintenance fuel line ● check the fuel lines for deterioration, damage, or leakage. Replace the fuel lines. Throttle grip operation ● check the throttle grip for smooth operation. ● complete opening and automatic closing in all steering positions. ● lubricate the throttle cables if throttle oper...

  • Page 27: Maintenance

    3-5 maintenance carburetor choke ● make sure if there is no deterioration, damage or kinking in the choke cable. Check for smooth chock lever operation at any adjusting position. ● pull the choke lever forward all the way up to fully closed. Make sure that the choke valve is fully closed by moving t...

  • Page 28: Maintenance

    3-6 maintenance ● make sure if there is no deterioration and damage in the air cleaner element. Replace damaged parts. •the element is a viscous type which contains oil. Therefore do not use compressed air to clean the air cleaner element. ● assemble the air cleaner element in the reverse order of r...

  • Page 29: Maintenance

    3-7 maintenance ● measure the valve clearance with filler gauge. Valve clearance: intake: 0.12 ± 0.02mm(0.05 ± 0.001in) exhaust: 0.12 ± 0.02mm(0.05 ± 0.001in) ● loosen the lock nut with a valve wrench, and adjust the adjuster screw to the standard clearance using a valve adjusting wrench. When the s...

  • Page 30: Maintenance

    3-8 maintenance carburetor idle speed •inspect all other engine adjustments are within specifications and adjust idle speed. •the engine must be warm for accurate adjustment. Support the motorcycle on a level surface and shift the transmission into neutral. Check the idle speed and adjust by truning...

  • Page 31: Maintenance

    3-9 maintenance installation ● after assembling the chain tensioner, keep the upper part of bracket which is holding chain tensioner-roller to the underline of rear swing arm under pipe. • install the drive chain with the closed area of the clip facing to the proceeding direction. While driving, mas...

  • Page 32: Maintenance

    3-10 maintenance brake pad/shoe brake pad replacement ● check the brake pads for wear. Replace the brake. If the red marks in the pads reach to the brake.(⇨15-4) • always replace the brake pads as a set to assure even disc pressure. Brake fluid ● check the fluid level of the front brake reservoir. I...

  • Page 33: Maintenance

    3-11 maintenance brake shoe replacement ● replace the brake shoes if the arrow on the brake arm aligns with the reference mark “△” on full application of the rear brake pedal. Brake system ● inspect the front brake hoses for deterioration, cracks. If there are signs of leakage, replace them as soon ...

  • Page 34: Maintenance

    3-12 maintenance headlight adjustment ● adjust the headlight beam by turning the case adjustment screw. • adjust the headlight beam as specified by local laws and regulations. • an improperly adjusted headlight may blind on coming drivers, or it may fail to light a road for a safe distance. Height a...

  • Page 35: Maintenance

    3-13 maintenance suspension ● do not ride a vehicle with a faulty suspension. Loose, worn or damaged suspension parts impair vehicle stability and control. Front ● check the action of the fork by compressing the front suspension several times. ● check the entire fork assembly for leaks, damage, or l...

  • Page 36: Maintenance

    3-14 maintenance rear ● check the action of the rear cushion by compressing them several times. Check the rear cushion for leaks, damage, or looseness. ● support the motorcycle with a main stand. ● check for worn rear fork bush by attempting to move the wheel side to side. Replace the bearings if an...

  • Page 37: Maintenance

    3-15 maintenance ● measure the tread depth at the center of the tire. ● replace the tire when the tread depth reaches the following limits: minimum tread depth: 4mm (0.16 in) 8.5mm (0.3 in) steering head bearings ● check that the control cables do not interfere with handle bar rotation. ● raise the ...

  • Page 38: Fuel System

    Fuel system 4-0

  • Page 39: Fuel System

    4-1 fuel system item specifications setting mark vl125 b main jet #102 slow jet #38 jet needle clip second float level 19mm pilot screw initial opening 2 idle speed 1,400±100(rpm) throttle grip free play 2~6mm service information general 1. Gasoline is extremely flammable and is explosive under cert...

  • Page 40: Fuel System

    4-2 fuel system troubleshooting engine cranks but won ’ ’ t start ● no fuel in tank ● no fuel to carburetor ● engine flooded with fuel ● clogged air cleaner ● no spark at plug(ignition system faulty) rough idle, hard starting or stalling starting ● incorrect idle ring adjustment ● lean mixture, rich...

  • Page 41: Fuel System

    4-3 fuel system fuel tank removal • gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled. ● loosen ...

  • Page 42: Fuel System

    4-4 fuel system air cleaner case removal ● remove the l. Side cover. ● remove the air cleaner connecting tube band out of the air cleaner side. Remove the battery. ● remove the air cleaner mounting bolt. ● remove the air cleaner case. Installation ● installation is essentially the reverse order of r...

  • Page 43: Fuel System

    4-5 fuel system throttle valve removal ● remove the r. Side cover. ● remove the seat and the fuel tank. Loosen the carburetor top slowly and remove the throttle valve. ● remove the throttle cable connection out of the throttle valve, then remove the throttle valve. ● remove the throttle valve spring...

  • Page 44: Fuel System

    4-6 fuel system carburetor removal ● remove the fuel tank and seat(⇨ 4-3) ● remove the carburetor top(⇨ 4-5) ● remove the carburetor drain screw and drain gasoline from the carburetor. • gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with th...

  • Page 45: Fuel System

    4-7 fuel system ● remove the throttle cable. ● loosen the carburetor mounting nut, and remove the carburetor. Disassembly ● remove the fuel and drain tube. Accelerator pump ● take of the 3 screws, and remove the pump cover. ● remove the spring. ● inspect the damage of accelerator pump rod and diaphr...

  • Page 46: Fuel System

    4-8 fuel system ● align the diaphragm projecting part with float chamber groove. Install the spring to diaphragm cover, and install the cover to the float chamber preventing the diaphragm form damaging. ● adjust the accelerator pump. Float, float valve ● take off the 3 screws and remove the float ch...

  • Page 47: Fuel System

    4-9 fuel system jet ● remove the main jet, needle jet holder, and needle jet. Remove the slow jet, remove the pilot screw after recording the number of turns until the pilot screw is tightened to clockwise completely. • do not tighten up the pilot screws by force. It can cause the damaging of the se...

  • Page 48: Fuel System

    4-10 fuel system ● blow each jet and body pathway with compressed air, and clean the clogged place. ● install the needle jet, needle jet holder, main jet and slow jet. Install the throttle stop screw and pilot screw. • after tighten the pilot screw completely, back it out according to the recorded t...

  • Page 49: Fuel System

    4-11 fuel system accelerator adjustment • do not adjust unless replacing the adjuster screws. • adjust the idling.(⇨ 3-8) • adjust the operation of throttle grip.(⇨ 3-4) • loosen the lock nut, turn the adjuster screws to contact with accelerator pump cap, and then adjust the accelerator pump rod cle...

  • Page 50: Fuel System

    4-12 fuel system pilot screw adjustment 1. Turn each pilot screw clockwise until it seats lightly and back it out to the specification given. Initial opening : 2 • damages to the pilot screw seat will occur if the pilot screw is tightened against the seat. 2. Warm up the engine to operating temperat...

  • Page 51: Engine Removal/installation

    5-1 engine removal/installation 5. Engine removal/installation service information ………………… 5-2 engine removal ……………………… 5-3 engine installation ……………………… 5-4 5.

  • Page 52: Service Information

    5-2 engine removal / installation service information general ● a floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the frame, engine body, cables, wire system. ● the following parts or components can not be served with the engine install...

  • Page 53: Engine Removal

    5-3 engine removal / installation engine removal ● drain the engine oil.(⇨2-3) ● remove the following - side cover(⇨ 12-2) - seat(⇨ 12-2) - fuel tank(⇨ 4-3) - mufflers(⇨ 12-3) ● disconnect the connector of the starter motor cable, ac generator wire, gear change switch wire. ● remove the battery nega...

  • Page 54: Engine Installation

    5-4 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 n...

  • Page 55

    Memo.

  • Page 56: Clutch, Gearshift

    6-0 clutch, gearshift.

  • Page 57: Clutch, Gearshift

    6-1 clutch, gearshift 6. Clutch / gearshift service information ………………… 6-1 troubleshooting …………………… 6-2 r. Crankcase cover dissembly … 6-3 clutch disassembly ………………… 6-4 gearshift linkage …………………… 6- 7 clutch installation ………………… 6- 9 primary drive gear ………………… 6-10 r. Crank case cover ……………… 6-11 ...

  • Page 58: Clutch, Gearshift

    6-2 clutch, gearshift troubleshooting clutch operation problem can be corrected by adjusting a cable free play. Clutch lever pull too hard ● damaged, clogged or sticking clutch cable ● damaged lifter mechanism ● damaged clutch lifter plate bearing ● incorrect wiring of clutch cable clutch slips ● to...

  • Page 59: Clutch, Gearshift

    6-3 clutch, gearshift r. Crankcase cover disassembly ● drain the engine oil(⇨ 2-3) ● remove the kick starter pedal. ● remove the clutch adjusting lock nut and adjusting nut. Separate the clutch cable from the clutch arm. ● remove the cable out of the cable holder. ● remove the right crank case cover...

  • Page 60: Clutch, Gearshift

    6-4 clutch, gearshift ● separate the clutch arm spring and o-ring from the clutch arm/lift shaft. ● inspect the wear and damage of the lifter rod and clutch arm/lift shaft. ● inspect the wear and damage of the clutch arm spring. Clutch arm/lifter shaft assembly ● coat the new o-ring with grease, and...

  • Page 61: Clutch, Gearshift

    6-5 clutch, gearshift ● press the clutch center using the clutch center holder and remove the clutch lock nut. Tools: clutch center holder lock nut wrench, 20 × 24mm extension bar ● remove the lock washer. ● remove the clutch center, disk, plate, and pressure plate. ● remove the spline washer and cl...

  • Page 62: Clutch, Gearshift

    6-6 clutch, gearshift inspection ● inspect the lifter plate bearing for scoring and other damage. ● inspect the lifter plate for damage. ● if necessary, replace them. ● measure the clutch spring free height. ● service limit:34.2mm(1.35in) ● check the clutch disk. If necessary, replace it. ● measure ...

  • Page 63: Clutch, Gearshift

    6-7 clutch, gearshift ● check the slots in the clutch outer for nicks or indentations made by the clutch discs. If necessary replace them. ● measure the clutch outer inside diameter. Service limit:28.030mm(1.1035in) ● measure the clutch outer guide outsider diameter. Service limit:27.950mm(1.1004in)...

  • Page 64: Clutch, Gearshift

    Gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam gear shift cam bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt bolt spring spring spring spring spring sprin...

  • Page 65: Clutch, Gearshift

    6-9 clutch, gearshift clutch assembly ● coat the clutch outer guide with clean engine oil. ● install the trust washer and outer guide into the main shaft. ● install the following: - clutch assy. - r. Crank case cover ● install the gear shift arm into the gear shift spindle ● install the clutch outer...

  • Page 66: Clutch, Gearshift

    6-10 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, 20 × 24mm extension bar ● install the clutch spring, lifter plate and clutch spring bolt diagonally several times. • check if ...

  • Page 67: Clutch, Gearshift

    6-11 clutch, gearshift ● when replacing the primary drive gear, select the gear which the paint mark, same colar of r.Crank case paint mark, is indicated. Paint mark of crank case paint mark of primary drive gear white white(primary drive gear a) blue blue(primary drive gear b) yellow yellow(primary...

  • Page 68: Clutch, Gearshift

    6-12 clutch, gearshift r. Crankcase cover installation ● remove the gasket from the crank case surface. ● install the dowel pins and a new gasket. ● install the right crank case cover, aligning the spline of the crank shaft and with the oil pump shaft spline. • if any difficulty is encountered in jo...

  • Page 69

    7-0 a.C generator / starter clutch.

  • Page 70: Service Information

    7-1 a.C generator / starter clutch 7. A.C generator / starter clutch service information ………………… 7-1 a.C generator ……………………… 7-2 starter clutch ……………………… 7-7 service information general ● this section covers removal and installation of the a.C. Generator. ● refer to section 16 for inspection of the ...

  • Page 71: A.C Generator

    7-2 a.C generator / starter clutch ● loosen the one bolt attaching a.C. Generator and remove the a.C. Generator wire clamp. A.C generator removal ● remove the gear change pedal. ● remove the l. Lower cover. ● disconnect the coupler of the a.C. Generator wire, gear change switch wire coupler. ● loose...

  • Page 72

    7-3 a.C generator / starter clutch ● remove the starter reduction gear shaft and starter reduction gear. ● loosen the left crank case cover adjusting bolt and remove the left crank cover. Remove the gasket and the dowel pins. ● remove the starter idle gear shaft and starter idle gear. ● hold the fly...

  • Page 73

    7-4 a.C generator / starter clutch ● remove the woodruff key from the crank shaft. ● remove the starter driven gear collar. ● after installing the flywheel puller on the rotor, remove the rotor. Tool: flywheel puller stator removal/installation ● loosen the pulse generator mounting screw and remove ...

  • Page 74

    7-5 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(0.393in) ● measure the gear shaft inside diameter. Service limit : 9.97mm(0.393in) reduction gear inspection ● inspect the ...

  • Page 75

    7-6 a.C generator / starter clutch ● install the starter idle gear and shaft. ● install the new gasket and dowel pin. ● install the l. Crankcase cover and tighten the bolt. Torque : 1.1kgf-m(11n.M) ● install the starter gear and shaft. ● install the new o-ring. Starter idle gear starter idle gear st...

  • Page 76: Starter Clutch

    7-7 a.C generator / starter clutch ● connect the ac generator wire and gear position light switch wire coupler, and install the wire clamp. ● install the l. Lower cover and gear change pedal bolt. ● tighten the gear change pedal bolt. Starter clutch ● remove the flywheel(⇨ 7-4) ● if the starter driv...

  • Page 77

    7-8 a.C generator / starter clutch ● check the starter driven gear for damage and wear. ● measure the driven gear i.D. And o.D. Service limit: o.D. : 42.180mm(1.658in) i.D. : 22.100mm(0.870in) assembly ● inspect the one way clutch for wear and damage. ● install the way clutch fringe onto the clutch ...

  • Page 78

    Memo.

  • Page 79: Cylinder Head / Valve

    8-0 cylinder head / valve.

  • Page 80: Cylinder Head / Valve

    8-1 cylinder head / valve service information general ● rocker arm and cam shaft can be serviced with the engine installed in the frame. To service the cylinder heads. The engine must be removed from the frame. ● cam shaft lubrication oil is fed through an oil pipe. Be sure that the oil pipes and or...

  • Page 81: Cylinder Head / Valve

    8-2 cylinder head / valve torque values cam chain tensioner pivot bolt 1.1kgf-m(11n.M) spark plug 1.1kgf-m(11n.M)-apply engine oil camshaft holder 8mm nut 2.0kgf-m(20n.M)-apply engine oil cam chain tensioner mounting bolt 1.2kgf-m(12n.M) cam chain tensioner sealing screw 0.4kgf-m(4n.M) cylinder head...

  • Page 82: Cylinder Head / Valve

    8-3 cylinder head / valve camshaft removal ● remove the fuel tank(⇨ 4-3) ● remove the cylinder head cover bolts and cover. ● remove the timing hole cap and crank shaft hole cap out of the left crankcase cover. ● rotate the crankshaft clockwise, place the flywheel “t”mark on the left crankcase cover ...

  • Page 83: Cylinder Head / Valve

    8-4 cylinder head / valve ● remove the cam chain from camshaft. ● in order to separate the cam chain from the crank case, bind it with the thread or a string. ● remove the camshaft. Camshaft holder disassembly ● remove the end of the rocker arm spring from the dowel pins. ● remove the dowel pins fro...

  • Page 84: Cylinder Head / Valve

    8-5 cylinder head / valve inspection ● inspect the rocker arm and rocker arm shaft for wear and damage. ● measure the rocker arm i.D. Service limit : 12.060mm(0.4748in) ● measure the rocker arm o.D. Service limit : 11.950mm(0.4505in) ● inspect the cam lobe of the camshaft for wear and damage. ● meas...

  • Page 85: Cylinder Head / Valve

    8-6 cylinder head / valve ● remove the valve spring, valve cotter, retainer, spring, and valve. Tool: valve spring compressor • to prevent the loss of tension, do not compress the valve springs more than necessary to remove the cotters. • mark all parts during disassembly so they can be placed back ...

  • Page 86: Cylinder Head / Valve

    8-7 cylinder head / valve ● inspect the spark plug assembly hole and the crack of near valve seat. Check for the warp of the cylinder head with a square and filler gauge. Service limit : 0.1mm(0.004in) valve spring ● measure the free field of valve spring. Service limit : 40.0mm(1.57in) • if any val...

  • Page 87: Cylinder Head / Valve

    8-8 cylinder head / valve valve guide replacement • when replacing the valve guide, valve seat must be amended. ● heat the cylinder head equally to 130-140℃. ● avoid heating over 150℃ • avoid performing the unskilled work. It is caused a burn. • when heating the cylinder head, do not heat it section...

  • Page 88: Cylinder Head / Valve

    8-9 cylinder head / valve • trim the reamer not to lean. If cutting the reamer by leaning, the valve hole is inclined, the step seal is leaked, and the around of valve seat is enlarged. So the around of seat is not amended. • the entrance of reamer is always performed by turning the reamer to the ri...

  • Page 89: Cylinder Head / Valve

    8-10 cylinder head / valve valve seat amendment ● if the seat part is damaged or rough, cut them using 45。cutter. • after replacing the valve guide, cut the seat part. ● amend the flat using a 35。cutter side by side. ● amend the inside using a 60。cutter side by side. ● amend the seat part with a sta...

  • Page 90: Cylinder Head / Valve

    8-11 cylinder head / valve ● coat the valve seat with the compound. ● use the valve guide reamer without turning the valve, check the attached state by hitting against lightly. ● if the position of contacting side is high, cut it using a 35。cutter, and then cut it using a 45。 cutter according to the...

  • Page 91: Cylinder Head / Valve

    8-12 cylinder head / valve ● install the valve springs. The springs tightly would coils should face toward the cylinder head. ● install the springs retainer. ● compress the valve spring and install the valve cotters. • to prevent the loss of tension, do not compress the valve springs more than neces...

  • Page 92: Cylinder Head / Valve

    8-13 cylinder head / valve cylinder head installation ● clean the cylinder head surface of any gasket materials. ● install the cam chain guide into the cylinder. ● install the dowel pins and a new gasket. ● install the cylinder head. ● install the cam shaft. ● install the engine into the frame(⇨ 5) ...

  • Page 93: Cylinder Head / Valve

    8-14 cylinder head / valve ● insert the dowel pins into the camshaft holder thoroughly. Align the teeth of the rocker arm spring with the dowel pins as shown. ● check the camshaft ass’ y for wear or damage, and install the cylinder head ● install the cam chain on the cam sprocket. ● rotate the crank...

  • Page 94: Cylinder Head / Valve

    8-15 cylinder head / valve ● install the dowel pin into the cylinder head. ● install the camshaft holder. ● apply engine oil to the nut part, install and tighten the cam shaft holder nut and bolt in two or three steps as shown torque : 2.0kgf-m(29n.M) ● remove the sealing screw and washer from the c...

  • Page 95: Cylinder Head / Valve

    8-16 cylinder head / valve ● hold the tensioner shaft with the light clip as shown install a new gasket into the tensioner lifter, then install the tensioner lifter into the cylinder. ● install the tensioner mounting bolt. Torque:1.2kgf-m(12n.M) ● from the tensioner lifter, remove the clip which hol...

  • Page 96

    Memo.

  • Page 97: Cylinder / Piston

    9-0 cylinder / piston.

  • Page 98: Cylinder / Piston

    9-1 cylinder / piston 9. Cylinder / piston service information ………………… 9-1 troubleshootint …………………… 9-1 cylinder ……………………………… 9-2 piston ………………………………… 9-3 piston/cylinder installation ……… 9-5 service information geaneral ●when removing the cylinder, avoid damaging the cylinder joint part with a driv...

  • Page 99: Cylinder / Piston

    9-2 cylinder / piston cylinder removal ● remove the cylinder head(section 8). ● remove the cam chain guide from the cylinder. ● loosen the cylinder mounting bolt, and remove the cylinder. ● remove the gasket and dowel pins. Remove the gasket from the cylinder. • avoid damaging the gasket surface. In...

  • Page 100: Cylinder / Piston

    9-3 cylinder / piston ● inspect the twist of cylinder. Service limit:0.1mm(0.004in) piston removal ● remove the piston pin clips. • do not let the clips fall into the crankcase. • push the piston pin out and remove the piston. ● check the piston ring for damage or deterioration. ● remove the piston ...

  • Page 101: Cylinder / Piston

    9-4 cylinder / piston ● insert the piston ring into the cylinder inside, and inspect the piston ring clearance. ● insert the piston ring horizontally using a piston head. Service limit: top/second:0.5mm(0.02in) oil(side rail):1.1mm(0.04in) ● measure the piston outside diameter at 10mm position in pi...

  • Page 102: Cylinder / Piston

    9-5 cylinder / piston piston/cylinder installation ● remove the gasket from the crankcase surface. • be careful not to damage the gasket surface. • place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase. ＊ ＊ note top ring mark top ring second ring s...

  • Page 103: Cylinder / Piston

    9-6 cylinder / piston ● install the piston, piston pin on the connecting rod. ● install new piston pin clips. • install the piston with the “in”mark facing towards the intake side. • place a shop towel over the opening to prevent piston pin clips from falling into the crankcase. • make sure that the...

  • Page 104: Cylinder / Piston

    9-7 cylinder / piston ● install the lower part of the cam chain into the slot of the crankcase. ● install the cam chain guide, aligning the tang of the crankcase with the slot of the cylinder. ● install the cylinder head(refer to section 8). Cam chain guide cam chain guide cam chain guide cam chain ...

  • Page 105

    10-0 crank case / transmission / crankshaft 1.2kgf-m(12n-m) 1.1kgf-m(11n-m).

  • Page 106: Service Information

    10-1 crank case / transmission / crankshaft / kick starter service information general ● to service the transmission, crank shaft and kick starter, the crank case must be separated. - clutch, gear shift linkage (⇨ section 6) - a.C. Generator, starter clutch (⇨ section 7) - cylinder head (⇨ section 8...

  • Page 107: Trouble Shooting

    10-2 crank case / transmission / crankshaft / kick starter torque values main shaft bearing setting plate 1.2kgf-m(12n.M) crank case bolt 1.1kgf-m(11n.M) tools special universal bearing puller bearing remover set, 15mm remover ass'y 15mm remover shaft remover head sliding weight thread adapter assem...

  • Page 108: Crankcase Disassembly

    10-3 crank case / transmission / crankshaft / kick starter crankcase disassembly ● the engine must be separated from the frame (⇨ section 5) ● refer to the service information for removal of necessary parts before disassembling the crankcase. Remove the cam chain set plate and cam chain. ● remove th...

  • Page 109: Transmission Disassembly

    10-4 crank case / transmission / crankshaft / kick starter inspection ● inspect the shift fork for wear and damaging. ● measure the shift fork inside diameter and projecting parts thickness in shift fork. Service limit: inside diameter: 12.05mm(0.474in) projecting parts thickness: 4.5mm(0.18in) ● in...

  • Page 110

    10-5 crank case / transmission / crankshaft / kick starter ● inspect the shift drum for wear and damaging. ● inspect the shift drum guide groove for partial wear and damaging. ● measure the main shaft and counter shaft outside diameter. Service limit: m3, m5:19.930mm(0.7486in) c1:16.440mm(0.6472in) ...

  • Page 111: Crankshaft Disassembly

    10-6 crank case / transmission / crankshaft / kick starter inspection ● install the crank shaft into the stand or v-block and measure the vibration of journal part. Service limit:right: 0.1mm(0.004in) left: 0.1mm(0.004in) ● measure the side gap of connecting rod end and crank weight. Service limit: ...

  • Page 112: Crankcase Bearing

    10-7 crank case / transmission / crankshaft / kick starter ● measure the state of vertical flux of the connecting rod end by x and y direction. Service limit:0.05mm(0.002in) crankcase bearing ● remove the transmission and crank shaft. Inspection ● turn the inner race of bearing with fingers and insp...

  • Page 113: Crankshaft Installation

    10-8 crank case / transmission / crankshaft / kick starter r. Crank case ● remove the main shaft bearing set plate. ● separate the main shaft bearing, counter shaft bearing and crank shaft bearing form crank case. ● coat the new bearing with clean engine oil and install it into crank case. ● insert ...

  • Page 114: Transmission Assembly

    10-9 crank case / transmission / crankshaft / kick starter transmission assembly ● coat the gear and gear bush with clean engine oil and install the mainshaft and counter shaft. ● check the gears for freedom of movement or rotation on the shaft. • note the installation direction of each snap ring. D...

  • Page 115: Kick Starter

    10-10 crank case / transmission / crankshaft / kick starter ● check the marks on the shift forks. - left fork: l. Mark - center fork: c. Mark - right fork: r. Mark kick starter removal ● remove the 16mm thrust washer, spindle collar, kick starter spring and spring retainer. ● install the shift fork ...

  • Page 116

    10-11 crank case / transmission / crankshaft / kick starter ● remove the 12mm thrust washer, snap ring, ratchet guide, plate, spring, 16mm trust washer and ratchet. ● measure the kick starter spindle outside diameter in the pinion gear part. Service limit: 19.90mm (0.783in) ● measure the pinion gear...

  • Page 117: Crankcase Assembly

    10-12 crank case / transmission / crankshaft / kick starter installation ● coat the pinion gear with clean engine oil. Install the gear into the 20mm thrust washer and tighten them with the snap ring. ● install the kick starter ratchet into the spindle, aligning the punch mark. Crankcase assembly ● ...

  • Page 118

    10-13 crank case / transmission / crankshaft / kick starter ● install the kick starter into the right crankcase, hanger the end of the kick starter spring on the case hole. ● after installation of the kick starter pedal temporarily, turn the kick starter to the right slowly to align the end of the s...

  • Page 119

    10-14 crank case / transmission / crankshaft / kick starter ● tighten the left crankcase bolt ina crisscross pattern in 2-3 steps. Torque: 1.1kgf-m(11n.M) ● install the cam chain and set plate. ● install the disassembled parts. ● install the engine on the frame. (⇨section 5) ● after replacing the o-...

  • Page 120: Cooling System

    11-1 cooling system 11. Cooling system service information ……………… 11-1 radiator ……………………………… 11-2 service information general the engine must be cool before servicing the cooling system. 11.

  • Page 121: Cooling System

    11-2 cooling system radiator hose inspection ● check if the radiator core is choked up or bended ● when bend of pin adjust the driver. ● inspect the hose or clamp of damage. Radiator removal ● remove the radiator grill ● remove the radiator from the frame. ● loosen the oil through bolt from the cyli...

  • Page 122: Seat/exhaust Muffler

    12-1 seat/exhaust muffler 12. Seat/exhaust muffler service information ……………… 12-1 side cover, seat …………………… 12-2 grab rail …………………………… 12-2 rear fender ………………………… 12-3 muffler ……………………………… 12-3 tool box ……………………………… 12-4 service information ● muffler is very hot after engine stops. Avoid inspection...

  • Page 123: Seat/exhaust Muffler

    12-2 seat/exhaust muffler side cover/seat side cover removal ● remove the r.Side cover. (removing with a lock key) ● loosen the screw with a “+” driver ● separate the side cover hook from grommet of frame. (when removing, remove the side cover with pushing toward the down.) seat removal ● remove 3 f...

  • Page 124: Seat/exhaust Muffler

    12-3 seat/exhaust muffler rear fender removal ● separate the seat and remove the code connection. ● remove the grab rail. (after removing, push the stay connecting bolt toward the inside.) ● remove the rear fender. (tail light is attached.) ● loosen the inside screws of rear fender. After removing t...

  • Page 125: Seat/exhaust Muffler

    12-4 seat/exhaust muffler tool box ● remove the r. Front cover (removing with a key.) ● loosen the tool box stay pinch bolt. ● assembly is done in reverse of disassembly. Muffler removal/assembly ● loosen the 3 pan screw of muffler protector and remove the protector. ● loosen the upper/low muffler b...

  • Page 126

    12-5 memo.

  • Page 127

    13-0 front wheel/front fork/steering.

  • Page 128: Service Information

    13-1 front wheel/front fork/steering service information ……………… 13-1 troubleshooting …………………… 13-2 handle bar ………………………… 13-3 front wheel ………………………… 13-6 front fork …………………………… 13-11 steering stem ……………………… 13-18 13. Front wheel/front fork/steering service information general ● contaminated brake di...

  • Page 129: Troubleshooting

    13-2 front wheel/front fork/steering tools special ball race driver steering stem driver fork seal driver steering stem socket common extension bar driver fork seal driver body lock nut wrench 30×32mm bearing remover shaft remover head attachment 42×47mm attachment 37×40mm pilot 12mm troubleshooting...

  • Page 130: Handle Bar

    13-3 front wheel/front fork/steering handle bar removal ● loosen the cable guide bolt and remove the guide. ● remove the starter kick switch, throttle cable and throttle grip. ● remove the master cylinder holder socket bolt with l.Wrench. ● remove the master cylinder holder. ● remove the master cyli...

  • Page 131

    13-4 front wheel/front fork/steering assembly ● install the handle into the top bridge connecting hole. ● tighten the handle washer and nut. Torque: 2.6kgf-m(26n.M) ● install the master cylinder into the handle bar with the “up” mark on the holder facing up. ● align the mating surface of the master ...

  • Page 132

    13-5 front wheel/front fork/steering ● apply grease to the ends of the throttle cable. ● install the throttle cable into the throttle pipe. ● install the lighting start switch housing mounting holder pin onto the handlebar hole and tighten the mounting holder pin. ● tighten the forward screws first,...

  • Page 133: Front Wheel

    13-6 front wheel/front fork/steering ● tighten the forward screws first, then tighten the rear screws. ● after installing the brake hose, kill switch cable, winker switch code and chock cable into the cable guide, tighten the guide. Inspection ● inspect the front axle for bent. ● install the front a...

  • Page 134

    13-7 front wheel/front fork/steering ● check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Service limit: radial runout: 2.0mm(0.08in) axial runout: 2.0mm(0.08in) wheel bearing inspection ● turn the inner race of each bearing...

  • Page 135

    13-8 front wheel/front fork/steering ● remove the bust seal of r. Side. ● remove the brake disc of l. Side. • inspection for the problems of disk. (⇨section 15-6) wheel bearing replacement ● install the bearing remover head and remover shaft into the wheel. Remove the distance collar and drive out o...

  • Page 136

    13-9 front wheel/front fork/steering assembly ● apply grease to the dust seal rim. ● install the dust seal, brake disk. ● install the brake disk. Torque: 4.2kgf-m(42n.M) ● install the right side collar. Dust seal dust seal dust seal dust seal dust seal dust seal dust seal dust seal dust seal dust se...

  • Page 137

    13-10 front wheel/front fork/steering ● loosen the brake disc by the disk bolt. ● align the speedometer gear retainer hole with the slot of the wheel hub. ● apply grease the dust seal rim. Install the dust seal. ● install the speedometer box, aligning the tangs in the speedometer gear retainer with ...

  • Page 138: Front Fork

    13-11 front wheel/front fork/steering ● loosen the fork tube cap bolt when disassem- bling the front fork. • don’t remove the fork tube cap bolt, but loosen it. • loosen the fork top socket bolt. • loosen the steering stem pinch flange bolt. • loosen the front fender pinch socket bolt. • remove the ...

  • Page 139

    13-12 front wheel/front fork/steering ● cover the bottom case with cloth, and remove the socket bolt. • if nto removing the socket bolt with turning, assemble temporarily the spring and fork tube cap bolt. • support the bottom case by vise strongly, preventing it from transformation or damaging. ● r...

  • Page 140

    13-13 front wheel/front fork/steering ● remove the set ring. ● remove the oil seal. • prevent the around of bottom case inside and outside from damaging. Inspection ● place the fork spring in flat place, and measure the fork spring free length. ● replace the new one if it is under the service limit....

  • Page 141

    13-14 front wheel/front fork/steering ● install the fork tube into v-block, and measure the bent with a dial gauge. Service limit: replacement if over 0.2mm ● inspect the contacted part of slider bush. Bottom case must be replaced if the copper portion is shown over three of quarter in teflon coatin...

  • Page 142

    13-15 front wheel/front fork/steering ● connect the rebound spring and fork piston into the fork tube. ● connect the oil lock piece into the piston top end part, and install the fork tube into the bottom case. ● cover the bottom case with cloth, and fix it into the vise. ● coat the bolt part of sock...

  • Page 143

    13-16 front wheel/front fork/steering ● install the set ring. ● install the set ring to bottom case exactly. ● install the dust seal. ● fill the auto-transmission fluid (aft) into the fork tube according to standard amount. Capacity: 280cm 3 ● pull out the air by pressing the fork tube 2-3 times slo...

  • Page 144

    13-17 front wheel/front fork/steering ● install the new o-ring to frok tube cap bolt. ● install the fork tube cap bolt to fork tube. • do not install the fork tube cap bolt again. Installation ● install the front fork into the steering stem, top bridge. ● align the top end of the fork tube with the ...

  • Page 145: Steering Stem

    13-18 front wheel/front fork/steering ● install the following: - brake caliper torque: 3.0kgf-m - front fender - front wheel (⇨13-6) steering stem removal ● remove the parts as following. - handle (⇨13-3) - remove the cable guide. - front wheel (⇨13-6) - front fender - brake caliper - front fork and...

  • Page 146

    13-19 front wheel/front fork/steering ● remove the steering head top thread. Tools: steering stem socket extension bar ● remove the steering upper bearing. Bearing replacement • always replace the bearing and races as a set. Tool: ball race driver ● to protect the nuts, install the stem nut into the...

  • Page 147

    13-20 front wheel/front fork/steering • if the motorcycle had caused an accident, check the steering head pipe for crack of damage. ● tighten the top thread. Torque: 1.8kgf tools: steering stem socket extension bar ● move the steering stem from side to side 4-5 times, and allow the steel ball to ope...

  • Page 148

    13-21 front wheel/front fork/steering ● after arranging the cable, install the cable guide. ● install the front fork. (⇨13-11) cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide cable guide ● install the par...

  • Page 149

    14-0 rear wheel/rear brake/suspension.

  • Page 150: Service Information

    14-1 rear wheel/rear brake/suspension service information ……………… 14-1 troubleshooting …………………… 14-2 rear wheel ………………………… 14-3 rear brake ………………………… 14-6 rear brake pedal …………………… 14-8 rear cushion ……………………… 14-8 rear fork …………………………… 14-10 14. Rear wheel/rear brake/suspension service information ge...

  • Page 151: Troubleshooting

    14-2 rear wheel/rear brake/suspension tools common rear cushion compressor rear cushion compressor attachment attachment, 32×35mm attatchment, 42×47mm pilot, 15mm driver bearing remover shaft remover head, 15mm troubleshooting wobble or vibration in motorcycle ● bent rim ● worn rear wheel bearings ●...

  • Page 152: Rear Wheel

    14-3 rear wheel/rear brake/suspension rear wheel removal ● raise and support the motorcycle with main stand. ● loosen the rear brake adjuster, remove the brake rod. ● loosen the chain adjusting nut. ● remove the axle nut, then disconnect the axle shaft. ● remove the drive chain by pressing the rear ...

  • Page 153

    14-4 rear wheel/rear brake/suspension ● check the teeth of the final driven sprocket. ● replace the worn, damaged final driven sprocket. • check the drive chain and drive sprocket at the same time. ● check the damper rubber. Replace the faulty, damaged, worn damper rubber. ● remove the dust seal if ...

  • Page 154

    14-5 rear wheel/rear brake/suspension ● coat the bearing with the grease. ● insert the new bearing in parallel with the seal side facing outside. After inserting the distance collar, insert the bearing of the right side with the seal side facing outside. Tools: driver attachment pilot, 15mm ● make t...

  • Page 155: Rear Brake

    14-6 rear wheel/rear brake/suspension ● install the chain adjuster, insert the axle shaft from the left side. ● install the chain case b. ● install the brake rod, brake adjusting nut. Check the drive chain operation. ● install the lock washer and axle nut. Torque: 8.8kgf-m ● adjust the brake pedal o...

  • Page 156

    14-7 rear wheel/rear brake/suspension assembly ● apply grease a little to the anchor pins and brake cam. ● assemble the brake cam. ● apply engine oil the dust seal, install it onto the brake panel. Install the wear indicator, aligning the punch mark on the brake cam with the gap. ● assemble the brak...

  • Page 157: Rear Brake Pedal

    14-8 rear wheel/rear brake/suspension rear brake pedal disassembly ● remove the bolts and brake pedal. ● loosen the rear brake adjusting nut and remove the brake rod from the brake arm. ● separate the stop switch spring from the return spring. ● tilt the motorcycle body to the left, remove the pedal...

  • Page 158

    14-9 rear wheel/rear brake/suspension disassembly ● install the rear cushion compressor and attachment. Tools: rear cushion compressor rear cushion attachment • avoid the upper joint from damage. ● fix the upper joint, and remove the upper joint by loosening the lock nut. ● remove the case, spring, ...

  • Page 159: Rear Fork

    14-10 rear wheel/rear brake/suspension ● coat the lock nut with oil to the thread, and install the rear cushion compressor attachment into the damper rod. ● coat the upper joint with oil to the thread and install it into the damper rod. ● fix the upper joint and tighten the lock nut. Torque: 3.8kgf-...

  • Page 160

    14-11 rear wheel/rear brake/suspension disassembly ● disassemble the rear sub fender. ● disassemble the chain slider. ● disassemble the rear fork pivot bearing. ● disassemble the dust seal and center collar. ● disassemble the pivot bush. ● inspect the center collar pivot bush for wear, damage, and d...

  • Page 161: Hydraulic Brake

    15-0 hydraulic brake.

  • Page 162: Hydraulic Brake

    15-1 hydraulic brake service information ……………… 15-1 troubleshooting …………………… 15-2 brake fluid/bleeding ……………… 15-3 brake pad …………………………… 15-4 brake disk …………………………… 15-6 brake caliper ……………………… 15-7 master cylinder …………………… 15-9 15. Hydraulic brake service information general do not allow foreign m...

  • Page 163: Hydraulic Brake

    15-2 hydraulic brake tools special snap ring pliers troubleshooting brake lever soft or too hard air bubbles in hydraulic system. Moisture in brake fluid. Brake pad and disk contaminated. Caliper piston worn. Master cylinder piston worn. Brake pad worn. Contaminated caliper inner part. Incorrectly i...

  • Page 164: Hydraulic Brake

    15-3 hydraulic brake brake fluid / bleeding brake fluid replacement • a contaminated brake disk or pad reduces stopping power. Discard contaminated pads and clean the disk with a high quality brake degreasing agent. • check the fluid level often while filling the reservoir. Avoid spilling fluid on p...

  • Page 165: Hydraulic Brake

    15-4 hydraulic brake if the brake bleeder is not available, use the following procedure. Fill the master cylinder reservoir to the upper level mark. Connect the bleeder hose to the bleed valve and bleed the system as follows. 1. Squeeze the brake lever, open the bleed valve 1/2 turn and then close t...

  • Page 166: Hydraulic Brake

    15-5 hydraulic brake remove the brake caliper from the left front fork. After removing the hanger pin(1pin) using by l. Lench, remove the piston. Remove the brake pad. Make sure that the pad spring is installed in the position shown. Install a new brake pad, pad pin retainer, hanger pins. Brake cali...

  • Page 167: Hydraulic Brake

    15-6 hydraulic brake install the brake caliper into the left front fork. • be careful not to damage the brake pad. Tighten the caliper bracket bolt. Torque: 3.0kgf-m tighten the hanger pin. Torque: 1.8kgf-m measure the brake disk for warpage. Service limit:0.3mm brake disk inspection measure the thi...

  • Page 168: Hydraulic Brake

    15-7 hydraulic brake brake caliper removal remove the brake hose bolt and brake hose from the brake caliper. Remove the caliper from the front fork, then remove the pad pin bolt, brake pad. ( 14-4) • avoid spilling brake fluid on painted, plastic, or rubber parts. • a contaminated brake disk or pad ...

  • Page 169: Hydraulic Brake

    15-8 hydraulic brake inspection inspect the caliper friction surface for damaging or crack. Measure the caliper inside diameter. Service limit: 34.02mm (1.339in) inspect the piston outside for damaging or crack. Measure the piston outside diameter. Service limit: 33.87mm (1.333in) assembly clean the...

  • Page 170: Hydraulic Brake

    15-9 hydraulic brake installation connect the brake hose to the caliper, and install the 2 sheets of sealing washer and brake hose bolt. Torque: 3.4kgf-m install the slide pin cap. Fill the brake fluid and bleed the mixed air. ( 15-3) master cylinder removal disconnect the brake light switch wires f...

  • Page 171: Hydraulic Brake

    15-10 hydraulic brake remove the washer, piston, spring from the master cylinder. Clean the master cylinder inside, resorber, master piston with brake fluid. Inspection inspect the piston circumference for damaging or crack. Inspect th primary cope and secondary cope for damaging and wear. Measure t...

  • Page 172: Hydraulic Brake

    15-11 hydraulic brake installation place the master cylinder into the handle bar. • install the holder with the “up” mark facing up. Align the end of master cylinder with the punch mark on the handle bar. • tighten the upper bolt first, then tighten the lower bolt. Install the brake hose to the mast...

  • Page 173: Charging System/battery

    16-0 charging system/battery regulator rectifier fuse battery ac generator.

  • Page 174: Charging System/battery

    16-1 charging system/battery service information ……………… 16-1 troubleshooting …………………… 16-2 battery ……………………………… 16-3 charging system inspection …… 16-5 regulator/rectifier ………………… 16-6 a.C generator inspection ………… 16-7 16. Charging system / battery service information general the battery contains s...

  • Page 175: Charging System/battery

    16-2 charging system/battery troubleshooting no power (main switch turned “on”) dead battery - low fluid level - low specified gravity - charging system failure disconnected battery cable main fuse burned out faulty ignition switch low power (main switch turned “on”) weak battery - low fluid level -...

  • Page 176: Charging System/battery

    16-3 charging system/battery battery removal remove the right side cover. Disassemble the battery holder. Remove the battery cable from the battery terminal. • remove the battery negative cable from the battery first, then the positive cable. Disconnect the battery bleed tube from the battery and re...

  • Page 177: Charging System/battery

    16-4 charging system/battery charging remove the battery caps. Fill the cells with distilled water to the upper level, if necessary. Connect the charger positive cable to the battery positive terminal. Connect the charger negative cable to the battery negative terminal. Charge the battery until spec...

  • Page 178: Charging System/battery

    16-5 charging system/battery charging system inspection leakage inspection turn the ignition switch off. Remove the negative cable from the battery. Connect the voltmeters between the negative cable and battery negative terminal. Measure the leakage voltage with the main switch off. • when measuring...

  • Page 179: Charging System/battery

    16-6 charging system/battery regulator/rectifier inspection of the harness circuit remove the left front side cover. Disconnect the voltage regulator / rectifier coupler. Check for continuity between each terminal and ground. Inspection regulator/rectifier inspection if there is no problem in the st...

  • Page 180: Charging System/battery

    16-7 charging system/battery ( - ) ( + ) red black yellow yellow green red ∞ ∞ ∞ ∞ black 1-30 0.05-20 0.5-20 0.2-1 yellow 0.5-10 ∞ ∞ ∞ yellow 0.5-10 ∞ ∞ ∞ green 1-30 0.2-1 0.5-10 0.5-10 replace the regulator / rectifier if the resistance is out of specification. Replacement remove the seat. Disconne...

  • Page 181: Ignition System

    17-0 ignition system a.C generator spark plug ignition coil cdi-unit.

  • Page 182: Ignition System

    17-1 ignition system service information ……………… 17-1 troubleshooting …………………… 17-2 c.D.I unit …………………………… 17-3 ignition coil inspection …………… 17-4 pulse generator …………………… 17-5 a.C. Generator inspection ……… 17-5 ignition timing inspection ……… 17-6 17. Ignition system service information general insp...

  • Page 183: Ignition System

    17-2 ignition system troubleshooting no spark at plug poorly connected, broken or shorted wires - between a.C. Generator and c.D.I unit - between c.D.I unit and ignition coil - between ignition coil and plug faulty main switch faulty ignition coil faulty c.D.I unit faulty a.C. Generator faulty pulse...

  • Page 184: Ignition System

    17-3 ignition system c.D.I unit c.D.I ignition circuit inspection • inspect the ignition system in proper sequence based on the troubleshooting table. Remove the side cover. Disconnect the cdi unit coupler, and measure the voltage between the terminals of the cdi unit coupler at the harness side cou...

  • Page 185: Ignition System

    17-4 ignition system ignition coil inspection remove the seat remove the fuel tank disconnect the primary circuit. Measure the ignition coil primary coil resistance between the ignition coil terminal and ground. Standard: (resistance) 0.2 0.02 (voltage) over 100v disconnect the spark plug caps from ...

  • Page 186: Ignition System

    17-5 ignition system performance test measure it using the daelim pva multi- tester. - pva multi-tester • well read the instruction manual of tester and handle it. Pulse generator disconnect the ac generator 3p coupler blue/yellow wire connector. Measure the resistance between green/white and blue/y...

  • Page 187: Ignition System

    17-6 ignition system ignition timing inspection • a cdi ignition system is used and it can not be adjusted. Inspect the ignition system if ignition timing is incorrect. Start the engine and warm it up. Remove the timing hole cap. Install the timing light into the high tension code. • handle the timi...

  • Page 188

    Memo.

  • Page 189: Electric Starter

    18-0 electric starter starter motor battery starter magnetic switch.

  • Page 190: Electric Starter

    18-1 electric starter service information ……………… 18-1 troubleshooting …………………… 18-1 starter motor ……………………… 18-2 starter magnetic switch ………… 18-5 18. Electric starter service information general the starter motor can be serviced with the engine in the frame. Specification troubleshooting starter mo...

  • Page 191: Electric Starter

    18-2 electric starter starter motor removal • turn the main switch off before servicing the starter motor. • the main switch on brings about an injury. Remove the starter motor cable from the motor. Remove the starter motor mounting bolt, and starter motor. Disassembly remove the following parts - m...

  • Page 192: Electric Starter

    18-3 electric starter inspect the continuity between cable terminal and case. Inspect the continuity between the terminal and brush. If it doesn’t have continuity between cable terminal and case, it is ok. If it doesn’t have continuity between the cable terminal and brush (case side), it is ok. Repl...

  • Page 193: Electric Starter

    18-4 electric starter assembly when removing the shim, install it by recorded order. Install the lock washer. Align the groove of front cover with the pin of brush holder and install them. Insert the armature into the brush holder center with driving each brush into the brush holder inside. Install ...

  • Page 194: Electric Starter

    18-5 electric starter starter magnetic switch inspection turn the main ignition switch “on”. There should be phonic signal in battery voltage while the starter magnetic switch is depressed. Tighten the two mounting bolts securely. Install the starter motor cable, tighten the terminal nuts securely. ...

  • Page 195: Electric Starter

    18-6 electric starter operation 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/red wire terminal and shown. There should be continuity. Ground circuit inspection disconnect the green/red wi...

  • Page 196

    Memo.

  • Page 197: Lights/switches/horn

    19-0 lights/switches/horn.

  • Page 198: Lights/switches/horn

    19-1 lights/switches/horn service information ……………… 19-1 troubleshooting …………………… 19-1 headlight …………………………… 19-2 speedometer/tachometer/fuel meter 19-2 tail/brake light …………………… 19-4 winker bulb ………………………… 19-5 winker ass y removal …………… 19-6 main switch ………………………… 19-7 handle switch ……………………… 19-...

  • Page 199: Lights/switches/horn

    19-2 lights/switches/horn speedometer/tachometer/fuelmeter removal loosen the speedometer cable nut and remove the cable from the meter. Remove the cable guide and meterstay from top bridge. Remove the seat and fuel tank, and separate the meter code from wire harness. Bulb replacement remove the hea...

  • Page 200: Lights/switches/horn

    19-3 lights/switches/horn meter bulb replacement loosen the 2 screw, and remove the speedometer. Loosen the 2 screw, and remove the tachometer. Take off the bulb socket, and replace the bulb. Remove the combination switch upper/ undercover. Remove the meter installation install the meter in the reve...

  • Page 201: Lights/switches/horn

    19-4 lights/switches/horn tail/brake light loosen the 2 screw remove the tail/brake light lens take off the bulb socket, and replace the bulb fuel mete removal remove the headlight and remove the individual code from the case. Loosen the 4 screw and remove the fuel meter from meter cover. Assembly i...

  • Page 202: Lights/switches/horn

    19-5 lights/switches/horn pull out the bulb and replace. Assembly is done in the reverse order of disassembly. Winker bulb loosen the screw and remove the winker unit. Remove the bulb in bulb socket by turning toward anti-clockwise take off the bulb by turning toward anti- clockwise, and replace it....

  • Page 203: Lights/switches/horn

    19-6 lights/switches/horn winker ass’y removal front loosen the head light case screw (2 screws) remove the winker connector connection in state of inclining for ward the head light lens. Remove the winker. • place the wiring and cables exactly according to a wiring diagram. • installation is done i...

  • Page 204: Lights/switches/horn

    19-7 lights/switches/horn main switch inspection remove the fuel tank. Disconnect the main switch code coupler connection. Check for continuity between terminals in each switch position. There should be a continuity between the colour coded wire. (○ ○) removal remove the combination switch upper/und...

  • Page 205: Lights/switches/horn

    19-8 lights/switches/horn handle switch remove the headlight case. Disconnect the handle bar switch couplers /connectors. Check for continuity between wire terminals. Continuity should exist between the colour coded wires o-o in each switch position. If the continuity is between o-o, it is correct. ...

  • Page 206: Lights/switches/horn

    19-9 lights/switches/horn gear chain switch disconnect the gear change switch wire coupler. Check for the continuity between the terminal and engine ground. Brake light switch front remove the headlight case. Disconnect the front brake light switch wire connectors and check for continuity between th...

  • Page 207: Lights/switches/horn

    19-10 lights/switches/horn the horn should sound when a fully charge 12v battery is connected across he horn terminals. Fuel unit remove the fuel tank. Drain fuel out of tank at clean container. Loosen the 4 nuts and remove the fuel unit from tank. • be careful float arm is not bended unit inspectio...

  • Page 208: Wiring Diagram

    20-1 wiring diagram 20. Wiring diagram 20

  • Page 209

    Memo.

  • Page 210: Troubleshooting

    21-1 troubleshooting engine does not starter is hard to start ……………………………………………… 21-1 engine lacks power ……………………………………………………………………… 21-2 poor performance(at low and idle speeds) …………………………………………… 21-3 poor performance (at high speed) ……………………………………………………… 21-4 poor handling ………………………………………………………………...

  • Page 211: Troubleshooting

    21-2 troubleshooting engine lacks power 1. Raise wheels off ground wheel don’t brake dragging and spin by hands. Spin freely. Worn or damaged wheel bearings wheel bearings need lubrication 2. Check tire pressure. Pressure low. Punctured tire faulty tire valve 3. Check clutch slipping. Engine speed n...

  • Page 212: Troubleshooting

    21-3 troubleshooting 10. Check oil level. Incorrect. Oil level too high. Oil level too low. Contaminated oil. 11. Remove cylinder head cover valve train clogged oil passage. And inspect lubrication. Lubricated clogged oil filter element. Properly. 12. Check for engine overheating excessive carbon bu...

  • Page 213: Troubleshooting

    21-4 troubleshooting poor performance(at high speed) 1. Check the ignition timing and incorrect. Faulty valve clearance adjustment. Valve clearance. Faulty cdi unit. Faulty pulse generator. Flywheel not installed properly. 2. Disconnect fuel tube at fuel flows carburetor choke closed. Carburetor. Re...

  • Page 214

    Sm38-9911-01e ■ head office:#16-6 pil-dong 2ka, chung-ku, seoul, korea tel:(82-2) 2267-6111 / fax:(82-2) 2269-7997 ■ factory:#58, sung san-dong, chang won, kyungnam, korea tel:(82-551) 279-1000 / fax:(82-551) 263-9761.