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  4. ROADWIN VJ125 - SERVICE
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DAELIM ROADWIN VJ125 - SERVICE Service Manual

Summary of ROADWIN VJ125 - SERVICE

  • Page 1

    Sm48-0401-01e head office (factory) #58, sung san-dong, changwon, kyungnam, korea tel : (82-55) 239-7000 / fax : (82-55) 239-7524 overseas sales office #13-5, sung soo 1dong 1ga, sung dong gu, seoul, korea tel : (82-2) 498-6465 / fax : (82-2) 467-9997.

  • Page 2: Contents

    How to use this manual this manual describes effective maintenance procedure for the vj125 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 2). Sections 1 through 2 pr...

  • Page 4: 1. General Information

    1-1 1. General information service information · ·· ·· ·· ·· ·· ·· · 1-1 service rules · ·· ·· ·· ·· ·· ·· ·· ·· ·· · 1-1 caution when wiring · ·· ·· ·· ·· · 1-5 model identification · ·· ·· ·· ·· · 1-9 specifications · ·· ·· ·· ·· ·· ·· ·· ·· · 1-10 torque values · ·· ·· ·· ·· ·· ·· ·· ·· · 1-12 sy...

  • Page 5

    1-2 general 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 6

    1-3 general information 11. Maintenance needed to use the specialized tools must be 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 ...

  • Page 7

    1-4 general 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 8: Caution When Wiring

    1-5 general 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 . Whe...

  • Page 9

    1-6 general 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) so...

  • Page 10

    1-7 general 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. The ...

  • Page 11

    1-8 general 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 be p...

  • Page 12: Model Identification

    1-9 general information model identification engine serial number location the engine serial number is stamped on left crankcase. Frame serial number location the frame serial number is stamped on the left side of steering head..

  • Page 13: Specifications

    1-10 general information specifications item specifications overall length 2,010mm overall width 740mm overall height 1,040mm dimensions wheel base 1,380mm seat height 780mm ground clearance 150mm dry weight 130kgf curb weight 147kgf type double cradle front suspension / stroke telescopic / 130mm re...

  • Page 14

    1-11 general information item specifications type pd 24 venturi bore 24mm setting series mark vj 125 c main jet #100 carburetor slow jet #38 pilot screw initial setting 2 1/8 float level 12.5mm idle speed 1,600 ± 100(rpm) clutch type multiplate wet clutch transmission type constant mesh transmission...

  • Page 15: Torque Values

    1-12 general information torque values engine frame kgf.M,(n.M) torque torque kgf.M,(n.M) reference thread dia (mm) q’ty item reference thread dia (mm) q’ty item 4 2 1 2 1 1 4 1 1 1 3 2 1 1 2 11 3 7 1 1 10 1 2 1 2 2 4 m8 × 1.25 m6 × 1.0 m8 × 1.25 m6 × 1.0 m6 × 1.0 m36 × 1.5 m5 × 0.5 m16 × 1.0 m16 × ...

  • Page 16

    Torque 1-13 general information reference thread dia (mm) q’ty item torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below. Type torque type torque kgf · · m n · · m kgf · · m n · · m 1 5mm bolt, nut 0.5 5 5mm screw 0.4 4 1 6mm bolt...

  • Page 17: Symbols / Abbreviations

    Symbol 1-14 general 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. Meaning indicates important work. Minor injury or vehic...

  • Page 18: Tools

    1-15 general information tools special common description ref. Sec. Description ref. Sec. Tester, gauge compression gauge digital multi tester pva tester battery tester 2 16, 17 16, 17 17 description reference section remark valve seat cutter valve seat cutter 45 ° valve seat cutter 35 ° valve seat ...

  • Page 19: Wiring Diagram

    1-16 general information wiring diagram fr. Brake hose spdmt. Cable throttle cable st.-haz. Sw. Cord fr. Brake hose cable guide clutch cable choke cable noise suppressor cap horn comp. Lh. Radiator hose rh. Radiator hose high tension cord clutch cable rr. Brake hose rr. Brake reserve tube rr. Brake ...

  • Page 20

    1-17 general information wire harness ign. Coil wire clip throttle cable junction clamp fuel cock wire clamp(wire pivot) fuel cock(res) fuel cock(on) fuel strainer comp. Wire harness air vent tube choke cable clutch cable lh. Radiator hose rh. Radiator hose throttle junction cable guide ign. Coil co...

  • Page 21

    1-18 general information st.-mag. Battery cable(+) st.-mag. Sw. Wire battery earth cable wire clip harness cover st.-mag. Battery cable(+) st.-mag. Sw. Ass'y. St.-motor cable battery earth cable side stand sw. Cord rr. Stop sw. Cord reserve tank rr. Brake hose rr. Brake hose guide rr. Brake reserve ...

  • Page 22

    1-19 general information brake hose clamp brake hose rh. Radiator hose brake hose clamper spdmt. Cable horn comp. Spdmt. Cable guide detail of view a fuel drain tube drain tube tube guide drain tube eng. Dreather tube clutch cable detail of view d rh. Cable guide combi. Meter cord winker sw. Cord rh...

  • Page 23: Memo

    Memo.

  • Page 24: 2. Inspections/adjustments

    2-1 2. Inspections/adjustments service information ● 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 2 service information · ·· ·· · 2-1 maintenance schedule · ·· · 2-3 fuel line (fuel tube...

  • Page 25

    2-2 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) ac generator cap 0.6 kgf-m( 6n.M) crankshaft hole cap 0.8 kgf-m( 8n.M) air cleaner case cover screw 0.43kgf-m( 4.3n.M) rear axle nut 8.8kgf-m(88n.M) drive sprocket bolt 1.2...

  • Page 26: Maintenance Schedule

    2-3 inspections / adjustments maintenance schedule ● perform the self inspections before operation at each scheduled maintenance period. I : inspect and clean, adjust, lubricate or replace if necessary. R : replace l : lubricate c : clean ● these instructions are based on the assumption that the mot...

  • Page 27: Fuel Line (Fuel Tube)

    2-4 inspections / adjustments fuel line (fuel tube) ● check the fuel tube for deterioration, damage or leakage. Replace it if necessary. Throttle grip operation ● check if the throttle grip operates smoothly in all steering positions. ● if not operating smoothly, check the deterioration, damage and ...

  • Page 28: Carburetor Choke

    2-5 inspections / adjustments carburetor choke ● check the deterioration, damage and kink of the choke cable. Check if the choke lever operates smoothly in any position. ● pull the choke lever to the left, and close it perfectly. Air cleaner ● remove the seat. ( ⇨ 12-2 ) ● loosen the 4 screws, remov...

  • Page 29: Spark Plug

    Feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge 2-6 inspections / adjustments check gap, deposits check for cracks...

  • Page 30: Carburetor Idle Speed

    2-7 inspections / adjustments ● measure the vlave clearance again. ● install the cylinder head cover and tighten the bolts. Torque : 1.0kgf · · m (10n · · m) ● install the a.C generator cap and crankcase hole cap. Torque : a.C generator cap : 0.6kgf · · m(6n · · m) crank case hole cap : 0.8kgf · · m...

  • Page 31: Drive Chain

    2-8 drive chain drive chain slack adjustment ● turn off the ignition switch, support the motorcycle on its main stand, and shift the transmission into neutral. ● check slack in the lower chain with a hand midway between the sprockets. Chain slack : 10~20mm ● adjust the slack of drive chain if necess...

  • Page 32

    2-9 inspections / adjustments drive chain inspection ● lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying fully. ● because an extremely lubricated oil splash while the chain moves round, clean it with a piece of cloth. ● after checking a wear and dama...

  • Page 33: Brake Fluid

    2-10 inspections / adjustments brake fluid drive chain slider ● inspect the drive chain slider for excessive wear or damage. ● if it is worn to the wear indicator, replace the drive chain slider. ● when the fluid level is low, check the brake pads for wear. If the brake pads are not worn and the flu...

  • Page 34: Brake System

    10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 10~20mm 2-11 inspections / adjustments brake system inspection ● firmly apply the brake lever or pedal, and check that no air has entered the system. ● if the lever or pedal feels ...

  • Page 35: Brake Stop Switch

    2-12 inspections / adjustments brake pedal height adjustment ● loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. ● after adjustment, tighten the lock nut securely. ● after adjusting the brake pedal height, inspect the operation of rear brake light switch and b...

  • Page 36: Side Stand

    2-13 inspections / adjustments ● minor adjustments are made using the upper adjuster at the clutch lever. ● loosen the lock nut and turn the adjuster. ● if the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn...

  • Page 37: Bolts, Nuts, Fasteners

    2-14 inspections / adjustments rear suspension inspection ● compress the near cushion up and down several times to check the operating conditions. ● check the rear cushion for oil leakage, parts damage or looseness . Bolts, nuts, fasteners ● check that all frame nuts and bolts are tightened to their...

  • Page 38: Steering Head Bearings

    2-15 inspections / adjustments ● check the tread depth at the tire center. ● if the tread depth has reached the service limit, replace the tires. Service limit : front : 5.5mm rear : 7.0mm ● support the motorcycle securely and raise the front wheel off the ground. ● check that the handlebar moves fr...

  • Page 39: Memo

    Memo.

  • Page 40: 3. Lubrication

    3-1 3. Lubrication service information general safety 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 contact with the skin for prolonged period...

  • Page 41: Troubleshooting

    3-2 lubrication troubleshooting engine oil level too 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 clog...

  • Page 42: Engine Oil Level Inspection

    Engine oil level inspection ● support the motorcycle by main stand. ● start the engine and let it be warm fully. ● stop the engine, remove the oil level gauge and wipe it clean. ● check the oil level with the level gauge by inserting it in engine screwing level gauge. It is good if the oil surface i...

  • Page 43: Oil Filter Element Change

    3-4 lubrication oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump oil pump flange bolts flange bolts flange bolts flange bolts flange bolts flange bolts flange bolts flange bolts flange bolts flang...

  • Page 44

    3-5 lubrication outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor outer rotor inner rotor inner rotor inner rotor inner rotor inner rotor inner ro...

  • Page 45

    3-6 lubrication ● install the pump shaft, oil seal and spacer, then assemble into the setting ring. ● install the inner and outer rotors to the pump body. ● install the dowel pins and oil pump plate into the pump body. Installation ● install the oil pump into the right crankcase cover and tighten th...

  • Page 46: Lubrication Points

    3-7 lubrication steering head bearings dust seal wheel bearing (at changed) speedometer gear brake caliper pivot brake pedal pivot rear fork pivot wheel bearing (at changed dust seal) drive chain (sae#80or#90gear oil) throttle grip clutch lever pivots throttle cable, choke cable, speedometer cable, ...

  • Page 47

    4-0 fuel system.

  • Page 48: Service Information

    4-1 service information general safety ● gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. ● exhaust gas contains poisonous substance. Do not...

  • Page 49: Troubleshooting

    4-2 fuel system troubleshooting engine cranks but won't start ● no fuel in tank ● no fuel to carburetor ● cylinder flooded with fuel ● clogged air cleaner ● no spark at plug rough idle, incorrect idle speed ● faulty idle adjustment ● excessively lean or rich mixture ● clogged fuel system ● intake ai...

  • Page 50: Fule Tank

    Fuel filler cap fuel tank cover fuel tank sealing rubber fuel unit fuel strainer fuel cock fuel tank fuel cap neck 4-3 fuel system fule tank removal installation ● install the fuel tank in the reverse order of removal. ● after installation, check if there is a gasoline leak. ● remove the seat. ( ⇨ 1...

  • Page 51: Air Cleaner Case

    Air cleaner case air cleaner inner pipe air cleaner element air cleaner case cover 4-4 fuel system air cleaner case removal ● remove the fuel tank. ( ⇨ 4-3 ) ● remove the rh. Lh. Side covers. ● remove the battery. ( ⇨ 16-3 ) ● remove the battery box by loosening the washer bolt. ● remove the air cle...

  • Page 52: Throttle Valve

    4-5 fuel system throttle valve removal ● remove the fuel tank. ( ⇨ 4-3 ) ● loosen the carburetor top slowly, and remove the throttle valve. ● disconnect the throttle cable from the throttle valve, and remove the throttle valve. ● remove the throttle valve spring and carburetor top from the throttle ...

  • Page 53: Carburetor

    Spring spring spring spring spring spring spring spring spring spring spring spring spring spring spring spring spring spring throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle valve throttle ...

  • Page 54

    4-7 fuel system ● remove the throttle cable. ● loosen the carburetor mounting nut, and remove the carburetor. Disassembly ● remove the air vent tube 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 a...

  • Page 55

    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 56

    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. ● remove the throttle stop screw. ● clean the jet with cleaning solvent. ● ins...

  • Page 57

    4-10 fuel system ● blow open air and fuel passages in the carburetor body with compressed air. ● install the needle jet, needle jet holder, main jet and slow jet. ● install the throttle stop screw and pilot screw. ● install the float valve, float and float arm pin. ● if installing the new pilot scre...

  • Page 58

    4-11 fuel system accelerator adjustment ● adjust the idling. ( 2-7) ● adjust the operation of throttle grip. ( 2-4) ● loosen the lock nut, turn the adjuster screws to contact with accelerator pump cap, and then adjust the accelerator pump rod clearance. Clearance : 0mm ● tighten the lock nut. ● inst...

  • Page 59: Pilot Screw Adjustment

    4-12 fuel system pilot screw adjustment 1. Turn the pilot screw clockwise until it seats lightly, then back it out to the specification given. Initial opening : 2 ⅛ ⅛ 2. Warm up the engine to operating temperature. Ten minutes of stop and go driving is sufficient. 3. Stop the engine and connect a ta...

  • Page 60: Memo

    Memo.

  • Page 61

    5-0 cooling system.

  • Page 62: 5. Cooling System

    5-1 5. Cooling system service information general safety torque value oil through bolt 3.2kgf · m (32n · m) 5 service information · ·· ·· ·· · 5-1 radiator · ·· ·· ·· ·· ·· ·· ·· ·· · 5-2 wait until the engine is cool before servicing the cooling system..

  • Page 63: Radiator

    5-2 cooling system radiator removal ● loosen the horn mounting bolt and remove the horn. ● loosen the 4 radiator cover mounting screws and remove the radiator cover. Radiator hose inspection ● check the radiator core for clog or damage. ● check the pin for deformation; adjust it if necessary. Instal...

  • Page 64: Memo

    Memo.

  • Page 65

    6-0 engine removal/installation.

  • Page 66: Service Information

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

  • Page 67: Engine Removal

    6-2 engine removal/installation engine removal ● drain the engine oil. ( ⇨ 3-3) ● remove the muffler. ( ⇨ 12-4) ● remove the noise suppressor cap. ● remove the battery ground cable and clutch cable. ● remove the sai pipe complete and sai reed valve assembly from the cylinder head. ● remove the carbu...

  • Page 68: Engine Installation

    6-3 engine removal/installation engine installation engine installation is essentially the reverse order of removal. Torque : engine hanger bolts : (front ) 4.9kgf · · m(49n · · m) (rear ) 4.9kgf · · m(49n · · m) gear change arm bolt 1.2kgf · · m(12n · · m) drive sprocket bolt 1.2kgf · · m(12n · · m...

  • Page 69

    7-0 clutch/gearshift.

  • Page 70: 7. Clutch / Gearshift

    7-1 7. Clutch / gearshift service information general safety ● the clutch, gearshift spindle can be serviced with the engine in the frame. ● if the shift fork, drum and transmission require service, remove the engine and separate the crankcase. ● the quality and level of fluid affect clutch operatio...

  • Page 71: Troubleshooting

    7-2 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 ● too...

  • Page 72: R. Crankcase Cover

    7-3 clutch/gearshift r. Crankcase cover removal ● drain the engine oil. ( 2-3) ● remove the bolts and clutch wire holder, then disconnect the clutch cable end from the clutch lever. ● remove the right crankcase cover bolts and remove the right crankcase cover. ● remove the two dowel pins and gasket....

  • Page 73: Clutch

    7-4 clutch/gearshift ● coat the new o-ring with grease, and install it to the clutch lever. ● install the clutch lever spring to the clutch lever. ● install the spring ends into the hole of the clutch lever. ● after installing the clutch lever into the r. Crankcase cover, turn the clutch lever to th...

  • Page 74

    7-5 clutch/gearshift ● remove the lock washer. ● remove the clutch center, disk, plate and pressure plate. ● remove the spline washer and clutch outer. ● remove the clutch outer guide and thrust washer. Clutch center clutch center clutch center clutch center clutch center clutch center clutch center...

  • Page 75

    7-6 clutch/gearshift ● measure the clutch spring free length; replace the springs if the measurement is not within the service limit. Service limit : 34.2mm ● check the clutch disk for scoring or discoloration; replace as necessary. ● measure the disk thickness and replace the disks if the service l...

  • Page 76: Gear Shift Spindle

    7-7 clutch/gearshift gear shift spindle removal ● loosen the hex bolt and remove the gear change arm. ● remove the rh. Crankcase cover. ( ⇨ 7-3 ) ● remove chutch assembly. ( ⇨ 7-4 ) ● remove the gear shift spindle and thrust washer. ● remove the gear shift cam bolt, cam and roller. ● remove the drum...

  • Page 77

    7-8 clutch/gearshift installation ● install the collar, spring, drum stopper and bolt. ● tighten the bolt. Torque : 1.2kgf · · m(12n · · m) ● press the drum stopper, and install the gear shift cam, aligning the roller with the gear shift cam hole. ● install the thrust washer into the gear shift spin...

  • Page 78: Clutch Installation

    7-9 clutch/gearshift clutch installation ● coat the clutch outer guide with clean engine oil. ● install the trust washer and outer guide into the main shaft. ● install the clutch outer and spline washer. ● coat the clutch and plate disk. With clean engine oil. ● install the 6 disks. And 5 plates to ...

  • Page 79: Primary Drive Gear

    7-10 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. P...

  • Page 80: R. Crankcase Cover

    7-11 clutch/gearshift woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key woodruff key lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nu...

  • Page 81

    Clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire holder clutch wire hol...

  • Page 82: Memo

    Memo.

  • Page 83

    8-0 a.C generator / starter clutch.

  • Page 84: Service Information

    8-1 8. A.C generator / starter clutch 8 service information · ·· · 8-1 troubleshooting · ·· ·· ·· · 8-1 a.C generator removal · · 8-2 starter clutch · ·· ·· ·· · 8-5 a.C generator installation · · 8-7 service information general safety ● this section covers removal and installation of the a.C. Gener...

  • Page 85: A.C Generator Removal

    8-2 a.C generator / starter clutch ● remove the a.C. Generator wire clamp bolt and a.C. Generator wire clamp. A.C generator removal ● remove the gear change arm. ● remove the l. Rear cover. ● disconnect the a.C. Generator wire coupler and gear change switch wire coupler. ● remove the reduction gear ...

  • Page 86

    8-3 a.C generator / starter clutch bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts bolts ● remove the starter reduction gear shaft and starter reduction gear. ● remove the left crankcase cover bolts and left crankcase cover. ● remove the gasket and the dowel...

  • Page 87

    8-4 a.C generator / starter clutch ● remove the woodruff key from the crank shaft. ● remove the starter driven gear collar. ● after installing the acg rotor puller on the rotor, remove the rotor. Tool : acg rotor puller stator removal/installation ● remove the pulse generator mounting screws and pul...

  • Page 88: Starter Clutch

    8-5 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 ● measure the gear shaft outside diameter. Service limit : 9.970mm reduction gear inspection ● inspect the wear and damage ...

  • Page 89

    8-6 a.C generator / starter clutch ● check the starter driven gear for damage or wear. ● measure the starter driven gear i.D. And o.D. Service limit : o.D. : 39.607mm i.D. : 22.100mm installation ● check the one-way clutch for wear or damage. ● install the one-way clutch flange onto the clutch outer...

  • Page 90: A.C Generator Installation

    8-7 a.C generator / starter clutch a.C generator installation ● install the starter driven gear collar. ● clean the taper part of crank shaft and remove the dust. If installing the rotor with dust in taper part, the key will be damaged. Because the contacted area of taper will be small and it will o...

  • Page 91

    8-8 a.C generator / starter clutch ● install the starter gear and shaft. ● install the new o-ring. ● install the reduction gear cover. Starter reduction gear starter reduction gear starter reduction gear starter reduction gear starter reduction gear starter reduction gear starter reduction gear star...

  • Page 92

    ● install the l. Rear cover. ● install the gear change arm a ligning its slit with the punch mark on the gearshift spindle. ● install and tighten the pinch bolt to the specified torque. Torque : 1.2 kgf · · m (12 n · · m) a.C generator / starter clutch 8-9 l. Rear cover l. Rear cover l. Rear cover l...

  • Page 93

    9-0 cylinder head / valves.

  • Page 94: 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 is supplied through the cylinder head oil hole. Clea...

  • Page 95: Troubleshooting

    9-2 cylinder head / valves tools valve guide reamer valve guide driver valve spring compressor valve seat cutter seat cutter in 35 ° (23mm) ex 35 ° (20mm) in 45 ° (24.5mm) ex 45 ° (24.5mm) in 60 ° (22mm) ex 60 ° (22mm) cutter holder 5mm troubleshooting enging top-end problems useally affect engine p...

  • Page 96: Camshaft

    9-3 cylinder head / valves camshaft removal ● remove the noise suppressor cap assembly from the spark plug. ● remove the cylinder head cover bolts and cover. ● remove the ac generator cap and crank shaft hole cap out of the left crankcase cover. ● turn the crankshaft to the left, and align the “ t ”...

  • Page 97

    9-4 cylinder head / valves ● remove the cam chain from the camshaft. ● remove the camshaft. Camshaft holder disassembly ● remove the rocker arm springs from the gear shift drum pin. ● remove the gear shift drum pin from the cam shaft holder. (in/ex) ● put the 6mm bolt into the rocker arm shaft, remo...

  • Page 98: Cylinder Head

    9-5 cylinder head / valves ● manually turn the camshaft bearing outer race, and check if it turns smoothly. ● check the bearing for wear or damage. Cylinder head removal ● remove the engine from the frame. ( section 6 ) ● remove the camshaft. ( ⇨ 9-3) ● remove the cylinder head from the cylinder. ● ...

  • Page 99: Valve Springs

    9-6 cylinder head / valves ● remove the valve spring, valve cotter, retainer, spring and valve. Using the valve spring compressor. Tool : valve spring compressor ● remove the valve spring seat and valve stem seal. Remove carbon deposits from the inside of the combustion chamber. Inspection ● remove ...

  • Page 100: Valves

    9-7 cylinder head / valves valves ● inspect each valve for bending, burning, scratches or abnormal wear. ● insert the valves in their original positions in the cylinder head. Check that each valve moves up and down smothly, without binding. ● measure and record the valve stem outer diameter in three...

  • Page 101: Valve Seats

    9-8 cylinder head / valves tool : valve guide reamer ● reface the valve seats and clean the cylinder head thoroughly to remove any metal particles. ● support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. Tool : valve guide driver ● apply oil to a...

  • Page 102

    9-9 cylinder head / valves ● 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. ● measure the valve seat width. Standard v...

  • Page 103

    9-10 cylinder head / valves 절 절삭 삭전 전 시 시트 트폭 폭 60 。 。 45 。 。 old seat width seat width ● if the contact area is too high on the valve, the seat must be lowered using a 35 degree flat cutter. ● refinish the seat to specifications, using a 45 degree finish cutter. ● if the contact area is too low on ...

  • Page 104: Cylinder Head Assembly

    9-11 cylinder head / valves ● after cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. ● lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide. Cylinder head assembly ● install new stem seal...

  • Page 105

    ● install the cylinder head. 9-12 cylinder head / valves pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt pivot bolt cam chain tensioner cam chain tensioner cam c...

  • Page 106: Camshaft Assembly

    9-13 cylinder head / valves ● tighten the rocker arm shaft with driver, and align the bolt hole of the camshaft holder with the fitting side of the rocker arm shaft. Camshaft assembly ● install the rocker arm spring and rocker arm on the camshaft holder. ● apply engine oil to the rocker arm shaft, a...

  • Page 107

    9-14 cylinder head / valves cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft dowel pins dowel pins dowel pins dowel pins dowel pins dowel pins dowel pins dowel pins dowe...

  • Page 108

    9-15 cylinder head / valves ● assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. ● tighten the tensioner mounting bolts to the specified torque. Torque : 1.2 kgf · · m (12n · · m) ● install the o-ring and sealing screw to the tensioner lifer. ● tighten t...

  • Page 109

    10-0 cylinder / piston.

  • Page 110: 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 111: Cylinder Removal

    10-2 cylinder / piston top middle bottom cylinder removal ● remove the cylinder head. ( ⇨ 9-5 ) ● remove the cylinder head gasket. ● remove the cam chain guide from the cylinder. ● remove the cylinder. ● remove the gasket and dowel pin. Carefully remove any adhering gasket material from the cylinder...

  • Page 112: Piston / Piston Ring

    10-3 cylinder / piston 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 : 0.100 mm · any clearance between the cylinder and head due to damage or warpage will re...

  • Page 113

    10-4 cylinder / piston ● insert the piston ring squarely into the bottom of the cylinder, using the piston. ● measure the end gap using a feeler gauge. Replace the ring if the service limit is exceeded. Service limit : top / second : 0.50 mm oil ring (side rail) : 1.10 mm tool : feeler gauge ● measu...

  • Page 114

    Piston assembly ● clean the piston heads, ring lands and skirts. ● carefully install the piston rings onto the piston with the markings facing up. ● after installation, the rings should rotate freely in the ring grooves. Piston installation ● install the piston and insert the piston pin. 10-5 cylind...

  • Page 115: Cylinder Installation

    10-6 cylinder / piston cylinder installation ● make sure that the piston ring end gap is correct. ● carefully remove any adhering gasket material from the cylinder / head mating surface. Do not scratch the surface. ● install a new cylinder gasket and dowel pins. ● coat the cylinder wall with clean e...

  • Page 116: Memo

    Memo.

  • Page 117

    11-0 crankcase/transmission/crankshaft.

  • Page 118: Service Information

    11-1 11. Crankcase/transmission/crankshaft service information · ·· ·· · 11-1 troubleshooting · ·· ·· ·· · 11-2 crankcase disassembly · ·· · 11-3 transmission disassembly · · 11-4 crankshaft · ·· ·· ·· ·· ·· ·· ·· · 11-6 crankcase bearing · ·· ·· ·· · 11-7 crankshaft installation · · 11-8 transmissi...

  • Page 119: Troubleshooting

    11-2 crankcase/transmission/crankshaft torque values main shaft bearing setting plate 1.2kgf · m(12n · m) crankcase bolt 1.1kgf · m(11n · m) tools universal bearing puller bearing remover set, 15mm remover assembly 15mm remover shaft remover head sliding weight thread adapter assembly shaft crankcas...

  • Page 120: Crankcase Disassembly

    11-3 crankcase/transmission/crankshaft crankcase disassembly ● the engine must be separated from the frame. ( section 6) ● refer to the service information for removal of necessary parts before disassembling the crankcase. ● remove the gear change switch. ● remove the 6mm bolt from the right crankca...

  • Page 121: Transmission Disassembly

    11-4 crankcase/transmission/crankshaft inspection ● check the shift fork for wear or damage. ● measure the shift fork inside diameter and projecting parts thickness in shift fork. Service limit : inside diameter : 12.050mm projecting parts thickness : 4.500mm ● check the shift fork shaft for wear or...

  • Page 122

    11-5 crankcase/transmission/crankshaft ● check the shift drum for wear or damage. ● check the shift drum guide groove for partial wear or damage. ● measure the main shaft and counter shaft outside diameter. Service limit : m3, m5 : 19.930mm c1 : 16.440mm c2 : 19.940mm c4 : 19.930mm ● check the gear ...

  • Page 123: Crankshaft

    11-6 crankcase/transmission/crankshaft inspection ● place the crankshaft on a stand or v-block, and measure the crankshaft runout using dial gauge. Service limit : right : 0.100 mm left : 0.100 mm ● measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod bi...

  • Page 124: Crankcase Bearing

    11-7 crankcase/transmission/crankshaft ● measure the connecting rod radial clearance in both x and y directions. ● replace the crankshaft if the service limit is exceeded. Service limit : 0.050 mm crankcase bearing ● remove the transmission and crank shaft. Inspection ● turn the inner race of bearin...

  • Page 125: Crankshaft Installation

    11-8 crankcase/transmission/crankshaft rh. Crank case ● remove the main shaft bearing set plate. ● remove the main shaft bearing, counter shaft bearing and crank shaft bearing form crankcase. ● coat the new bearing with clean engine oil and install it into crankcase. ● insert closely the cooling jet...

  • Page 126: Transmission Assembly

    11-9 crankcase/transmission/crankshaft transmission assembly ● coat the gear and gear bush with clean engine oil and install the main shaft and counter shaft. ● check the gears for freedom of movement or rotation on the shaft. ● install the main shaft and counter shaft into the left crankcase togeth...

  • Page 127: Crankcase Assembly

    11-10 crankcase/transmission/crankshaft ● check the marks on the shift forks. - l. Fork : “l” mark - center fork : “c” mark - r. Fork : “r” mark ● install the shift fork into the shift fork shaft, then install the shift fork into the left crankcase assembling hole. ● with the left fork mark and cent...

  • Page 128

    11-11 crankcase/transmission/crankshaft ● install the right crankcase into the left crankcase . Make sure that there is no gap between the mating surfaces of the right and left crankcase. ● tighten the left crankcase bolts in a crisscross pattern in 2-3 steps. Torque : 1.1kgf · · m(11n · · m) ● afte...

  • Page 129

    11-12 crankcase/transmission/crankshaft ● install the cam chain. ● install the disassembled parts. ● install the engine on the frame. ( ⇨ section 6) cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain c...

  • Page 130: Memo

    Memo.

  • Page 131

    12-0 external parts.

  • Page 132: 12. External Parts

    12-1 12. External parts service information general safety ● this section covers removal and installation of the seat and exhaust muffler. ● always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. ● always inspect the exhaust muffler for leaks after installation. Tro...

  • Page 133: Seat / Side Cover

    Seat / side cover seat removal ● insert the ignition key into the seat lock. ● turn the ignition key counterclockwise, and then pull the seat back and up. ● installation is in the reverse order of removal. Rear seat(pillion seat) ● remove the seat (see above). ● remove the center cover setting gromm...

  • Page 134: Rear Cowl

    12-3 external parts rear cowl ● remove the seat. ● remove the r/l. Side cover. ● remove the center cover. ● remove the pillion seat. ● remove the two flange bolts and two special bolts. ● remove the rear fender mounting body cover clips. ● carefully spread the bottom of both sides of the rear cowl, ...

  • Page 135: Muffler/exhaust Pipe

    12-4 external parts muffler/exhaust pipe removal ● remove the exhaust pipe to muffler mounting bolts. ● remove the muffler mounting bolt/nut and washer, then remove the muffler. ● remove the exhaust pipe joint cap nuts. ● remove the exhaust pipe flange gasket. ● remove the following. - exhaust pipe ...

  • Page 136: Front Fender

    12-5 external parts installation ● install the removed parts in the reverse order of removal. Front fender ● remove the wire grommat from the front fender. ● remove the front fender mounting special screws. ● remove the front fender forward. ● installation is in the reverse order of removal. Check t...

  • Page 137

    13-0 front wheel/front fork/steering.

  • Page 138: Service Information

    13-1 13. Front wheel/front fork/steering service information general safety ● a contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk with a brake degreasing agent. ● because inhaled asbestos fibers have been found to cause respiratory disease...

  • Page 139: Troubleshooting

    13-2 front wheel/front fork/steering tools ball race driver steering stem driver fork seal driver steering stem socket extension bar driver fork seal driver body lock nut wrench bearing remover shaft remover head attachment pilot troubleshooting hard steering ● steering bearing adjustment nut too ti...

  • Page 140: Handlebars

    13-3 front wheel/front fork/steering handlebars removal ● remove the back mirrors. ● remove the socket bolt and right handle weight cap. ● disconnect the front stop switch wires connectors from the switch. ● remove the master cylinder holder bolts, holder and master cylinder assembly. ● remove the r...

  • Page 141

    13-4 front wheel/front fork/steering ● remove the screws and left handlebar switch housing. ● remove the socket bolt and left handle weight cap. ● remove the left handle grip and choke lever from the handlebar. ● loosen the clutch lever bracket holder bolts. ● loosen the handle pipe pinch bolt. ● re...

  • Page 142

    13-5 front wheel/front fork/steering installation ● install the handlebars onto the front forks. ● install the handle pipe while aligning its grooves with the fork top bridge holes. ● tighten the handle pipe pinch bolts to the specified torque. Torque : 2.6kgf · · m (26n · · m) ● install the clutch ...

  • Page 143

    13-6 front wheel/front fork/steering ● apply grease to the sliding surface of the throttle pipe. ● connect the throttle cable to the throttle pipe. ● install the right handlebar switch housing by aligning its locating pin with the hole in the handlebar. ● tighten the forward screw first, then the re...

  • Page 144: Front Wheel

    13-7 front wheel/front fork/steering wheel rim runout ● check the rim runout by placing the wheel in a turning stand. ● spin the wheel slowly and read the runout using a dial indicator. ● actual runout is 1/2 the total indicator reading. Service limit : radial : 2.0mm service limit : axial : 2.0mm f...

  • Page 145

    13-8 front wheel/front fork/steering wheel bearing ● turn the inner race of each bearing with your finger. ● bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. ● remove and discard the bearings if the races do not turn smoothly and quietly, or i...

  • Page 146

    13-9 front wheel/front fork/steering wheel bearing replacement ● install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub. ● remove the distance collar and drive out the other bearing. Tools : bearing remo...

  • Page 147

    Assembly 13-10 front wheel/front fork/steering ● install the brake disk on the wheel hub. ● install and tighten the new mounting bolts to the specified torque. Torque : 4.2 kgf · · m (42n · · m) ● apply grease to the rim part of the dust seal. ● inatall the dust seal. Dust seal dust seal dust seal d...

  • Page 148

    13-11 front wheel/front fork/steering ● align the wheel hub tangs with the slots of the gear box retainer, and assemble the speedometer gear box seal. ● apply grease to the dust seal rim. ● install the dust seal, and align the tangs of the gear box ratainer with the gear groove to assemble the speed...

  • Page 149: Front Fork

    13-12 front wheel/front fork/steering front fork removal ● remove the front fender. ( ⇨ 12-5 ) ● remove the front wheel. ( ⇨ 13-7 ) ● install the brake caliper and tighten the new mounting bolts to the specified torque. Torque : 3.0kgf · · m (30n · · m) ● install the brake hose clamp. ● with the fro...

  • Page 150

    13-13 front wheel/front fork/steering socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt ● wrap the bottom case with a piece of cloth, ...

  • Page 151

    13-14 front wheel/front fork/steering ● remove the oil seal stopper ring. ● pull the fork pipe out until you feel resistance from the slider bushing. ● then move it in and out, tapping the bushing lightly until the fork pipe separates from the bottom case. ● the slider bushing will be forced out by ...

  • Page 152

    13-15 front wheel/front fork/steering ● check components for damage or abnormal wear. Replace defective parts with new ones. ● place the fork pipe in v-block and measure the runout. Actual runout is 1/2 the total indicator reading. Service limit : 0.2mm ● visually inspect the slider and fork pipe bu...

  • Page 153

    13-16 front wheel/front fork/steering assembly ● before assembly, wash all parts with a clean oil and wipe them dry. ● install the dust seal, stopper ring, new oil seal, back-up ring, and slider bushing. ● install a new fork pipe bushing. ● install the fork pipe into the bottom case. ● apply atf to ...

  • Page 154

    13-17 front wheel/front fork/steering stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring stopper ring dust seal dust seal dust seal dust seal dust seal dust...

  • Page 155

    13-18 front wheel/front fork/steering ● pour the specified amount of automatic transmission fluid(atf) into the fork pipe. Capacity : 265 ± ± 2.5cc ● slowly press the fork tube 2-3 times to discharge air. ● install the fork spring to the fork pipe. ● install the new o-ring to the fork cap bolt. ● in...

  • Page 156

    13-19 front wheel/front fork/steering installation ● install the fork pipe through the bottom bridge, fork top bridge and handle pipe. ● position the marking line of the fork pipe with the upper surface of the top bridge as shown. ● tighten the bottom bridge pinch bolt to the specified torque. Torqu...

  • Page 157: Steering Stem

    13-20 front wheel/front fork/steering steering stem removal ● remove the following : - front wheel ( ⇨ 13-7 ) - handlebar ( ⇨ 13-3 ) - front fork ( ⇨ 13-12 ) ● remove the flange bolts and front brake hose stay. ● remove the steering stem nut. ● remove the steering head top thread nut using the speci...

  • Page 158

    13-21 front wheel/front fork/steering race replacement ● install the new ball races into the head pipe using the driver and attachment. ● remove the ball races from the steering head using the ball race dirver. Tool : ball race driver ● temporarily install the steering stem nut onto the stem to prev...

  • Page 159

    13-22 front wheel/front fork/steering ● install the steel ball. ● apply grease to top and bottom ball races and cone races. ● instert the steering stem into the steering head pipe. ● insall the steel ball and top cone race. ● install and tighten the steering head top thread to the initial torque. To...

  • Page 160

    13-23 front wheel/front fork/steering ● install the top bridge, washer and steering stem nut. ● temporarily install the r/l front forks, then tighten the steering stem nut to the specified torque. Torque : 7.4 kgf · · m (74n · · m) ● install the following: - front fork ( ⇨ 13-17 ) - handlebar ( ⇨ 13...

  • Page 161

    14-0 rear wheel/rear suspension.

  • Page 162: Service Information

    14-1 14. Rear wheel/rear suspension 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 respiratory diseas...

  • Page 163: Troubleshooting

    Troubleshooting wobble or vibration in motorcycle ● bent rim ● worn rear wheel bearing ● damaged tire ● axle not tightened properly ● insufficient air in tire ● worn rear fork bush soft suspension ● weak spring ● improper rear cushion adjust ● incorrect rear damper hard suspension ● improper rear cu...

  • Page 164: Rear Wheel

    14-3 rear wheel/rear suspension rear wheel removal ● support the motorcycle using a safety stand or hoist, raise the rear wheel off the ground. ● loosen the chain adjust nuts and lock nuts. ● remove the axle nut (u-nut). Inspection axle ● place the axle in v-blocks and measure the runout. ● actual r...

  • Page 165

    14-4 rear wheel/rear suspension driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sprocket driven sproc...

  • Page 166

    14-5 rear wheel/rear suspension oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal remover head remover head remover head remover head remover head remover head remover head remover head remover head remover...

  • Page 167

    14-6 rear wheel/rear suspension wheel bearing installation ● drive in a new left bearing squarely. ● install the distance collar. ● drive in a new right bearing. Tools : driver attachment pilot 15mm ● apply grease to the new dust seal and install it into the wheel hub. ● if having removed the damper...

  • Page 168: Rear Cushion

    14-7 rear wheel/rear suspension installation ● install the side collar. ● place the rear wheel into the swingarm. ● install the drive chain over the driven sprocket. ● install the axle from the left side. ● install the axle nut. ● adjust the drive chain slack. ( ⇨ 2-8 ) ● tighten the axle nut to the...

  • Page 169

    14-8 rear wheel/rear suspension inspection ● visually inspect the rear cushion for damage. ● check for the : - damper rod for bend or damage - damper unit for deformation or oil leaks - cushion rubber for wear or damage ● inspect all the other parts for wear or damage. ● if necessary, replace the re...

  • Page 170: Swingarm

    14-9 rear wheel/rear suspension installation ● install the rear cushion into the frame from the bottom, and install the upper mounting bolt. ● tighten the bolt to the specified torque. Torque : 3.4 kgf · · m ( 3.4 n · · m) ● install the lh. Side cover. ● install the rear cushion lower mounting bolt....

  • Page 171

    14-10 rear wheel/rear suspension chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider chain slider dust seal cap dust seal cap dust ...

  • Page 172

    14-11 rear wheel/rear suspension assembly ● apply grease to the center collar, bearing and bushes. ● install the center collar, bearings and bushes to the swingarm. ● install the dust seal caps into the swingarm. ● install the drive chain slider on the swingarm, then tighten the screws. Torque : 0.6...

  • Page 173

    14-12 rear wheel/rear suspension installation ● apply thin coat of grease to the swingarm pivot bolt surface. ● install the swingarm into the frame, then install the pivot bolt from the left side. ● install the u-nut. ● hold the pivot bolt using a special tool, tighten the u- nut to the specified to...

  • Page 174: Memo

    Memo.

  • Page 175

    15-0 hydraulic brake front : rear :.

  • Page 176: 15. Hydraulic Brake

    15-1 15. Hydraulic brake service information general safety ● don't put in dust or water when filling the reservoir. ● don't mix different types of fluid to prevent from changing chemically. ● don't use the removed brake fluid. ● avoid spilling brake fluid or painted plastic and rubber parts because...

  • Page 177: Troubleshooting

    15-2 hydraulic brake troubleshooting 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/disk. ● contaminated caliper. ● caliper not slid...

  • Page 178: Brake Fluid Replacement/

    15-3 hydraulic brake brake fluid replacement/ air bleeding screws screws screws screws screws screws screws screws screws screws screws screws screws screws screws screws reservoir cap reservoir cap reservoir cap reservoir cap reservoir cap reservoir cap reservoir cap reservoir cap reservoir cap res...

  • Page 179

    15-4 hydraulic brake ● connect a bleeder hose to the caliper bleeder valve. ● loosen the bleeder valve and pump the brake lever or pedal. ● stop pumping the lever or pedal when no more fluid flows out of the bleeder valve. Brake fluid filling ● fill the reservoir with dot3 or dot4 brake fluid up to ...

  • Page 180

    15-5 hydraulic brake diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm diaphragm dia...

  • Page 181: Brake Pad/disk

    Brake pad/disk front brake pad replacement ● push the caliper pistons all the way in to allow installation of new brake pads. ● remove the hanger pin and brake pads. ● clean the inside of the caliper especially around the caliper pistons. ● remove the brake hose clamp from the front fork. ● remove t...

  • Page 182

    15-7 hydraulic brake dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dust plugs/hanger pins dus...

  • Page 183

    15-8 hydraulic brake ● remove the rear caliper bracket bolts and brake caliper. ● remove the hanger pins and brake pads. ● make sure the brake pad spring is in place. ● install the new brake pads. ● install the hanger pins. ● install the brake caliper to the caliper bracket so the disk is positioned...

  • Page 184: Front Master Cylinder

    15-9 hydraulic brake oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt oil bolt master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder maste...

  • Page 185

    15-10 hydraulic brake disassembly ● remove the handle lever bolt/nut and rh. Handle lever assembly. ● remove the screw and front stop switch. ● remove the boot. ● remove the snap ring from the master cylinder body using the special tool as shown. Tool : snap ring pliers ● remove the master piston an...

  • Page 186

    15-11 hydraulic brake inspection ● check the piston for abnormal scratches. ● check the primary cup and secondary cup for fatigue or damage. ● measure the master cylinder piston o. D. Service limit : 12.645mm assembly ● check the master cylinder for abnormal scratches. ● measure the master cylinder ...

  • Page 187

    15-12 hydraulic brake ● coat all parts with clean brake fluid before assembly. ● dip the piston in brake fluid. ● install the spring into the piston. ● install the piston assembly into the master cylinder. ● install the snap ring. Tool : snap ring pliers ● install the boot. ● install the front stop ...

  • Page 188: Rear Master Cylinder

    15-13 hydraulic brake ● install the rh. Handle lever assembly, tighten the bolt. ● hold the bolt and tighten the nut. Installation ● place the master cylinder assembly on the handlebar. ● align the end of the master cylinder with the punch mark on the handlebar. ● install the master cylinder holder ...

  • Page 189

    15-14 hydraulic brake ● loosen the rear master cylinder mounting socket bolts. ● remove the main step holder socket bolts and main step bar assembly. ● unhook the stop switch spring from the brake pedal spring. ● remove and discard the brake pedal joint cotter pin. ● remove the joint pin c. ● remove...

  • Page 190

    15-15 hydraulic brake ● remove the brake rod joint, master piston and spring. ● clean the inside of the cylinder with brake fluid. Inspection ● check the piston for abnormal scratches. ● check the primary cup and secondary cup for fatigue or damage. ● measure the master cylnder piston o.D. Service l...

  • Page 191

    15-16 hydraulic brake assembly ● install the rear brake rod into the master cylinder. ● install the snap ring. Tool : snap ring pliers ● install the boot. Snap ring pliers snap ring pliers snap ring pliers snap ring pliers snap ring pliers snap ring pliers snap ring pliers snap ring pliers snap ring...

  • Page 192

    15-17 hydraulic brake ● apply brake fluid to a new o-ring and install it onto the tube joint pipe. ● install the tube joint pipe into the master cylinder. ● install and tighten the screw to the specified torque. Installation ● place the master cylinder onto the main step holder, install the master c...

  • Page 193: Front Brake Caliper

    15-18 hydraulic brake front brake caliper removal ● drain the front brake hydraulic system. ( ⇨ 15-5 ) ● remove the oil bolt and washers. ● remove the speedometer cable clamp. ● remove the caliper mounting bolts, caliper and the brake pads. ( ⇨ 15-6 ) disassembly ● remove the pad spring, slide pin, ...

  • Page 194

    15-19 hydraulic brake inspection ● check the caliper cylinder for scoring or other damage. ● measure the caliper cylinder i. D. Service limit : 25.42mm assembly ● check the caliper pistons for scratches, scoring or other damage. ● measure the caliper piston o. D. Service limit : 25.27mm caliper brac...

  • Page 195: Rear Brake Caliper

    15-20 hydraulic brake ● coat the new piston seals with clean brake fluid. ● coat the new dust seals with silicone grease. ● install the piston seal and dust seal into the groove of the caliper body. ● coat the caliper pistons with clean brake fluid and install them into the caliper cylinder with the...

  • Page 196

    15-21 hydraulic brake ● remove the rear caliper bracket bolts and the brake pads. ( ⇨ 15-7 ) ● pivot the caliper up and remove it. Disassembly ● remove the pad spring, slide pin, caliper bracket and boot from the caliper body. ● if there is any wear or damage in the boot, replace it with a new one. ...

  • Page 197

    15-22 hydraulic brake inspection ● check the caliper cylider for scoring or other damage. ● measure the caliper cylinder i. D. Service limit : 25.070mm ● check the caliper pistons for scratches, scoring or other damage. ● measure the caliper piston o. D. Service limit : 24.870mm ● coat the new pisto...

  • Page 198: Brake Pedal

    15-23 hydraulic brake ● apply the boot with silicone grease. ● install the boot into the groove of the caliper body. ● install the pad spring into the caliper body. ● install the caliper pin bolt and caliper bracket into the caliper body. Installation ● install the brake pads and caliper onto the re...

  • Page 199

    15-24 hydraulic brake installation ● apply grease to the sliding surface of the brake pedal. ● assemble the brake pedal, washer and external cir-clip. ● hook the brake pedal spring. ● connect the brake pedal to the brake rod joint. ● install the joint pin c and secure it with a new cotter pin. ● hoo...

  • Page 200: Memo

    Memo.

  • Page 201

    16-0 battery/charging system g b r r r b p p b b l (high) (low) w lighting switch dimmer switch br/w br/w br/w br/w br/w br/w cdi unit br/w b(cable) headlight relay headlight (12v 35/35w) speedometer illum. (12v 2w x 2ea, 12v 3w) tail light (12v 5w) battery (12v 10ah) y y a.C. Generator reg. Recti. ...

  • Page 202: 16. Battery/charging System

    16-1 16. Battery/charging system service information · do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery. · do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can caus...

  • Page 203: Troubleshooting

    16-2 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 p...

  • Page 204: Battery

    16-3 battery/charging system battery removal/installation ● remove the seat. ( ⇨ 12-2 ) ● remove the battery band. ● disconnect the negative cable and then the positive cable and remove the battery. ● install the battery in the reverse order of removal with the proper wiring. Voltage inspection ● me...

  • Page 205: Charging System Inspection

    Charging system inspection current leakage inspecition ● turn the ignition switch off and disconnect the negative battery cable from the battery. ● connect an ampere meter between negative (-) terminal and ground cable. ● with the ignition switch off, check for current leakage. Leak current : not to...

  • Page 206: Regulator/rectifier

    16-5 battery/charging system regulator/rectifier harness side circuit inspection ● remove the seat. ( ⇨ 12-2 ) ● remove the lh. Side cover. ( ⇨ 12-2 ) ● disconnect the regulator/rectifier coupler. ● inspect the wiring circuits at each terminal of the wire harness side. Inspection items check that th...

  • Page 207: A.C. Generator Charging

    16-6 battery/charging system regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator rectifier regulator r...

  • Page 208: Memo

    Memo.

  • Page 209

    Side stand switch g fuse (15a) g/w gear position switch spark plug ignition coil battery (12v 10ah) g g w/l b/y r g b p b/w g/w g l/y a.C. Generator pulse generator headlight relay l/y w/l b/y cdi unit b/w main switch b...... Black y.......Yellow l..... Blue g..... Green r......Red w..... White p......

  • Page 210: 17. Ignition System

    17-1 17 17. 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 ...

  • Page 211: Troubleshooting

    17-2 ignition system troubleshooting no spark at plug. 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 212: Cdi Unit Inspection

    17-3 ignition system follow the steps described in the troubleshooting flow chart when servicing the ignition system. Follow the tester manufacturer’s instructions. Improper connections could damage the cdi unit or tester. Cdi unit inspection cdi ignition circuit inspection pulse generator inspectio...

  • Page 213: Ignition Coil Inspection

    17-4 ignition system pva measurement ● disconnect the a.C generator blue / yellow wire connector. ● connect the peak voltage adaptor probes to the pulse generator wire terminal of the wire harness side connector and ground. ● crank the engine with the starter motor and measure the peak voltage of pu...

  • Page 214: Ignition Timing

    17-5 ignition system replacement ● remove the high-tension cord from the plug, remove the plug cap. ● remove the wire from the ignition coil. ● remove the primary wire from the ignition coil. ● loosen the ignition coil mounting bolt securing the frame, remove the ignition coil. ● install in the reve...

  • Page 215

    Ignition system 17-6 side stand switch inspection ● remove the rh. Side cover. ( ⇨ 12-2 ) ● remove the side stand switch coupler connected with wire. ● check the following terminals. Black/white and green terminal black/white and green terminal normal if there is continuity normal if there is no con...

  • Page 216: Memo

    Memo.

  • Page 217

    18-0 electric starter b......Black y.......Yellow g......Green r......Red w..... White lg.....Light green ignition control unit side stand switch starter magnetic switch starter switch main switch neutral lamp y/r fuse (15a) battery (12a 10ah) b(cable) b(cable) b g r gear position g/y g/w b/w lg/r l...

  • Page 218: 18. Electric Starter

    18-1 18. Electric starter service information general safety · always turn the ignition switch off before servicing the starter motor. The moter could suddenly start, causing serious injury. ● the starter motor can be maintained without removing the engine from the vehicle. ● a weak battery may be u...

  • Page 219: Troubleshooting

    18-2 electric starter troubleshooting starter motor will not turn. ● check for a blown out main fuse before servicing. ● make sure the battery is fully charged and in good condition. With the ignition switch “ on ” , check for a “ click ” sound from starter magnetic switch. ( ⇨ 18-9 ) connect the st...

  • Page 220: Starter Motor

    Starter motor removal ● with the ignition switch turned to "off", remove the negative cable at the battery before servicing the starter motor. ● remove the rubber cap. ● remove the nut and starter motor cable from the starter motor. ● remove the holder mounting bolts and clutch wire holder. ● remove...

  • Page 221

    18-4 electric starter commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars commutator bars armature armature arma...

  • Page 222

    18-5 electric starter ● check for continuity between the cable terminal and the case. ● there should be no continuity. ● check for continuity between the insulated brush and cable terminal. ● there should be continuity. ● check for continuity between each commtator bar and armature shaft. ● there sh...

  • Page 223

    18-6 electric starter ● inspect the brushes for damage and measure the brush length. Service limit : 5 mm ● remove the following: - washer nut - washer - o-ring - terminal setting bush - brush holder rear cover armature brush brush holder seal ring seal ring front cover shim o-ring lock washer brush...

  • Page 224

    18-7 electric starter ● install the armature in the motor case, while pushing in the brushes into the brush holder. ● when installing the armature into the motor case, hold the armature tightly to keep the magnet of the case from pulling the armature against it. ● install the two washers. ● install ...

  • Page 225

    18-8 electric starter ● install the cir-clip and washers onto the armature shaft. ● install a new seal ring onto the motor case. ● apply grease to the bushing in the front cover. ● install the lock washer onto the front cover. ● install the front cover, aligning its mark with the motor case mark. ● ...

  • Page 226: Starter Magnetic Switch

    18-9 electric starter starter magnetic switch removal ● remove the seat. ( ⇨ 12-2 ) ● remove the rh. Side cover. (12-2) ● disconnect the battery wire cable from the starter magnetic switch terminal. ● disconnect the starter motor cable from the starter magnetic switch terrminal. ● disconnect the yel...

  • Page 227

    18-10 electric starter continuity inspection ● disconnect the wire connector of the magnetic switch. ● connect the positive wire to the yellow/red wire terminal and the negative wire to the green/yellow wire terminal. ● there should be continuity. Installation ● install in the reverse order of remov...

  • Page 228: Memo

    Memo.

  • Page 229

    Lights/meter/switches 19-0 starter relay neutral switch right handlebar switch ignition switch left handlebar switch horn fuel unit fr. Stop switch winker relay.

  • Page 230: 19. Lights/meter/switches

    19-1 19. Lights/meter/switches service information general safety ● connect the same color wires together. Connect couplers carrying the same color and the same number of pins together. ● all couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert ...

  • Page 231: Troubleshooting

    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 charged ● faulty light bulb ● faul...

  • Page 232: Headlight

    19-3 lights/meter/switches headlight bulb replacement ● remove the headlight mounting screws and headlight. ● disconnect the headlight socket. ● unhook the bulb retainer and remove the headlight bulb. ● install the new headlight bulb aligning its tabs with the groove in the headlight unit. ● hook th...

  • Page 233: Position Light

    19-4 lights/meter/switches position light bulb replacement ● pull out the position light bulb socket. ● remove the bulb from the socket, replace it with a new one. ● install the position light bulb socket and headlight unit in the reverse order of removal. Front/rear winker bulb rreplacement ● remov...

  • Page 234: Combination Meter

    19-5 lights/meter/switches bulb replacement ● remove the screws and tail light lens. ● slightly press down on the bulb and turn it counterclockwise. ● replace with a new bulb. ● install in the reverse order of removal. Combination meter removal ● loosen the speedometer cable nut and remove the cable...

  • Page 235

    19-6 lights/meter/switches ● remove the meter stay mounting nuts. ● remove the meter stay from the combination meter assembly ● install the meter stay to the combination meter and tighten the meter stay mounting nuts securely. Installation ● install the combination meter onto the fork top bridge. ● ...

  • Page 236: Main Switch

    19-7 lights/meter/switches main switch inspection ● remove the headlight. ( ⇨ 19-3 ) ● disconnect the main switch wire connector. ● remove the socket bolts and combi switch. ● install the new main switch mounting socket bolts and tighten the bolts to the specified torque. ● install in the reverse or...

  • Page 237: Handlebar Switches

    Bat3 hi lo bat2 hi (n) lo color b/w l w b bat2 hi hi color b l ho bat 2 free push color lg b w r l r n l color gr sb o bat2 tl hl off p h color v br br/l w r l off haz color gr sb o st 1 bat 2 free push color y/r b 19-8 lights/meter/switches handlebar switches ● remove the headlight. (19-3) ● discon...

  • Page 238: Front/rear Stop Switch

    19-9 lights/meter/switches front/rear stop switch front ● disconnect the front stop switch connectors and check for continuity between the terminals. ● there should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released. Neutral switch ● remove...

  • Page 239: Winker Relay

    19-10 lights/meter/switches winker relay ● remove the rear seat. ( ⇨ 12-2 ) ● check the following: - battery condition - burned bulbs - burned fuse - main switch and winker switch function - loose connectors ● if the above items are all normal, check the following: fuel unit removel ● remove the sea...

  • Page 240

    19-11 lights/meter/switches inspection ● move the float upward and downward, and measure the resistance between the terminals. Installation ● install the base packing ● install the fuel unit aligning its groove with the part of the fuel tank. ● install the unit set cap. ● connect the fuel unit coupl...

  • Page 241: Memo

    Memo.

  • Page 242

    20-1 20. Wiring diagram 20 / b w lg/r g/w g/w w g / b/w 3p mini b/w g/w lg/r b/w g/w lg/r ignition control unit v sb sb o o g g g g g b b b bat 2 ho gr w lg b bat l hi sb r 2 o l w lo 3 br/w bat b bat winker,dimmer,passing,horn s/w. 2 12v 5w position light br g hl 3 bat tl br/l v br off p h color li...

  • Page 243: 21. Troubleshooting

    21-1 21 21. Troubleshooting engine won’t start or is hard to start · ·· ·· ·· ·· · 21-1 engine lacks power · ·· ·· ·· ·· · 21-2 poor performance (at low and idle speed) · ·· ·· ·· · 21-3 poor performance (at high speed) · ·· ·· ·· ·· ·· ·· ·· · 21-4 engine won’t start or is hard to start 1. Check fu...

  • Page 244: Engine Lacks Power

    21-2 troubleshooting engine lacks power pressure normal pressure low ● punctured tire. ● faulty tire valve. 1. Check tire pressure. Wheel rotate freely. Wheel don’t rotate freely ● dragged brake. ● worn or damaged wheel bearings. ● lacked wheel bearings lubrication. ● d ● axle nut tightened excessiv...

  • Page 245

    21-3 troubleshooting poor performance (at low and idle speed) inspection cause of trouble not contaminated or not discolored. Contaminated or discolored ● lean fuel mixture. ● using spark plug with on incorrect heat range. 9. Check the spark plug. Level normal level low or high ● oil level too high....

  • Page 246: Poor Handling

    21-4 troubleshooting poor handling 1. If steering is heavy. ● too tight steering top thread. ● damaged steering bearings. 2. If either wheel is wobbling ● excessive wheel bearing play. ● bent rim. ● improperly installed wheel hub. ● worn rear fork pivot bush. ● bent frame. ● rear fork pivot adjustin...

  • Page 247: Fuel Gauge

    21-5 troubleshooting inspection cause of trouble inspection cause of trouble ● cushion spring weak. ● overloaded. ● damper oil leaks. ● fork pipe or cushion rod bent. ● sliders stuck. ● cushion stopper rubber damaged. 1. Suspension excessively soft. 2. Suspension excessively hard. 3. Noise from the ...

  • Page 248

    21-6 troubleshooting inspection cause of trouble ● fuse cut. ● battery weak or totally discharged. ● ignition switch damaged or shorted. ● terminal loose of faulty connection. ● wire harness damaged. ● faulty fuel level sensor connection. ● damper oil inside the meter insufficient. ● faulty connecti...

  • Page 249: Memo

    Memo.

  • Page 250: Memo

    Memo.

  • Page 251

    Service manual 2004. 1. Printed 2004. 1. Publication no c copy.