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  4. HISTORY 125 - SERVICE
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DAELIM HISTORY 125 - SERVICE Service Manual

Summary of HISTORY 125 - SERVICE

  • Page 2: Contents

    How to use this manual this manual describes effective maintenance procedure for the sl125 manufactured by daelim motor co., ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (section 3). Sections 1 through 3 pr...

  • Page 3: 1. Service Information

    1-1 1. Service information general safety · ·· ·· ·· ·· ·· ·· ·· · 1-1 service rules · ·· ·· ·· ·· ·· ·· ·· ·· ·· · 1-1 caution when wiring · ·· ·· ·· ·· · 1-5 serial number location · ·· ·· · 1-9 specifications · ·· ·· ·· ·· ·· ·· ·· ·· · 1-10 torque values · ·· ·· ·· ·· ·· ·· ·· ·· · 1-12 symbols ...

  • Page 4

    1-2 service information 9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils. 10. Recommended grease must be applied to or filled in the specified place. 7. A...

  • Page 5

    1-3 service information 11. Maintenance needed to use the specialized tools must performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the ball bearing by ...

  • Page 6

    1-4 service information 21. Keep the pneumatic system interior or the engine interior from the infiltration of dust. 22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone...

  • Page 7: Caution When Wiring

    1-5 service information •each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. •identify the two-colored cord by main color first and then spriped color . •...

  • Page 8

    1-6 service information •insert the lock of the coupler until the lock is fully secured. •turn off the main switch before connecting/dis- connecting. •release the lock to disconnect the lock of the coupler. •the lock of the coupler has two types according to releasing method(press type and pull type...

  • Page 9

    1-7 service information •wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part. •secure the wire harness firmly using the clamp. •insert the connector until the vinyl cover is fully inserted into the terminal. •...

  • Page 10

    1-8 service information •if necessary, lock the wire harness properly. •when mounting parts, make sure that the wire harness is not pressed by the parts. •in case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. •the wire must not hang down or ...

  • Page 11: Serial Number Location

    1-9 service information serial number location engine serial number location frame serial number location.

  • Page 12

    1-10 service information item specifications 1,965 mm 690 mm 1,230 mm 1,350 mm 780 mm 120 mm 125 kg 255 kg underbone telescopic / 77mm swing arm / 66mm 120 / 70 - 12 53k / tubeless 130 / 70 - 12 62k / tubeless 2.00 kgf / ㎠ (200 kpa) 2.00 kgf / ㎠ (200 kpa) 2.00 kgf / ㎠ (200 kpa) 2.25 kgf / ㎠ (225 kpa...

  • Page 13

    1-11 service information item specifications cv type ( vacuum ) 24.2 mm bds 26 - 112 auto-bystarter # 95 1 and ½ trust out 13 mm 1.800±100 ( rpm ) automatic transmission 3.231 (42/13) 2.786 (39/14) c.D.I ignition 15。 btdc / 1.800 ( rpm ) 12v 10a / 5,000 ( rpm ) closed type (mf) 12v 8ah cr8eh - 9 (ng...

  • Page 14: Torque Values

    1-12 service information item reference torque value thread dia (mm) q’ty 1.1 kgf·m 2.5 kgf·m 0.8 kgf·m 1.0 kgf·m 5.5 kgf·m 7.5 kgf·m 5.5 kgf·m 1.0 kgf·m 1.2 kgf·m 5.5 kgf·m 2.0 kgf·m 1.0 kgf·m 0.4 kgf·m 0.9 kgf·m 1.2 kgf·m 1.0 kgf·m 0.9 kgf·m 1.0 kgf·m 9.5 kgf·m 0.9 kgf·m 3.2 kgf·m 1.0 kgf·m 1.0 kg...

  • Page 15

    1-13 service information item reference torque value thread dia (mm) q’ty 4.5 kgf·m 2.7 kgf·m 0.6 kgf·m 2.3 kgf·m 1.8 kgf·m 1.8 kgf·m 0.15 kgf·m 3.0 kgf·m 1.0 kgf·m 1.0 kgf·m 10 kgf·m 0.4 kgf·m 4.0 kgf·m 4.0 kgf·m 4.0 kgf·m apply locking agent apply locking agent 10 8 8 8 8 8 4 10 6 6 6 5 10 10 10 1...

  • Page 16: Symbols / Abbreviations

    Symbol caution note symbol 1-14 service information symbols / abbreviations the following symbols are used in this manual to represent job-related warnings or cautions. Meaning indicates dangerous area. Serious accident may result if instructions are not followed. The following symbols indicate oil ...

  • Page 17: Wiring Diagram

    1-15 service information wiring diagram fr. Brake hose frame earth connector (tight at the same time with the reg. Rec.) throttle cable starter s/w unit fr. Stop s/w connector fr. Brake hose seat open cable reg. Rectifier main s/w speedometer cable cable guide rr. Brake hose rr. Stop s/w connector h...

  • Page 18

    1-16 service information master cylinder ass'y fr. Brake hose speedometer cable throttle cable main s/w seat lock cable wire harness air cleaner trunk lamp trunk lamp s/w parking brake cable rr. Brake hose b bleeder tube battery earth cable high tension cord throttle cable wire harness rh. Radiator ...

  • Page 19: 2. Lubrication

    2-1 2. Lubrication service information general safety warning 1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. 2. Used engine oil may cause skin cancer if repeatedly left in contect with the skin for prolonge...

  • Page 20: Troubleshooting

    2-2 lubrication troubleshooting oil level low •oil consumption. •external oil leaks. •worn piston ring or incorrect piston ring installation. •worn valve guide or seal. Oil contamination •oil or filter not changed often enough. •faulty head gasket. •worn piston rings. Low or no oil pressure •clogged...

  • Page 21: Engine Oil Level Inspection

    Engine oil level inspection ● erect the motorcycle on the main stand. ● warm up the engine to heat the engine oil to an appropriate level. ● stop the engine, and check the oil level line on the sight-glass installed on the lh. Crank case cover. ● if the oil level is between the lower and higher sigh...

  • Page 22: Oil Filter Element Change

    Oil filter element change ●drain engine oil. ( ⇨ 2-3) ●loosen the 3 flange bolts securing the oil filter cover, remove the oil filter cover. ●remove the oil filter element and oil filter spring. ●change the oil filter element with a new one. ●check if the oil filter seal is in good condition. ●assem...

  • Page 23

    Oil pump disassembly ●loosen the screw securing the oil pump plate. ●remove the oil pump body and the oil pump plate. ●clean the oil pump body, inner and outer rotors with fresh cleaning oil. Oil pump inspection ●assemble the inner and outer rotors to the oil pump body. ●measure the pump body cleara...

  • Page 24

    2-6 lubrication pump plate pump body inner rotor pump shaft outer rotor roller2.5x11.8 inner rotor outer rotor pump plate pan screw flat screw oil pump assembly ●clean all parts with fresh cleaning oil. ●install the inner and outer rotors to the pump body. ●assemble the pump shaft with setting pin. ...

  • Page 25: Radiator

    Radiator removal ●remove the front cover. ( ⇨ 4-3) ●remove the front wheel. ( ⇨ 12-5) ●loosen the 2 oil bolts and the 4 drain cock packings from the main pipe bracket. ●loosen the 3 flange bolts securing the radiator. ●remove the radiator. Caution •be careful not to damage the radiator when removing...

  • Page 26: Transmission Oil Inspection

    Radiator installation ●tighten the 3 radiator setting flange bolts to the main pipe bracket. ●tighten the drain cock packings and oil bolts. Torque value : 3.2kgf · m ●install the front wheel. ( ⇨ 12-9) ●install the front cover. ( ⇨ 4-3) caution •pay attention not to turn over the vehicle. •when ins...

  • Page 27: Lubrication Points

    Lubrication points unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. Control cable lubrication remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it. 2...

  • Page 28: Memo

    Memo.

  • Page 29: 3. Inspections/adjustments

    3-1 3. Inspections/adjustments service information warning ●the exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. Specifications tires 3 service information · ·· ·· · 3-1 maintenance schedule ·· 3-3 fuel line (fuel t...

  • Page 30

    Torque values spark plug 1.1kgf·m cylinder head cover bolts 1.0kgf·m valve adjusting nuts 1.1kgf·m timing hole cap 0.6kgf·m tools wrench 8x9mm adjust wrench compression gauge 3-2 inspections / adjustments.

  • Page 31: Maintenance Schedule

    3-3 inspections / adjustments maintenance schedule ● carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : inspect and clean, adjust, lubricate or replace if necessary. R : replace l : lubricate c : clean ● these instructions...

  • Page 32: Fuel Line(Fuel Tube)

    Fuel line(fuel tube) ● remove the luggage box .( ⇨ 4-4) ● check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. Throttle grip operation ● check if the throttle grip operates smoothly in any steering position. ● if t...

  • Page 33: Spark Plug

    ● be sure to allow the element to dry thoroughly before applying oil. Otherwise, the oil will be diluted by the and the filtering ability of the filter will be much less effective. ● spread clean #80~90 gear oil on the element, rubbing inthoroughly over the surface with both hands, and then squeeze ...

  • Page 34: Carburetor Idle Speed

    ● loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. ● after setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut. Torque values : 1...

  • Page 35: Brake Fluid

    Brake fluid ● loosen the 3 screen setting screws securing the wind screen. ● remove the oil cup cap covers. ● check the oil level inside the front/rear brake reservoirs. If the oil level is near the lower limit line, remove the reservoir diaphragms and fill dot 3 and dot 4 brake fluid to the top lim...

  • Page 36: Headlight Aim

    Brake lever free play ● check the free play after pulling the lever. Front : 10~20mm rear : 10~20mm parking brake free play adjustment ● turn the adjuster nut to adjust the free play. ● after initial adjustment, check the operation of the parking brake light switch. Make additional adjustments, if n...

  • Page 37: Suspension

    ● check the side stand ignition cut-off switch : -put the side stand up. -start the engine. -lower the side stand. The engine should stop as you put the side stand down. ● if there is a problem with the system, check the side stand switch. Suspension note •do not ride motorcycle with an unsatisfacto...

  • Page 38: Wheels/tires

    Wheels/tires note •check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. Standard pressure ● check the tread depth at the tire center. ● if the tread depth has reached t...

  • Page 39: 4. External Parts

    4-1 4. External parts service information note ● this section describes external parts removal/installation. ● do not apply unreasonable force when disassembling covers, to prevent possible damage. ● a muffler is hot. Do not service it immediately after the engine is stopped. 4 service information ·...

  • Page 40: Maintenance Procedure

    4-2 external parts 2 4 3 13 16 21 17 11 8 9 9 10 6 5 12 15 20 7 22 14 1 19 18 maintenance procedure names of frame covers ● this chart shows arrows connected in the order of disassembling covers. ① front cover ② front fender ③ front wheel ④ front under cover ⑪ rear combination light ⑤ seat ⑥ luggage...

  • Page 41: Front Cover

    4-3 external parts special screw special screw special screw special screw front cover special screw special screw front fender front cover ● loosen the 4 special screws securing the inner box. ● loosen the special screw securing the front of the front cover. ● loosen the 2 special screws securing t...

  • Page 42: Front Under Cover

    4-4 external parts tapping screw flange bolt special screw open stay nut fuel tank cap fuel guide rubber screw trunk lamp front under cover ● remove the front fender. ( ⇨ 4-3) ● remove the front wheel. ( ⇨ 12-5) ● loosen the 4 tapping screws securing the inner box. ● remove the floor mat, and loosen...

  • Page 43: Center Cover

    4-5 external parts seat washer screw special screw plug maintenance cover center cover flange bolt hinge pin special screw rear center cover special screw washer screw rh. Rear winker assembly reflex reflector special screw special screw lh. Rear winker assembly washer screw center cover ● release t...

  • Page 44: Rear Carrier/back Rest

    4-6 external parts special bolt back rest flange bolt rear carrier flange bolt special screw special screw body cover clip upper body cover rear reflector tapping screw tapping screw special screw body cover clip body cover rear carrier/back rest ● remove the rear center cover. ( ⇨ 4-5) ● loosen the...

  • Page 45: Rear Combination Light

    4-7 external parts tapping screw rear combination light washer screw body cover special screw body cover clip lh. Floor side cover special screw rear combination light ● release the seat lock by turning the main switch key to open the seat. ● remove the seat. ● remove the following parts. -luggage b...

  • Page 46: Floor Panel

    4-8 external parts floor mat tapping screw battery cover floor panel under cover setting screw battery washer bolt washer bolt floor panel ● release the seat lock by turning the main switch key to open the seat. ● remove the following parts. -seat and center cover ( ⇨ 4-5) -rear carrier and back res...

  • Page 47: Inner Box / Inner Box Lid

    Inner box / inner box lid ● remove the following parts. -front cover ( ⇨ 4-3) -luggage box ( ⇨ 4-4) -center cover ( ⇨ 4-5) -rear center cover ( ⇨ 4-5) -rear carrier and back rest ( ⇨ 4-6) -body cover ( ⇨ 4-6) -floor side cover ( ⇨ 4-7) -floor panel ( ⇨ 4-8) ● loosen the 2 tapping screws securing the...

  • Page 48: Wind Screen /

    Wind screen / front handle cover ● loosen the 3 screen setting screws securing the front handle cover. ● pulling the cover to the under slightly and remove the wind screen from the front handle cover groove. ● loosen the 4 tapping screws (fr./rr.) securing the rear handle cover. ● loosen the front h...

  • Page 49: Rear Wheel Mud Guard

    Rear wheel mud guard ● loosen the washer bolt securing the lh. Crankcase. ● loosen the washer bolt securing the rh. Crankcase. ● loosen the washer bolt securing ex. Muffler bracket. ● remove the rear wheel mud guard. ● install in the reverse order of removal. Note •never perform the maintenance of t...

  • Page 50: Muffler

    Muffler removal ● loosen the 3 cap nuts securing the ex. Pipe comp. ● loosen the flange bolt securing the upper part of the rh. Crankcase cover. ● loosen the rear brake hose setting bolt. ● loosen the flange bolt securing the rear wheel mud guard. ● loosen the 2 flange bolts securing the lower part ...

  • Page 51: Memo

    Memo.

  • Page 52

    Fuel system 5-0 fuel tank fuel strainer fuel pump carburetor.

  • Page 53: Service Information

    Service information general safety warning ● gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. ● exhaust gas contains poisonous substance. Do...

  • Page 54: Troubleshooting

    5-2 fuel system troubleshooting the vehicle does not start. ● no gasoline in fuel tank. ● fuel is not coming out of carburetor. ● too much fuel is flowing into cylinder. ● no spark emitted from spark plug. ● air cleaner is blocked. ● suction system is experiencing secondary intake of air. ● using lo...

  • Page 55: Fuel Tank

    5-3 fuel system fuel tank fuel tube fuel pump flange bolt fuel unit coupler flange bolt fuel tank cap fuel tank removal warning •gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthermore, the evaporated (gasified) gasoline is highly explosi...

  • Page 56: Air Cleaner

    5-4 fuel system flange bolt coupling band a intake coupling coupling band b air cleaner duct clip inlet duct flange bolt air cleaner throttle cable setting screw carburetor insulator band 46 auto bystarter wiring air cleaner removal ● remove the luggage box. ( ⇨ 4-4) ● remove the center cover. ( ⇨ 4...

  • Page 57

    5-5 fuel system needle screw diaphragm jet needle spring spring holder jet needle holder screw air band hose drain tube diaphragm spring diaphragm diaphragm cover carburetor disassembly ● remove the drain tube and air band hose. ● loosen the 4 diaphragm cover setting screws. ● remove the diaphragm c...

  • Page 58

    5-6 fuel system screw screw float body ass'y pin float valve float float valve seat slow jet main jet holder main jet float chamber/float/jet disassembly ● loosen the 4 screws securing the float body. ● remove the float pin, float, and float value. ● check the float valve and valve seat for scores, ...

  • Page 59

    5-7 fuel system carburetor body plunger ass'y diaphragm cover spring jet needle diaphragm slow jet main jet needle jet float body float float valve pilot jet pilot jet carburetor cleaning ● after removing all parts, blow open air and fuel passages in the carburetor body with compressed air. Caution ...

  • Page 60

    5-8 fuel system float level gauge float body diaphragm diaphragm cover float level inspection ● install the float valve, float, float pin. ● measure the float level with the float level gauge. Float level : 13 mm tool : float level gauge ● if the level is out of specification and the float arm lip c...

  • Page 61

    5-9 fuel system insulator band throttle cable setting screw negative pressure tube socket bolt insulator insulator band setting plate o-ring insulator caburetor installation ● install the carburetor to the carburetor insulator. ● tighten the carburetor insulator band screw. ● tighten the setting scr...

  • Page 62: Pilot Screw Adjustment

    Pilot screw adjustment ● remove the luggage box. ( ⇨ 4-4) ● remove the pilot jet rubber. ● remove the plug maintenance cover. ( ⇨ 4-5) ① turn the pilot screw clockwise until it seats lightly, then back it out to the specification given (1½). ② warm up the engine to operating temperature (60℃). ③ adj...

  • Page 63: 6. Engine Removal

    6-1 6. Engine removal service information general safety note •use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •attach tape to the frame to protect it during the engine removal or installatio...

  • Page 64: Engine Removal

    6-2 engine removal starter motor cable acg wiring coupler battery earth cable adjuster nut b rear brake caliper under cover engine removal ● drain the engine oil. ● release the seat lock by turning the main switch key to open the seat. ● remove the following parts. -luggage box ( ⇨ 4-4) -center cove...

  • Page 65

    6-3 radiator hose lower bolt engine removal u-nut ● remove the rh./lh. Radiator hose, remove the rh./lh. Radiator hose from the frame setting clamp. ● loosen the u-nut securing the engine hanger. ● loosen the rear cushion lower bolt. ● remove the engine. (with the rear swing arm and rear wheel attac...

  • Page 66

    7-0 lh. Crankcase cover/kick starter/continuously variable transmission lh. Crankcase cover.

  • Page 67: Service Information

    7-1 7. Lh. Crankcase cover/kick starter /continuously variable transmission service information general safety ● do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil contact. ● do not operate starter motor while the lh. Crank case ...

  • Page 68: Lh. Crankcase Cover

    Lh. Crankcase cover removal ● remove the 12 flange bolts securing lh. Crankcase. ● remove the lh. Crankcase cover. ● remove the gasket and dowel pin. Installation ● install the new gasket and dowel pin after removing the gasket of the crankcase surface. Note ·align the bolts to uniform the tightenin...

  • Page 69: Kick Starter

    Kick starter removal ● remove the lh. Crankcase cover. ( ⇨ 7-2 ) ● rotate the kick starter spindle using the kick starter pedal, remove the kick driven gear and 13mm thrust washer. ● loosen the kick starter pedal bolt. ● remove the kick starter pedal. ● remove the 14mm external circlip. ● remove the...

  • Page 70

    ● after removing the kick starter spindle from the return spring, remove the kick starter spindle from the lh. Crankcase cover. ● remove the kick starter return spring, kick starter bush from the lh. Crankcase cover. Kick starter inspection ● check the kick starter spindle for wear or damage. ● chec...

  • Page 71

    Kick starter installation ● install the kick spindle bush, spring in the lh. Crankcase cover. ● install the kick starter spindle, then install the return spring to the kick starter spindle. ● install the kick starter spindle washer and 14mm external cir-clip. ● install the kick starter pedal to the ...

  • Page 72: Drive Belt

    Drive belt removal ● remove the lh. Crankcase cover. ( ⇨ 7-2 ) ● hold the clutch outer using the universal holder and remove the nut. ● remove the clutch outer. Tool: universal holder caution ·use the special tool when loosening the lock nut. Holding the rear wheel or rear brake will damage the fina...

  • Page 73

    Drive belt inspection ● check the drive belt for cracks, pry separation and wear; replace as necessary. ● measure the width of the drive belt as shown. ● replace the belt if the service limit is exceeded. Service limit : 20.5mm note ·use only a genuine daelim replacement drive belt. ·do not get oil ...

  • Page 74: Movable Drive Face

    ● reinstall the driven pulley on the drive shaft with the drive belt attached. ● hold the clutch outer using the universal holder. Tighten the nut to the specified torque. Torque value : 5.0-6.0 kgf · m tool : universal holder ● reinstall the lh. Crankcase cover. ( )xh @)x?G @v/xg @?V/x?F @@@@@@@@@@...

  • Page 75

    Movable drive face inspection ● the weight rollers push on the movable drive face (by centrifugal force); worn or damaged weight rollers will interfere with this force. ● check the rollers for wear or damage and replace as necessary. ● measure the o.D. Of each roller, replace if the service limit is...

  • Page 76

    ● install the movable drive face on the crank shaft. ● squeeze the drive belt into the drive face groove and pull the drive belt over the drive face shaft. ● install the drive face and kick starter ratchet, temporarily tighten the drive face nut. ● hold the drive face using the drive face holder and...

  • Page 77: Clutch/driven Pulley

    Clutch/driven pulley removal ● remove the lh. Crankcase cover. ( )xh @)x?G @v/xg @?V/x?F @@@@@@@@@@@??V/xf @?Hfv/x?E @?Hf?V/xe @? N1e @? J5e @?Hf?W.Ye @@@@@@@@@@@?Ew.Y?E @??W.Yf @?W.Y?F @w.Yg @(y?G (yh 7-2) ● remove the drive face. ( )xh @)x?G @v/xg @?V/x?F @@@@@@@@@@@??V/xf @?Hfv/x?E @?Hf?V/xe @? N...

  • Page 78

    ● remove the seal collar from the driven pulley. ● remove the guide pins and guide pin rollers and the movable driven face. ● remove the o-ring and oil seals from the movable driven face ● remove the movable driven face. 7-12 lh. Crankcase cover/kick starter/continuously variable transmission.

  • Page 79

    Clutch / driven pulley inspection driven face bearing inspection ● check the inner bearing oil seal (if installed) for damage; replace as necessary. ● check the needle bearing for damage or excessive play and replace as necessary. ● turn the inner race of the outer bearing with your finger. Check th...

  • Page 80

    ● check the following; -movable driven face for damage or excessive wear. -guide pin groove for damage or deformation. ● replace damaged or worn parts as necessary. ● measure the i.D. Of the movable driven face; replace if the service limit is exceeded. Service limit : 38.060 mm ● check the driven f...

  • Page 81

    Clutch / driven pulley assembly ● install new oil seals and o-rings on the movable driven pulley face. ● install the movable face on the driven pulley face. ● install the guide pins, or guide pins and guide pin rollers. ● install the seal collar. ● assemble the driven pulley, spring and clutch in th...

  • Page 82

    Clutch/driven pulley installation ● install the clutch / driven pulley and drive belt onto the drive shaft. ● install the drive belt. ( )xh @)x?G @v/xg @?V/x?F @@@@@@@@@@@??V/xf @?Hfv/x?E @?Hf?V/xe @? N1e @? J5e @?Hf?W.Ye @@@@@@@@@@@?Ew.Y?E @??W.Yf @?W.Y?F @w.Yg @(y?G (yh 7-6) ● install the drive fa...

  • Page 83: Memo

    Memo.

  • Page 84

    8-0 flywheel stator comp rh. Shroud cooling fan a.C generator / starter clutch.

  • Page 85: Service Information

    8-1 8. A.C generator / starter clutch service information general safety ● this section describes the removal and assembling of the a.C generator. ● for information on a.C generator inspection, refer to the section 15. ● the charging system can be maintained without removing the engine. Specificatio...

  • Page 86: Shroud

    8-2 a.C generator / starter clutch rh. Shroud setting screw lh. Shroud a.C.G wiring coupler cooling fan shroud removal ● remove the following parts. -luggage box (⇨ 4-5 ) -center cover (⇨ 4-5 ) -engine (⇨ 6-2 ) ● loosen the rh. Shroud 4 flange bolts and 4 tapping screws. ● remove the rh. Shroud. ● l...

  • Page 87

    8-3 a.C generator / starter clutch flange nut drive face holder universal holder a,c,g. Rotor puller flywheel pan screws pan screws ● install the universal holder on the flywheel. ● if the universal holder connot be used, remove the lh. Crankcase cover at the left side of the crankshaft, and hold th...

  • Page 88: Rh. Crankcase Cover

    8-4 a.C generator / starter clutch drive face holder pan screw pan screw universal holder cooling fan rh. Crankcase cover a.C generator installtion ● install the stator to the rh. Crankcase cover. ● clean the tapered portion of the crankshaft. ● clean the inside part of the flywheel. ● check the woo...

  • Page 89: Starter Reduction Gear

    8-5 a.C generator / starter clutch oil seal rh. Crankcase cover reduction gear shaft starter reduction gear shaft dowel pin ● loosen the 9 rh. Crankcase cover setting bolts. ● remove the rh. Crankcase cover. ● remove the gasket and dowel pin. ● remove the rh. Crankcase cover oil seal. ● check the oi...

  • Page 90: Starter Clutch

    8-6 a.C generator / starter clutch reduction gear shaft rh. Crankcase cover starter clutch special socket (12.7x28x120) starter reduction gear installation ● install the starter reduction gear and shaft. ● remove the gasket residues from the rh. Crankcase. ● install a new gasket and dowel pin. ● tig...

  • Page 91

    8-7 a.C generator / starter clutch starter clutch washer starter clutch starter driven gear starter oneway clutch set a b ● remove the washer. ● remove the starter driven gear and starter clutch. ● check the starter driven gear and starter clutch for proper operation. ● remove the starter clutch. St...

  • Page 92

    8-8 a.C generator / starter clutch starter oneway clutch set lock nut special socket rh. Crankcase cover starter clutch installation ● install the starter oneway clutch set, starter driven gear and needle bearing to the starter clutch assembly. ● install the starter clutch to the rh. Crankshaft. Not...

  • Page 93: Memo

    Memo.

  • Page 94

    9-0 cylinder head / valves cam cover plate in. Valve rocker arm ex. Valve rocker arm cam shaft holder cam shaft comp carburetor insulator cylinder head comp cylinder head gasket inlet valve ex. Valve.

  • Page 95: 9. Cylinder Head / Valves

    9-1 9. Cylinder head / valves service information general safety ● the rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed from the frame to maintain the cylinder head. ● the oil of camshaft oil is supplied through the cylinder head oil hole. ...

  • Page 96: Troubleshooting

    Tools valve guide reamer valve guide driver valve spring compressor valve seat cutter seat cutter in 37°(21.5mm) ex 37°(18.5mm) in 45°(22.0mm) ex 45°(22.0mm) in 55°(20.0mm) ex 55°(20.0mm) troubleshooting enging top-end problems useally affect engine performance. These can be diagnosed by a compressi...

  • Page 97: Camshaft

    Camshaft removal ● remove the luggage box. ( ⇨ 4-4 ) ● remove the center cover. ( ⇨ 4-5 ) ● loosen the cylinder head cover bolts, remove the cover. ● remove the shroud grommet b of the fan cover. Note ·the camshaft can be maintained without removing the engine. ● turn the crankshaft to the left, and...

  • Page 98

    ● remove the cam chain from the camshaft. Note ·take precautions not to allow the cam chain to drop into the crankcase. ● remove the camshaft. ● insert the 6mm bolt into the rocker arm shaft, and pulling bolts to remove the rocker arm shaft. ● remove the rocker arm. ● remove the other side rocker ar...

  • Page 99: Cylinder Head

    ● manually turn the camshaft bearing outer race, and check if it turns smoothly. ● check the bearing for wear or damage. Caution ·be sure to check the valve clearance. Cylinder head removal ● remove the engine from the frame. ( ⇨ 6-2 ) ● remove the cylinder head cover. ● remove the rh. Lh. Shroud. (...

  • Page 100: Valve Springs

    ● remove the valve spring, valve cotter, retainer, spring and valve. Using the valve spring compressor. Tool : valve spring compressor note ·to prevent the loss of tension, do not compress the valve spring more than necessary. ·mark the disassembled parts so that they can be reassembled into the ori...

  • Page 101: Valve Guides

    Valve guides inspection ● insert the valve guide reamer from the combustion chamber side and ream the guide to remove any carbon build-up before measuring the guide. Note ·take care not to tilt or lean the reamer in the guide while reaming. Otherwise, the valve is installed slanted, that causes oil ...

  • Page 102: Valve Seats

    ● support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. Tool : valve guide driver caution ·avoid damaging the head when driving the valve guide out. ● apply oil to a new o-ring and install it onto a new valve guide. ● drive the new guide in from ...

  • Page 103

    ● remove the valve and inspect the valve seat face. ● the valve seat contact should be within the specified width and evenly all around the circumference. If the valve seat width is not within specification, reface the valve seat. Note ·valve faces and stem tips cannot be ground. If a valve face or ...

  • Page 104

    ● using a 55 degree cutter, remove the bottom ¼ of the old seat. ● using a 45 degree cutter, cut the seat to the proper width. ● if the contact area is too high on the valve, the seat must be lowered using a 37 degree flat cutter. Refinish the seat to specifications, using a 45 degree finish cutter....

  • Page 105: Cylinder Head Assembly

    ● after cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. Note ·do not excessively press and turn the valve to set it as it may cause damage. Gently strike and set the valve. ·the seat surface may become worn on one side if the valve is...

  • Page 106

    ● tap the valve stems gently with a soft hammer to firmly seat the cotters. Caution ·take necessary precautions not to damage the valve. ● apply engine oil to the new o-ring, and assemble it to the carburetor insulator groove. ● tighten the carburetor insulator with mounting bolts. ● install the cam...

  • Page 107: Camshaft Assembly

    Camshaft assembly ● apply engine oil to the rocker arm shaft, and assemble the rocker arm to the camshaft holder. ● tighten the rocker arm shaft with 6mm bolts, and align the bolt hole of the camshaft holder with the fitting side of the rocker arm shaft. ● check the camshaft assembly for abnormal co...

  • Page 108

    ● apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. ● assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head. ● install the dowel pins on the cylinder head. ● install t...

  • Page 109

    ● fix the tensioner shaft with a hard clip. ● assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. ● tighten the tensioner mounting bolts. Torque value : 1.2 kgf · m ● remove the tensioner shaft clip from the tensioner lifter. Assemble the o-ring and pan s...

  • Page 110

    10-0 cylinder / piston cylinder cylinder gasket piston top ring second ring oil ring.

  • Page 111: 10. Cylinder / Piston

    10-1 10. Cylinder / piston service information general safety ● be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to t...

  • Page 112: Cylinder

    10-2 cylinder / piston cam chain guide cylinder comp dowel pin piston cylinder gauge top middle bottom cylinder removal ● remove the engine from the frame. (⇨ 6-2 ) ● remove the ex. Pipe. (⇨ 4-12 ) ● remove the camshaft. (⇨ 9-3 ) ● remove the cylinder head. (⇨ 9-5 ) ● remove the cam chain guide from...

  • Page 113: Piston / Piston Ring

    10-3 cylinder / piston feeler gauge straight edge piston piston ring warpage inspection ● check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. Service limit : 0.02 mm note ·any clearance between the c...

  • Page 114

    10-4 cylinder / piston feeler gauge 90° specified distance 1 2 3 ● insert the piston ring into the bottom of the cylinder squarely, using the piston. ● measure the end gap using a feeler gauge. Replace the ring if the service limit is exceeded. Note ·always replace piston ring as a set. Service limi...

  • Page 115

    10-5 cylinder / piston top ring second ring side rail piston spacer oil ring side rail 20mm 20mm 120° 120° mark r crank shaft piston / piston ring installation ● clean the piston heads, ring lands and skirts. ● carefully install the piston rings onto the piston with the markings facing up. Note ·be ...

  • Page 116

    10-6 cylinder / piston piston pin dowel pin gasket cylinder cam chain guide cam chain ● install new piston pin clips. Caution ·always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. Note ·take care not to drop the piston pin clip into the crankcase. ·s...

  • Page 117: Memo

    Memo.

  • Page 118

    11-0 transmission/crankshaft/crank case rh. Crankcase lh. Crankcase crankshaft.

  • Page 119: Service Information

    11-1 11. Transmission/crankshaft/crankcase service information general safety ● this section describes how to remove the crank case and to maintain the transmission and the crankshaft. ● service transmission without removing the engine from the vehicle. However, to prevent damage to the lh. Crank ca...

  • Page 120: Troubleshooting

    Torque value crank case bolt 1.0kg-m tools -universal bearing puller -bearing remover set -remover assembly -remover shaft -remover head -sliding weight -assembly shaft troubleshooting engine noise ● connecting rod big and small ends loose. ● crank pin bearing loose. Engine started but unable to mov...

  • Page 121: Transmission

    Transmission disassembly ● loosen the drain bolt, drain the mission oil. ● remove the lh. Crankcase cover. ( ⇨ 7-2 ) ● remove the continuously variable transmission. ( ⇨ section 7 ) ● remove the ex. Muffler. ( ⇨ 4-12 ) ● remove the rear swing arm. ( ⇨ 13-8 ) ● remove the rear brake caliper. ( ⇨ 14-6...

  • Page 122

    ● remove the final shaft and the counter shaft comp. Transmission inspection ● check the drive shaft for wear or damage. ● check the final shaft for wear or damage. ● check the counter shaft for wear or damage. 11-4 transmission/crankshaft/crank case final shaft counter shaft final shaft counter sha...

  • Page 123

    Transmission bearing inspection ● check that the bearing outer race fits the case tightly without play. ● turn the inner race and check that the bearing turns smoothly and quietly. ● replace the bearings if necessary. ● install the bearing to the case with special tools. Tools : drive handle a outer...

  • Page 124: Crank Case Removal

    ● install a new gasket and dowel pin. ● tighten the transmission cover with the setting bolts. ● install the following parts. -rear wheel ( ⇨ 13-3 ) -rear swing arm ( ⇨ 13-8 ) -rear brake caliper ( ⇨ 14-6 ) -ex. Muffler ( ⇨ 4-12 ) -continuously variable transmission ( ⇨ section 7 ) -rh. Crank case c...

  • Page 125: Crankshaft Removal

    ● remove the transmission bleeder tube. ● remove the rh./lh. Radiator hose from the rh. Crankcase. ● face the lh. Crankcase downward, and remove the rh. Crankcase from the lh. Crankcase while tapping a few places on the lh. Crankcase with a plastic hammer. Note ·be careful not to distort the mating ...

  • Page 126: Transmission Bearing

    Crankshaft inspection ● place the crankshaft on a stand or v-block, and measure the crankshaft runout using dial gauge. Service limit : right : 0.1 mm left : 0.1 mm ● measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end as shown. Tool : feeler ga...

  • Page 127: Crankshaft Installation

    Transmission bearing replacement lh. Crankcase ● use special tools to remove the drive shaft bearing. Tools : bearing remover set remover shaft remover head ● remove the final shaft bearing and oil seal. ● remove the countergear bearing. ● apply clean engine oil to a new bearing, and assemble it to ...

  • Page 128: Crankcase Installation

    Crankcase installation ● install the dowel pins and a new gasket. ● install the cam chain to the lh. Crankcase. ● install the rh. Crankcase to the lh. Crankcase. Note ·make sure that the gasket is completely attached without any clearance. ● install the rh./lh. Radiator hose. ● install the bleeder t...

  • Page 129: Memo

    Memo.

  • Page 130

    12-0 front wheel/front fork/steering steering handle steering stem front disk fornt tire front casting wheel fornt fork.

  • Page 131: Service Information

    12-1 12. Front wheel/front fork/steering service information general safety caution ● keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance. If contaminated, replace the pad with a new one, and clean the disk. ● use special tir...

  • Page 132: Troubleshooting

    12-2 front wheel/front fork/steering troubleshooting hard steering ● steering bearing adjustment nut too tight. ● faulty steering stem bearings. ● damaged steering stem bearings. ● insufficient tire pressure. Steers to one side or does not track straight ● unevenly adjusted right and left shock abso...

  • Page 133: Steering Handle

    12-3 front wheel/front fork/steering front handle cover master cylinder speedometer cable winker relay setting bolt setting bolt handle setting collar flange bolt handle setting u-nut steering handle removal ● remove the following parts. -back mirror -front cover ( ⇨ 4-3 ) -wind screen ( ⇨ 4-10 ) -f...

  • Page 134

    12-4 front wheel/front fork/steering pan screw throttle housing throttle grip setting bolt master cylinder punch mark ● clean the throttle grip sliding surface. ● apply grease to the throttle grip sliding surface and install the throttle grip. ● apply grease to the throttle cable ends and connect th...

  • Page 135: Front Wheel

    12-5 front wheel/front fork/steering fr/rr. Master cylinder winker relay speedometer cable rh/lh. Winker wiring front cover front axle axle nut ● install the winker relay. ● install the front / rear brake hose, speedometer cable, throttle cable to the handle cable guide. ● install the rear handle co...

  • Page 136

    12-6 front wheel/front fork/steering front axle dial gauge bearing speedometer gear box gear box retainer dust seal front wheel inspection ● check the front axle for deflection. Place the front axle on a v-block, and measure deflection with a dial gauge. Service limit : 0.2mm ● place the front wheel...

  • Page 137

    12-7 front wheel/front fork/steering rh. Side collar special flange bolt brake disk dust seal bearing ● remove the front brake collar a. ● remove the dust seal and brake disk. ● check the disk for defects. ( ⇨ 14-11 ) wheel bearing replacement ● install the bearing remover head and the remover shaft...

  • Page 138

    12-8 front wheel/front fork/steering speedometer gear box speedometer gear dust seal rh. Side collar speedometer gear replacement ● remove the speedometer gear and washer from the speedometer gear box. ● check the gear for wear or damage. ● install the washer. ● apply grease to the speedometer gear ...

  • Page 139

    12-9 front wheel/front fork/steering gear box retainer speedometer gear box front axle axle nut ● align the wheel hub tangs with the slots of the speedometer gear retainer, and assemble the speedometer gear box seal. ● apply grease to the dust seal rim. ● install the dust seal, and align the tangs o...

  • Page 140: Front Fork

    12-10 front wheel/front fork/steering axle nut setting bolts setting bolts fork pipe bolt spring socket bolt front fork removal ● remove the following parts. -front cover ( ⇨ 4-3 ) -front brake caliper ( ⇨ 14-6 ) -front fender ( ⇨ 4-3 ) -front wheel ( ⇨ 12-5 ) ● when removing the front fork, loosen ...

  • Page 141

    12-11 front wheel/front fork/steering bracket vise dust seal oilseal stop ring oil seal note ·if the socket bolt turns idle but cannot be removed, temporarily assemble the spring and the fork tube cap bolt first. ·hold the bottom case firmly with a vise, taking precautions not to distort or damage i...

  • Page 142

    12-12 front wheel/front fork/steering bottom case fork pipe fork spring rebound spring free length v-blocks dial gauge bottom case fork pipe ● remove the fork pipe from the bottom case. ● remove the piston and rebound spring from the fork pipe. Front fork inspection ● place the fork spring on a leve...

  • Page 143

    12-13 front wheel/front fork/steering socket bolt fork seal driver oil seal stop ring fork oil fork oil oil level ● wrap the bottom case with a piece of cloth, and fix it to the vise. ● apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. Torque value...

  • Page 144

    12-14 front wheel/front fork/steering fork spring rebound spring top bottom fork pipe cap bolt setting bolts setting bolts ● assemble the springs to the fork pipe. Note ·install the spring with the smaller pitch side facing downward. ● assemble the fork bolt to the fork pipe. Front fork installation...

  • Page 145: Steering Stem

    12-15 front wheel/front fork/steering front cover steering handle steering stem nut socket steering stem socket steering stem removal ● remove the following parts. - back mirror - front cover ( ⇨ 4-3 ) - wind screen ( ⇨ 4-10 ) - front handle cover ( ⇨ 4-10 ) - rear handle cover ( ⇨ 4-10 ) - steering...

  • Page 146

    12-16 front wheel/front fork/steering upper ball ass'y top cone race bottom cone race steel ball bottom cone race under ball ass'y steering stem bottom cone race stem nut ● remove the top cone race, upper ball assembly, steering stem. Note ·place a shop towel under the steering stem to catch the ste...

  • Page 147

    12-17 front wheel/front fork/steering top ball race head pipe bottom ball race top thread top cone race upper ball ass'y under ball ass'y bottom cone race dust seal dust seal washer upper ball ass'y top cone race steering stem socket steering stem lock nut socket ● remove the steering top ball race ...

  • Page 148

    ● temporarily install the rh./lh. Front fork, and tighten the steering stem lock nut to the specified torque. Torque value : 6~8 kgf · m ● install the brake hose clamp to the steering stem, and clamp the brake hose. ● install the front fork. Torque value : 7.0 kgf · m ● install the following parts. ...

  • Page 149: Service Information

    13-1 13. Rear wheel/brake/suspension/rear swing arm service information general safety ● if the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe. ● inhaled asbestos fibers have been found to cause re...

  • Page 150: Troubleshooting

    Troubleshooting wobble or vibration in motorcycle ● tire pressure incorrect ● faulty tire ● bent rim ● loose wheel bearing ● swing arm bushing worn ● wheel out of balance soft suspension ● weak springs ● rear damper improperly adjusted, oil leakage hard suspension ● rear damper improperly adjusted ●...

  • Page 151: Rear Wheel

    Rear wheel removal ● support the motorcycle on the main stand. ● loosen the parking brake rod adjust nut b, and remove the parking brake cable. ● remove the brake arm joint b from the rear parking brake arm. ● remove the muffler. ( ⇨ 4-12 ) ● remove the rear brake caliper assembly from the rear swin...

  • Page 152

    Rear wheel inspection ● check the rim for wobbles by rotating the wheel. Service limit : radical 2.0mm axial 2.0mm tool : dial gauge rear wheel installation ● install the rear brake disk. ● insert the rear wheel over the final shaft. ● install the rear wheel inside collar. ● install the rear swing a...

  • Page 153: Parking Brake

    Parking brake removal ● remove the ex. Muffler. ( ⇨ 4-12 ) ● remove the rear caliper assembly. ( ⇨ 14-6 ) ● remove the rear swing arm. ( ⇨ 13-8 ) ● remove the rear wheel. ( ⇨ 13-3 ) inspection ● measure the brake drum for inner diameter service limit : 111mm ● measure the brake lining for thickness....

  • Page 154

    Brake shoe disassembly ● manually open the brake shoe and remove it. ● remove the shoe spring from the brake shoe. Brake cam disassembly ● loosen the adjust nut b, remove the brake arm joint b. ● after removing the brake arm spring, loosen the brake arm fixing bolt. ● remove the rear brake arm, rear...

  • Page 155: Rear Cushion

    Rear cushion removal ● remove the luggage box. ( ⇨ 4-4 ) ● loosen the top and bottom rear cushion setting bolts. Note ·support the frame firmly prior to working. Disassembly ● install the compressor attachment as shown in the figure. ● install the cushion on the cushion compressor, and compress the ...

  • Page 156: Rear Swing Arm

    Rear cushion installation ● install the spring, stopper rubber to the damper component. Note ·install the spring with its narrow pitch side facing upward. ● apply thread locking agent to the hex nut, and install the rear cushion compressor attachment on the damper rod. ● fix the upper metal, and tig...

  • Page 157: Memo

    Memo.

  • Page 158

    Brake system 14-0

  • Page 159: 14. Brake System

    14-1 14. Brake system brake lever / pedal soft or spongy ● air bubbles in the hydraulic system. ● leaking hydraulic system. ● contaminated brake pad / disk . ● worn caliper piston seal. ● worn master cylinder piston seal. ● worn brake pad. ● contaminated caliper. ● caliper not sliding properly. ● wo...

  • Page 160: Brake Fluid/bleeding

    14-2 brake system master cylinder front caliper bleeder hose brake lever bleeder valve brake bleeder brake fluid/bleeding brake fluid change caution ·a contaminate disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. ·replace contaminated pads, and remove pollut...

  • Page 161

    14-3 brake system bleeder hose 재사용 엄금 bleeder valve brake lever master cylinder when the brake bleeder is not available > ● fill the brake fluid up to the upper limit line. ● connect the transparent bleeder hose to the bleeder valve and place the other end of the hose in a container. ① squeeze the b...

  • Page 162: Brake Pad Replacement

    14-4 brake system lock plate front caliper setting bolts hanger pin lock plate brake pad brake pad brake pad replacement front brake pad note ·when replacing brake pads, replace whole set. ·do not remove the brake hose when replacing brake pads. ● open the lock plate tangs, and loosen the hanger pin...

  • Page 163

    14-5 brake system setting bolts lock plate lock plate hanger pin setting bolts rear caliper ● install a new brake pad, lock plate, and hanger pin. ● bend the lock plate tangs, and fix the hanger pin. ● install the brake caliper into the rh. Front fork. Note ·be careful not to damage the brake pad. R...

  • Page 164: Brake Caliper

    14-6 brake system oil bolt setting bolts setting bolts piston piston seal dust seal brake caliper removal front brake caliper ● remove the brake oil bolt, the brake hose and oil bolt washer from the brake caliper. ● remove the caliper from the rh. Front fork and remove the pad spring, hanger pin and...

  • Page 165

    14-7 brake system lock plate hanger pins dust plug slide pin pin boot pin bush dust seal piston seal piston caliper comp. Caliper bracket pads pad spring dust plug piston brake caliper inspection caliper cylinder ● check the caliper cylinder bore for scoring, scratches or other damage. Caliper pisto...

  • Page 166: Master Cylinder

    14-8 brake system front caliper rear caliper master cylinder oil bolt cir clip brake caliper installation front brake caliper ● install the brake caliper to the front fork, and connect the brake hose to the caliper, and install 2 sealing washers and the brake hose bolt. Torque value : 3.5 kgf · m ● ...

  • Page 167

    14-9 brake system cir clip master cylinder body boot lever stop switch master cylinder set secondary cup primary cup piston boot cir clip washer lever stop switch master cylinder body oil cup cap diaphragm diaphragm plate spring ● remove the washer, piston, spring from the master cylinder. ● clean t...

  • Page 168

    14-10 brake system setting bolts oil bolt flat screws oil cup cap diaphragm plate diaphragm upper level boot ● install the primary cup with its concaved side toward the inner side of the master cylinder. ● install the snap ring. Tool : snap ring pliers caution ·when installing the cups, do not allow...

  • Page 169: Brake Disk Inspection

    14-11 brake system brake disk brake disk dial gauge button cover pan screw parking brake lever flange bolt brake disk inspection ● measure the thickness of the disk. Service limit : 3.0 mm note ·measure the brake disk thickness at the several points and replace if the smallest measurement is less th...

  • Page 170: Memo

    Memo.

  • Page 171: 15. Battery/charging System

    15-1 15. Battery/charging system service information warning ·do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery. ·do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact ca...

  • Page 172: Charging Device Location

    Charging device location 15-2 battery/charging system regulator rectifier a.C.Generator battery (12v 1.7wx2) regulator rectifier a.C.Generator headlight ic main switch hi lo (12v 60/55w) taillight (12v 5w) fuse red yellow yellow yellow meterlight dimmer switch lighting switch black brown pink green ...

  • Page 173: Troubleshooting

    15-3 battery/charging system troubleshooting no power (key turned on) low power (engine running) ● dead battery. ● battery undercharged. -low fluid level. ● battery is failing. -low specific gravity. ● charging system failure. -charging system failure. ● disconnected battery cable. Intermittent powe...

  • Page 174: Battery

    15-4 battery/charging system battery removal ● turn off the ignition switch. ● remove the floor panel mat. ● loosen the 2 battery cover setting screws, remove the battery cover. ● disconnect the negative “⊖” battery cable first, and then disconnect the positive “⊕” cable. ● install in the reverse or...

  • Page 175: Charging System Inspection

    Charging system inspection leak test ● trun off the ignition switch, and disconnect the ground (-) cable from the battery. ● connect an ampere meter between negative (-) terminal and ground cable. ● with the ignition switch off, measure the leakage current. Leak current : not to exceed 1ma tool : di...

  • Page 176: Headlight Voltage Inspection

    Headlight voltage inspection ● remove the front cover. ( ⇨ 4-3) note ·check voltage with the headlight coupler connected. ● after starting the engine, place the dimmer switch to hi and measure the headlight lighting voltage between the terminals connected to blue (+) and green (-) wires. ● gradually...

  • Page 177: Regulator Rectifier Unit

    Regulator rectifier unit inspection ● provided that all inspections on the wire harness side are normal and there are no loose connections at the regulator rectifier coupler, inspect the regulator rectifier unit by measuring the resistance between the terminals. Note ·resistance value will not be ac...

  • Page 178: Memo

    Memo.

  • Page 179: 16. Ignition System

    16-1 16. Ignition system service information general safety ● follow the steps described in the troubleshooting flow chart when servicing the ignition system. ● the cdi unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the...

  • Page 180: Ignition Devices Location

    Ignition devices location 16-2 ignition system ignition coil main switch a.C.Generator dc. Cdi unit blue/yellow black/yellow black green green green cdi unit ignition coil spark plug green /red black /blue side stand switch green pulse generator main switch red red fuse battery _ _ + + ignition syst...

  • Page 181: Troubleshooting

    Troubleshooting no spark at plug. 16-3 ignition system unusual condition probable cause (check in numerical order) 1. The multitester impedance is too low. 2. Cranking speed is too slow. - battery is undercharged (or operating force of the kick starter is weak). 3. The sample timing of the tester an...

  • Page 182: Cdi Unit Inspection

    16-4 ignition system cdi unit a.C.Generator coupler cdi unit inspection cdi ignition circuit inspection note ·follow the steps described in the troubleshooting flow chart when servicing the ignition system. ● release the seat lock with the main key. ● remove the luggage box. (⇨4-4) ● disconnect the ...

  • Page 183: Ignition Coil Inspection

    16-5 ignition system ignition coil fixing bolt ignition coil ignition coil inspection ● release the seat lock with the main key. ● remove the luggage box. (⇨4-4) ● remove the center cover. (⇨4-5) ● remove the primary wire. Note ·measure the peak voltage of the ignition coil primary side first. ·sinc...

  • Page 184: Ignition Timing Inspection

    Ignition system ignition timing inspection note ·as the system uses the cdi unit, the ignition timing need not be adjusted. Check the ignition system if the ignition timing is incorrect. ● start and warm up the engine. ● remove the plug maintenance cover. ● connect the timing light to the high-tensi...

  • Page 185

    Removal ● remove the floor mat. ● remove the center cover. (⇨4-5) ● remove the rh. Floor side cover. (⇨4-7) ● remove the coupler of the side stand switch. ● remove the lh. Floor side cover. (⇨4-7) ● loosen the side stand switch mounting 2 bolts. ● release the wire clamps and remove the side stand sw...

  • Page 186: Memo

    Memo.

  • Page 187: 17. Starter System

    17-1 17. Starter system service information general safety warning ·always turn the ignition switch off before servicing the starter motor. The moter could suddenly start, causing serious injury. ● the starter motor can be maintained without removing the engine from the vehicle. ● a weak battery may...

  • Page 188: Starter Devices Location

    17-2 starter system battery fuse15a main switch starter switch starter motor starter magnetic switch m + - red main switch fuse front stop switch red/white starter system circuit starter motor starter switch green green starter magnetic switch rear stop switch yellow /red black battery green starter...

  • Page 189: Troubleshooting

    17-3 starter system troubleshooting starter motor will not turn. ● check for a blown main fuse before servicing. ● check that the stop light is correctly adjusted. ● check that the side stand is positioned in the condition under which the engine can be started. With the ignition switch “on”and squee...

  • Page 190: Starter Motor

    Starter motor removal ● release the seat lock with the main key. ● remove the luggage box. ( ⇨ 4-4) ● remove the starter motor cable from the starter magnetic switch. ● loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor. ● install in the reverse orde...

  • Page 191

    ● remove the brush spring, and then remove the brush. ● measure the brush length. Replace the brush if it is worn beyond the service limit. Service limit : 5 mm tool : vernier caliper note ·if replacement, replace with a brush holder set. ● check the commutator for : -damage or abnormal wear. → repl...

  • Page 192

    Starter motor assembly ● install the brush and brush spring to the brush hold set. ● insert the brush terminal into the rear bracket, and install the terminal set and flange nut. ● align the brush holder set with the rear bracket groove, and install the brush holder set. ● apply grease to both ends ...

  • Page 193: Starter Magnetic Switch

    Starter magnetic switch removal ● release the seat lock with the main key. ● remove the luggage box. ( ⇨ 4-4) ● remove the center cover. ( ⇨ 4-5) ● remove the battery (+) cable from the starter magnetic switch terminal. ● remove the starter motor cable from the starter magnetic switch terminal. ● di...

  • Page 194

    17-8 starter system operation check ● disconnect the magnetic switch wire connector. ● apply battery voltage between terminals, when the yellow / red wire is connected to the positive (+) battery terminal and the green / yellow wire to the negative (-) battery terminal. ● if there is continuity betw...

  • Page 195: 18. Lights/meter/switches

    18-1 18. Lights/meter/switches troubleshooting light not turned on when the main switch is on ● faulty light bulb ● faulty switch ● faulty or disconnected wiring ● fuse cut ● battery discharged dim headlight ● battery discharged ● wiring and switch resistance high headlight hi-low bean cannot be cha...

  • Page 196: Headlight

    18-2 lights/meter/switches headlight coupler headlight bulb rubber cover a winker bulb headlight removal ● remove the front cover. ( ⇨ 4-3 ) ● disconnect the headlight wiring. ● loosen the 4 setting bolts securing the front cover. ● remove the headlight assembly. ● install in the reverse order of re...

  • Page 197: Rear Combination Light

    18-3 lights/meter/switches tail light lens tapping screws front handle cover speedometer wire speedometer rear combination light bulb replacement ● loosen the 2 screws and remove the tail light lens. ● remove the bulb from the tail light socket. ● replace with a new bulb. ● install in the reverse or...

  • Page 198: Horn Inspection

    Horn inspection ● remove the front cover. ( ⇨ 4-3) ● remove the horn wiring, and connect a fully charged 12v battery. Check the sound quality for any abnormalities. ● install in the reverse order of removal. Main switch removal ● remove the front cover. ( ⇨ 4-3) ● disconnect the main switch coupler....

  • Page 199: Trunk Lamp Switch

    18-5 lights/meter/switches re hl tl bat ● install in the reverse order of removal. Trunk lamp switch inspection ● release the seat lock with the main key, open the seat. ● disconnect the trunk lamp switch, check for continuity between the terminals. Front/rear stop switch inspection ● remove the win...

  • Page 200: Parking Brake Switch

    18-6 lights/meter/switches parking brake switch coupler fuel unit groove parking brake switch inspection ● remove the front cover. ( ⇨ 4-3) ● disconnect the parking brake switch coupler, check for continuity between the terminals. -when the brake lever is pulled - continuity. -when the brake lever i...

  • Page 201: 19. Wiring Diagram

    Wiring diagram 19. Wiring diagram 19 b b b b b b b b b b b b b b b b b b b b b g g g charge socket y y y y b/s auto p p 30w 5.9 br br br g position light 12v 5w br br tl bat hl re br br / p lighting sw. W ig bat0 side stand s/w. B/l b/l 2p mini b/l horn b/l gg b b/lg b/lg mini 2p tr bat r m br/b br/...

  • Page 202: 20. Troubleshooting

    20-1 20. Troubleshooting engine won’t start or hard to start cause of trouble ·no fuel to fuel tank. ·disconnected or damaged fuel pump negative pressure tube. ·clogged fuel tube. ·clogged float valve. ·clogged fuel strainer. ·clogged fuel tank cap. ·fuel pump malfunction. ·faulty spark plug. ·conta...

  • Page 203

    20-2 troubleshooting engine stalls, hard to start, rough idling cause of trouble ·no fuel to fuel tank. ·clogged fuel tube. ·clogged float valve. ·clogged fuel tank cap. ·clogged fuel strainer. ·disconnected or damaged fuel pump negative pressure tube. ·contaminated spark plug. ·using spark plug wit...

  • Page 204

    20-3 troubleshooting engine speed does not increase sufficiently. Abnormal low clogged contaminated or discolored. Overheated engine knocking poor performance at low speed and idling cause of trouble ·clogged air cleaner. ·insufficient fuel supply. ·clogged fuel tank cap air hole ·clogged muffler. ·...

  • Page 205: Poor Operation

    20-4 troubleshooting poor operation cause of trouble ·worn or damaged drive belt. ·damaged ramp plate. ·faulty weight roller. ·faulty movable drive face. ·damaged driven pulley weight shoe spring. ·faulty transmission. ·seized transmission. ·broken driven pulley weight spring. ·seized clutch outer a...

  • Page 206

    20-5 troubleshooting cause of trouble ·weak cushion spring ·overloaded ·oil leakage from damper unit ·bent fork pipe or cushion rod ·worn slider ·damaged cushion stopper rubber soft suspension. Hard suspension. Suspension noisy. Poor front/rear suspension performance.

  • Page 207

    Service manual 2001. 11. Printed 2001. 11. Publication no copy.

  • Page 208

    Sm42-0111-01e head office (factory) #58, sung san-dong, changwon, kyungnam, korea tel : (82-55) 239-7000 / fax : (82-55) 239-7524 overseas sales office #16-6, pil-dong 2ka, chung-ku, seoul, korea tel : (82-2) 2274-3171 / fax : (82-2) 2269-7997.