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DAELIM S2-125 Service Manual - 10. Cylinder / Piston

Other manuals for S2-125: Owner's Manual, Service Manual

Summary of S2-125

  • Page 2: Contents

    How to use this manual this manual describes effective maintenance procedure for the s2-125 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 p...

  • Page 4: 1. Service Information

    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 standard torque values 1-13 symbols 1-13 lubrication oil 1-14 wiring diagram 1-15 general safety 1. Do not run the engine for a long time in closed or...

  • Page 5

    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 6

    1-3 service 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 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 8: 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 9

    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 10

    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 11

    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 12: Serial Number Location

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

  • Page 13: Specifications

    1-10 service information specifications item specifications 2,110 mm 745 mm 1,356 mm 1,481 mm 760 mm 121 mm 150 kg 294 kg underbone telescopic swing arm 120 / 70 - 12 / tubeless 130 / 70 - 12 / tubeless 2.00 kgf / ㎠ 2.00 kgf / ㎠ 2.00 kgf / ㎠ 2.25 kgf / ㎠ hydraulic disk hydraulic disk 11ℓ 2.8ℓ 27。 87...

  • Page 14

    1-11 service information item specifications cv type ( vacuum ) ф25 mm cvk 116 a auto-bystarter # 102 2 and ½ trust out 20.5 mm 1.700±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 10ah cr8eh - 9 (ng...

  • Page 15: Torque Values

    1-12 service information torque values item reference torque value thread dia (mm) q’ty 7.0 kgf·m 0.25 kgf·m 7.5 kgf·m 6.0 kgf·m 6.0 kgf·m 3.1 kgf·m 1.2 kgf·m 4.25 kgf·m 12.5 kgf·m 3.1 kgf·m 1.2 kgf·m 4.25 kgf·m 0.43 kgf·m 2.25 kgf·m 4.0 kgf·m 4.0 kgf·m 3.5 kgf·m 5.25 kgf·m 4.5 kgf·m 4.0 kgf·m 1.5 k...

  • Page 16: Standard Torque Values

    1-13 service information standard torque values item item torque value torque value 0.5 kgf·m 1.0 kgf·m 2.2 kgf·m 3.5 kgf·m 5.5 kgf·m 0.4 kgf·m 0.9 kgf·m 1.2 kgf·m 2.7 kgf·m 4.0 kgf·m 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut 5mm screw 6mm screw 6mm flange bolt, nut 8mm...

  • Page 17: Wiring Diagram

    1-14 service information wiring diagram level level oil oil lighting cord (export use only) winker sw. Cord fr. Brake hose rr. Brake hose throttle cable horn wire wire clip horn wire clip fr. Brake hose hose clip fuel supply tube tube clamp fr. Brake hose speedometer cable brake hose clamp radiator ...

  • Page 18

    1-15 service information fuel tube (to. Insulator) fuel strainer wire clip wire clip ign. Coil wire harness hightension cord tube c, a.I.C.V side stand sw. Coupler auto choke coupler lh. Seat lock coupler air cleaner connecting tube band b 45, air cleaner connecting tube rh. Seat lock cable rr. Brak...

  • Page 19

    1-16 service information reg. Rectifier wier clip wier clip acg. Cord start-magnetic sw. Start-motor cable earth cable start-magnetic sw. Cord reg. Rectifier cord battery + cable head light relay winker relay earth cable battery box coupler *note - white color : export use only - black color : domes...

  • Page 20

    1-17 service information start-mag. Sw. Cord battery earth cable wire clip acg. Wire to. Fuel tank acg. Cord tube clip tube clip to. Insulator fuel pump to. Carbulator tube clip start motor cable start-magnet sw. Ass’y. Battery + cable frame body comp. Battery + cable 12v 10ah battery (mf) earth cor...

  • Page 21: Memo

    Memo.

  • Page 22: 2. Inspections/adjustments

    2-1 2. Inspections/adjustments service information specifications tires 2 service information · ·· ·· · 2-1 maintenance schedule ·· 2-3 fuel line (fuel tube) · ·· ·· · 2-4 throttle grip operation · ·· · 2-4 air cleaner · ·· ·· ·· ·· ·· ·· · 2-4 spark plug · ·· ·· ·· ·· ·· ·· · 2-5 valve clearance · ...

  • Page 23

    2-2 inspections / adjustments 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.

  • Page 24: Maintenance Schedule

    2-3 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 25: Fuel Line(Fuel Tube)

    2-4 inspections / adjustments fuel line(fuel tube) ● remove the luggage box . ● check the fuel tube of the fuel auto cock connected to the fuel tank and carburetor. If the fuel tube is cranked, damaged or leaks, replace it. Throttle grip operation ● check if the throttle grip operates smoothly in an...

  • Page 26: Air Cleaner

    2-5 inspections / adjustments air cleaner ● loosen the 6 screws securing the air cleaner case cover, remove it. ● loosen the 2 screws securing the air cleaner element holder, remove it. Valve clearance ● remove the following parts. -luggage box. ( ⇨ 4-4) -center cover. ( ⇨ 4-5) ● loosen the 4 cylind...

  • Page 27: Spark Plug

    2-6 inspections / adjustments spark plug ● remove the plug maintenance cover. ● remove the spark plug cap and disassemble the plug. ● check the plug for damage, contamination or deposits. ● if the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after...

  • Page 28: Carburetor Idle Speed

    Oil check bolt 2-7 inspections / adjustments carburetor idle speed ● remove the plug maintenance cover. ( ⇨ 4-5) ● check the idle speed and adjust if necessary by turning the throttle stop screw. •verify all engine adjustments satisfy specifications. Make adjustments, if necessary. •heat the engine ...

  • Page 29: Brake Fluid

    2-8 inspections / adjustments brake fluid ● remove the brake fluid cover. ● check the oil level inside the front brake reservoir. If the oil level is near the lower limit line, remove the reservoir diaphragm and fill dot 3 and dot 4 brake fluid to the top limit line. ● if the brake fluid reaches the...

  • Page 30: Suspension

    2-9 inspections / adjustments suspension front wheel ● hold the brake lever, and compress the front cushion up and down several times to check the operating conditions. ● check the front fork for oil leakage, parts damage or looseness. Rear wheel ● compress the near cushion up and down several times...

  • Page 31: Wheels/tires

    2-10 inspections / adjustments wheels/tires standard pressure •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. ● check the tread depth at the tire center. ● if the...

  • Page 32: Service Information

    3-1 service information ● 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. 3. External parts 3 service information · ·· ·...

  • Page 33: Seat

    3-2 external parts seat ● release the seat lock by turning the main switch key to open the seat. ● loosen the flange nuts and remove the seat. ● install in the reverse order of removal. Rear grip ● remove the rear grip cap (r.L) ● loosen the 4 special bolts. ● install in the reverse order of removal...

  • Page 34: Luggage Box

    3-3 external parts luggage box ● remove the seat. ● remove the pillion seat. ● remove the luggage box top cover. ● loosen the screws on the seat catch. ● loosen the open stay nuts. ● loosen the washer bolts. ● remove the wire for the trunk lamp. ● install in the reverse order of removal. Center cove...

  • Page 35: Body Cover

    3-4 external parts body cover ● remove the rr. Grip r/l ● remove the following parts - seat - luggage box - center cover - body side cover ● loosen the special screw ● loosen the body cover clip (r/l) ● remove the wire for the tail light and pull the body cover backward. ● install in the reverse ord...

  • Page 36: Front Cover

    3-5 external parts front cover ● loosen the 2 tapping screws securing the fornt cover ● loosen the 2 tapping screws securing the inner cover ● install in the reverse order of removal under cover ● loosen the 4 special screws (r/l, 2ea for each) to remove the under cover ● install in the reverse orde...

  • Page 37: Windscreen

    3-6 external parts windscreen ● remove the front cover ● loosen the 4 washer bolts and remove the windscreen ● install in the reverse order of removal front under cover a ● remove the front cover and windscreen ● loosen the 7 tapping screws securing the inner cover ● install in the reverse order of ...

  • Page 38: Inner Cover

    3-7 external parts ● loosen the 4 tapping screws securing the inner cover inner cover ● remove the front cover and windscreen ● remove the coolant reserve tank ● remove the fuel tube clip ● remove the breather tube ● loosen the 3 screws securing the inner cover ● remove the bag holder ● loosen the 2...

  • Page 39: Front Fender

    3-8 external parts front fender ● loosen the 4 screws (r/l, 2ea for each) ● install in the reverse order of removal ex. Pipe ● loosen the 2 cap nuts securing the cylinder comp. ● pull the ex. Pipe comp. Downward to remove it ● install in the reverse order of removal muffler ● loosen the muffler flan...

  • Page 40: 4. Lubrication System

    4-1 lubrication system 4. Lubrication system 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 contect with the...

  • Page 41: Troubleshooting

    4-2 lubrication system 4-2 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 pressu...

  • Page 42: Engine Oil Level Inspection

    4-3 lubrication system upper line proper line lower line sight glass oil drain plug oil pick up collar oil filter screen tappet adjusting hole cap 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 eng...

  • Page 43: Oil Filter Element Change

    4-4 lubrication system oil filter element change ●drain engine oil. ( ⇨ 4-3) ●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...

  • Page 44

    4-5 lubrication system 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. ●measu...

  • Page 45

    4-6 lubrication system ●install the inner and outer rotors to the pump body. ●assemble the pump shaft with setting pin. Oil pump assembly ●clean all parts with fresh cleaning oil. ●install the oil pump plate to the pump body. ●tighten the pan screw. Oil pump installation ●install the oil pump to the...

  • Page 46: Radiator

    4-7 lubrication system radiator removal ●remove the front cover. ( ⇨ 3-5) ●remove the front wheel. ( ⇨ 12-4) ●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. Inspection ●check the oil line connec...

  • Page 47: Transmission Oil Inspection

    4-8 lubrication system radiator installation ●tighten the 3 radiator setting flange bolts to the main pipe bracket. •oil level inspection must be performed in the flat ground with the vehicle being straight by raising the main stand. Recommended oil : sae 80w/90 ●tighten the oil check bolt. Torque v...

  • Page 48: Lubrication Points

    4-9 lubrication system 4-9 lubrication system 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...

  • Page 49: Memo

    Memo.

  • Page 50: Service Information

    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 kee...

  • Page 51: 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 52: Fuel Tank

    5-3 fuel system fuel tank removal ● release the seat lock by turning the main switch key to open the seat. ● remove the following parts. - luggage box . ( ⇨ 3-2) - floor panel leg . - center cover. - rear center cover. - rear carrier/back rest . - body cover. ● remove the fuel tube from the fuel tan...

  • Page 53

    5-4 fuel system •air leaks out of the vacuum chamber if the diaphragm is damaged in any way-even a pin hole. Jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet needle jet ...

  • Page 54

    5-5 fuel system 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, scratches, clogging and damage. Replace if necessary. ● check the float valve operation. ● remove the ...

  • Page 55

    5-6 fuel system carburetor cleaning ● after removing all parts, blow open air and fuel passages in the carburetor body with compressed air. Float chamber/float/jet assembly ● install the needle jet, needle jet holder, main jet and slow jet. ● tighten the pilot jet until it seats lightly, then turn i...

  • Page 56

    5-7 fuel system 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 can be bent, adjust the float level by bending the lip. ...

  • Page 57

    5-8 fuel system caburetor installation ● install the carburetor to the carburetor insulator. ● tighten the carburetor insulator band screw. ● tighten the setting screw securing the carburetor and set plate. ● install the fuel tube to the carburetor. ● install the wiring coupler of the auto bystarter...

  • Page 58: Pilot Screw Adjustment

    5-9 fuel system pilot screw adjustment ● remove the carburetor maintenance cover. ( ⇨ 3-3) 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 adjust the idle speed with the throttle stop sc...

  • Page 59: Memo

    Memo.

  • Page 60: Service Information

    Service information general safety •use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •attach tape to the frame to protect it during the engine removal or installation. ● the following works ca...

  • Page 61: Engine Removal

    6-2 engine removal/installation 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 ( ⇨ 3-2) -center cover ( ⇨ 3-3) -air cleaner ( ⇨ 2-5) -carburetor ( ⇨ 5-3) ● disconnect the a.C generator coupler...

  • Page 62

    6-3 engine removal/installation ● 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 attached) ● remove the ...

  • Page 63

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

  • Page 64: 7. Lh. Crankcase Cover

    7-1 7. Lh. Crankcase cover /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 cover is remo...

  • Page 65: Lh. Crankcase Cover

    7-2 lh. Crankcase cover/continuously variable transmission 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 crankc...

  • Page 66: Drive Belt

    7-3 lh. Crankcase cover/continuously variable transmission 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 ● squeeze the drive belt into the pulley groove as shown ...

  • Page 67

    7-4 lh. Crankcase cover/continuously variable transmission 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 ● turn the pu...

  • Page 68: Movable Drive Face

    7-5 lh. Crankcase cover/continuously variable transmission ● 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 th...

  • Page 69

    7-6 lh. Crankcase cover/continuously variable transmission 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. ● measu...

  • Page 70

    7-7 lh. Crankcase cover/continuously variable transmission ● 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. ● hold the drive face using the drive face holder and tighten the nut to the specifie...

  • Page 71: Clutch/driven Pulley

    7-8 lh. Crankcase cover/continuously variable transmission 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...

  • Page 72

    7-9 lh. Crankcase cover/continuously variable transmission ● 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. Seal collar oil seal...

  • Page 73

    7-10 lh. Crankcase cover/continuously variable transmission 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 th...

  • Page 74

    7-11 lh. Crankcase cover/continuously variable transmission ● 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...

  • Page 75

    7-12 lh. Crankcase cover/continuously variable transmission 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 c...

  • Page 76

    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 7-3) ● install the drive fa...

  • Page 77

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

  • Page 78: 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 79: A.C Generator

    8-2 a.C generator/starter clutch ● loosen the rh. Shroud 4 flange bolts and 4 tapping screws. ● remove the rh. Shroud. ● loosen the lh. Shroud setting screw. ● remove the lh. Shroud. ● install in the reverse order of removal. A.C generator removal ● loosen the rear cushion under bolt. ● remove the f...

  • Page 80

    8-3 a.C generator/starter clutch ● 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 the drive face with the drive face holder. ● loosen the flange nut securing the fly wheel, and remove...

  • Page 81: Rh. Crankcase Cover

    8-4 a.C generator/starter clutch 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 woodruff key, install the flywheel by aligning the groove with the woodruff key. ● temporari...

  • Page 82: Starter Reduction Gear

    8-5 a.C generator/starter clutch ● 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 oil seal for wear or damage and replace with a new one as necessary. Starter reduction gear r...

  • Page 83: 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. Starter clutch removal ● loosen the rear cushion under bolt. ● remove the following parts. -rh. Fl...

  • Page 84

    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 for wear or damage. ● measure the inner diameter of the starter driven gea...

  • Page 85

    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. Torqu...

  • Page 86: Memo

    Memo.

  • Page 87

    9-0 cylinder head / valve inlet valve rocker arm exhavst valve rocker arm cam shaft holder cam shaft comp carburetor insulator cylinder head comp cylinder head gasket inlet valve exhavst valve.

  • Page 88: 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 89: Troubleshooting

    9-2 cylinder head / valve 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 b...

  • Page 90: Camshaft

    9-3 cylinder head / valve camshaft removal ● remove the luggage box. ( ⇨ 3-2 ) ● remove the center cover. ( ⇨ 3-3 ) ● loosen the cylinder head cover bolts, remove the cover. ● remove the shroud grommet b of the fan cover. ● turn the crankshaft to the left, and align the “t”mark of the flywheel with ...

  • Page 91

    9-4 cylinder head / valve ● 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 arm shaft and rocker arm in the same sequence. Camshaft inspection ● check the rocker arm and rocker arm shaft for wear...

  • Page 92: Cylinder Head

    9-5 cylinder head / valve cylinder head removal ● remove the engine from the frame. ( ⇨ 6-2 ) ● remove the cylinder head cover. ● remove the rh. Lh. Shroud. ( ⇨ 8-2 ) ● remove the camshaft. ( ⇨ 9-3 ) ● remove the ex. Pipe. ( ⇨ 3-8 ) ● remove the cylinder head. ● manually turn the camshaft bearing ou...

  • Page 93: Valve Springs

    9-6 cylinder head / valve ● 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. Cylinder head inspect...

  • Page 94: Valve Guides

    9-7 cylinder head / valve 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. Tool : valve guide reamer ● measure and record each valve guide inner diameter. Service limit : 5.030 mm ● m...

  • Page 95: Valve Seats

    9-8 cylinder head / valve valve guide driver ● 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 new o-ring and install it onto a new valve guide. ● drive the new guide in from the camshaft side of t...

  • Page 96

    9-9 cylinder head / valve 37° valve seat 45° 37° 55° roughness 37° ● 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. ● ...

  • Page 97

    9-10 cylinder head / valve 55° 45° seat width 37° contact too high old seat width 55° contact too low old seat width ● using a 55 degree cutter, remove the bottom ¼ of the old seat. ● if the contact area is too low on the valve, the seat must be raised using a 55 degree inner cutter. Refinish the se...

  • Page 98: Cylinder Head Assembly

    9-11 cylinder head / valve stem seal valve spring retainer cotter narrow pitch ● after cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. Cylinder head assembly ● install new stem seals. ● lubricate each valve stem with molybdenum disulf...

  • Page 99

    9-12 cylinder head / valve cam chain guide cylinder head ● tap the valve stems gently with a soft hammer to firmly seat the cotters. ● 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 cha...

  • Page 100: Camshaft Assembly

    9-13 cylinder head / valve ex. Rocker arm shaft ex. Valve rocker arm in. Valve rocker arm in. Rocker arm shaft cam shaft holder cam shaft cam chain cylinder head "t" mark camshaft assembly ● apply engine oil to the rocker arm shaft, and assemble the rocker arm to the camshaft holder. ● slowly rotate...

  • Page 101

    9-14 cylinder head / valve cam shaft holder ● 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 ...

  • Page 102

    9-15 cylinder head / valve cam chain tensioner lifter clip ● install the cylinder head cover. ● tighten the cylinder head cover bolts. Torque value : 0.9 kgf · m ● install the carburetor insulator. ● install the ex. Pipe. ( ⇨ 3-8 ) ● install the rh. / lh. Shroud. ( ⇨ 8-12 ) ● install the engine to t...

  • Page 103

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

  • Page 104: 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 105: Cylinder

    10-2 cylinder/piston ·take care not to damage the cylinder mating surface. Cylinder removal ● remove the engine from the frame. (⇨ 6-2 ) ● remove the ex. Pipe. (⇨ 3-8 ) ● remove the camshaft. (⇨ 9-3 ) ● remove the cylinder head. (⇨ 9-5 ) ● remove the cam chain guide from the cylinder. ● remove the c...

  • Page 106: Piston / Piston Ring

    10-3 cylinder/piston ·any clearance between the cylinder and head due to damage or warpage will result in compression leaks and reduced performance. ·place a clean shop towel over the crankcase to prevent the possibility of the clip falling into the crankcase. Warpage inspection ● check the cylinder...

  • Page 107

    10-4 cylinder/piston ·always replace piston ring as a set. ● 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. Service limit : top / second : 0.50 mm oil ring (side rail) :...

  • Page 108

    10-5 cylinder/piston ·be careful not to damage the piston and rings during assembly. ·do not confuse the top and second rings. ·space the ring end gaps 120 degrees apart. ·space the side rail gaps 40mm or more apart as shown. ·place a clean shop towel over the crankcase to prevent the clip from fall...

  • Page 109

    10-6 cylinder/piston ·take care not to drop the piston pin clip into the crankcase. ·set the piston pin clip in the groove properly. ·do not align the clip’s end gap with the piston cutout. ·take care not to damage the cylinder mating surface. ·be careful not to damage the piston rings. ·be careful ...

  • Page 110: Memo

    Memo.

  • Page 111

    11-0 transmission/crankshaft/crankcase rh. Crankcase lh. Crankcase crankshaft.

  • Page 112: 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 113: Troubleshooting

    11-2 transmission/crankshaft/crankcase 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 ...

  • Page 114: Transmission

    11-3 transmission/crankshaft/crankcase 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. ( ⇨ 3-8 ) ● remove the rear swing arm. ( ⇨ 13-8 ) ● r...

  • Page 115

    11-4 transmission/crankshaft/crankcase ● 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. Final shaft counter shaft final shaft counter shaf...

  • Page 116

    11-5 transmission/crankshaft/crankcase transmission assembly ● install the drive shaft on the transmission cover. ● install a new drive shaft oil seal. Tools : crank assembly shaft crank assembly collar transmission bearing inspection ● check that the bearing outer race fits the case tightly without...

  • Page 117: Crank Case Removal

    11-6 transmission/crankshaft/crankcase transmission cover oil check bolt setting bolts setting bolts ● install a new gasket and dowel pin. ● tighten the transmission cover with the setting bolts. ● install the following parts. -rear wheel ( ⇨ 13-5 ) -rear swing arm ( ⇨ 13-8 ) -rear brake caliper ( ⇨...

  • Page 118: Crankshaft Removal

    11-7 transmission/crankshaft/crankcase rh. Crankcase lh. Crankcase crankshaft dowel pin rh. Crankcase crank bearing universal bearing puller ● remove the transmission bleeder tube. ● remove the rh./lh. Radiator hose from the rh. Crankcase. ● face the lh. Crankcase downward, and remove the rh. Crankc...

  • Page 119: Transmission Bearing

    11-8 transmission/crankshaft/crankcase measuring point dial gauge feeler gauge dial gauge bearings oil seal 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 transmission bearing ● remo...

  • Page 120: Crankshaft Installation

    11-9 transmission/crankshaft/crankcase bearing remover set driver handle a outer driver driver pilot driver handle a crankshaft assembler transmission bearing replacement lh. Crankcase ● use special tools to remove the drive shaft bearing. Tools : bearing remover set remover shaft remover head ● rem...

  • Page 121: Crankcase Installation

    11-10 transmission/crankshaft/crankcase ● install the rh. Crankcase to the lh. Crankcase. ● install the rh./lh. Radiator hose. ● install the bleeder tube to the lh. Crankcase. ● install the removed parts. ● install the engine on the frame. ( ⇨ 6-2 ) crankcase installation ● install the dowel pins an...

  • Page 122: Memo

    Memo.

  • Page 123

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

  • Page 124: Service Information

    12-1 12. Front wheel/front fork/steering/brake service information general safety ● 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 tire ...

  • Page 125: Troubleshooting

    12-2 front wheel/front fork/steering/brake 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 shoc...

  • Page 126: Steering Handle

    12-3 front wheel/front fork/steering/brake steering handle removal ● remove the upper handle cover and the under handle cover from the handle bar. ● loosen the bolts securing the front and rear break master cylinder. ● remove the front cover, front under cover and speedometer cover. ● loosen the 4 s...

  • Page 127: Front Wheel

    12-4 front wheel/front fork/steering/brake ● lubricate the throttle grip front end with grease and then install the throttle grip. ● connect the throttle cable to the throttle grip. ● install the right and left handlebar switches and tighten the screws. ● install the front and rear brake master cyli...

  • Page 128: Front Wheel Bearing

    Wheel rim ● check the wheel rim runout. Service limit : radial : 2.0mm replace if over axial : 2.0mm replace if over front wheel bearing inspection ● turn the inner race of each bearing with your finger to see if they turn smoothly and quietly also check if the outer race fits tightly in the hub. ● ...

  • Page 129

    12-6 front wheel/front fork/steering/brake 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 prior to assembling. ● install the washer. ● apply grease ...

  • Page 130: Front Wheel

    ● apply grease to the dust seal rim. ● install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box. Front wheel installation ● insert the front wheel between the front forks. ● insert the disk, taking precautions not to damage...

  • Page 131

    Disassembly ● remove the fr/rr stop switch. ● take out the boot and circlip from the master cylinder. Tools : snap ring pliers ● remove the washer, piston, spring from the master cylinder. ● clean the master cylinder, reserve, master piston with the recommended brake fluid. Inspection ● check the pi...

  • Page 132

    ● check the master cylinder for scores, scratches or nicks and replace if necessary. Assembly installation ● coat the piston, cup with the fresh brake fluid and install it on the piston. Install the spring with its larger diameter end toward the master cylinder. 12-9 front wheel/front fork/steering/...

  • Page 133: Brake Fluid

    ● install the brake hose to the master cylinder with 2 new sealing washers and the hose bolt. Torque value : 2.5~3.5 kgf · m ● loosen the 2 flat screws, remove the oil cup cap, diaphragm plate and diaphragm. ● fill the brake fluid, and bleed air. ● install the diaphragm, diaphragm plate and the oil ...

  • Page 134

    ● repeat the above procedures until no air bubbles appear in the bleeder hose. ● squeeze the bleeder valve and operate the brake lever to check the ingress of air. When the brake bleeder is not available > ● fill the brake fluid up to the upper limit line. ● connect the transparent bleeder hose to t...

  • Page 135: Brake Caliper

    ● disassemble the piston seal and the dust seal ● clean the piston and the inside of the caliper and remove the oil from the seal groove. Brake caliper removal ● first drain the brake fluid from the hydraulic brake system. ● remove the brake fluid tube bolt. ● remove the two bolts securing the brake...

  • Page 136

    Inspection ● check the caliper cylinder bore for scoring, scratches or other damage. ● measure the caliper i.D. Service limit : 25.42mm ● check the piston for scratches or wear. ● measure the piston o.D. With a micrometer gauge. Service limit : 25.27mm ● clean the piston seal and the dust seal with ...

  • Page 137: Front Fork

    ● apply the silicone grease to the boot. ● connect the boot to the portion of the caliper. ● install the pad spring in the caliper. ● install the caliper pin bolt and the slide pin in the caliper. ● install the brake pad and the hanger pin in the caliper. ● install the front caliper to the front for...

  • Page 138

    Disassembly ● remove the fork pipe bolt. ● wrap the bottom case with a piece of cloth, and remove the socket bolt. ● remove the dust seal. 12-15 front wheel/front fork/steering/brake ·if the screw is completely loosened, the fork tube cap bolt may spring out by the force of the spring. Take due prec...

  • Page 139

    ● remove the oil seal stop ring. ● remove the oil seal. ● remove the fork tube from the bottom case. ● remove the piston and rebound spring from the fork tube. Front fork inspection ● place the fork spring on a level place, and measure the free length. ● if the free length deviates from the service ...

  • Page 140

    ● check the slider bush contact face. ● if the slider bush is extensively damaged, replace the bottom case. Front fork assembly ● wash parts with clean oil prior to assembling. ● assemble the rebound spring and thd fork piston to the fork tube. ● assemble the fork tube to the bottom case. ● wrap the...

  • Page 141

    ● install the dust seal. ● fill a prescribed amount of automatic transmission fluid(atf) into the fork tube. Capacity : 90cm 3 ● slowly press the fork tube 2-3 times to discharge air. ● install the oil seal stopper ring ● accurately assemble the oil seal stop ring to the bottom case. ● assemble the ...

  • Page 142: Steering Stem

    12-19 front wheel/front fork/steering/brake ● remove the steering stem nut using the steering stem nut socket. Tool : steering stem nut socket ● remove the steering top thread nut using the steering stem socket. Tool : steering stem socket ● remove the top cone race. ● check the upper ball assembly,...

  • Page 143

    ● remove the steering top ball race from the head pipe. ● remove the steering bottom race. Installation ● install the steering head dust seal washer and dust seal onto the steering stem. ● press in the steering bottom cone race using the steering stem driver. ● install the under ball ass’y into the ...

  • Page 144: Memo

    Memo.

  • Page 145

    13-0 rear wheel / brake / suspension / rear swing arm.

  • Page 146: 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 147: Troubleshooting

    13-2 rear wheel / brake / suspension / swing arm 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 ha...

  • Page 148: Rear Brake

    Setting bolts piston piston seal dust seal 13-3 rear wheel / brake / suspension / swing arm rear brake removal ● remove the muffler. ● loosen the rear break tube bolt and remove the break tube. ● loosen 2 bolts and remove rear break caliper. ● wind the caliper facing down with cloth to prevent the p...

  • Page 149

    13-4 rear wheel / brake / suspension / swing arm ● disassemble the piston seal and the dust seal. ● clean the piston and inside of caliper with break fluid. ● apply the silicone grease to the pin bush. ● connect the pin bush to the portion of the caliper. ● install the pad spring in the caliper. ● i...

  • Page 150: 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. ( ⇨ 3-8 ) ● remove the rear brake caliper assembly from the rear swing...

  • Page 151

    Rear wheel inspection ● check the rim for wobbles by rotating the wheel. Service limit : radical 2.0mm axial 2.0mm tool : dial gauge ● insert the brake arm joint b into the rear parking brake arm, and connect the brake arm joint b to the parking brake cable and tighten the adjust nut b. ● install th...

  • Page 152: Rear Cushion Adjust

    13-7 rear wheel / brake / suspension / swing arm rear cushion adjust ● adjust the cushion spring according to the load condition. ● the rear cushion can be adjusted as below. 1 - 2 - 3 - 4 - 5 soft medium hard rear cushion removal ● remove the luggage box. ● remove the air cleaner. ● remove the uppe...

  • Page 153

    13-8 rear wheel / brake / suspension / swing arm axle u-nut rear swing arm disassembly ● disassemble the rear wheel outside collar from the rear swing arm. ● disassemble the oil seal (28×42×7) and radial ball bearing (6302uu). ● install in the reverse order of removal. Torque value - rear wheel axle...

  • Page 154: Memo

    Memo.

  • Page 155

    14-0 charging system green green regulator rectifier ac.Generator yellow engine earth + battery (12v 10ah) _ main switch fuse (15a) black red black (cable) red yellow yellow frame earth regulator rectifier main switch a.C. Generator.

  • Page 156: 14. Charging System

    14-1 14. 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 cause burns or...

  • Page 157: Troubleshooting

    14-2 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 power ● main...

  • Page 158: Battery

    14-3 charging system battery charger battery ● remove the seat and luggage box. ● loosen the screws secuning the battery cover and remove the battery cover. ● remove the battery. ● first disconnect the negative “⊖” battery cable, and then disconnect the positive “⊕” cable. ● the installation sequenc...

  • Page 159: Charging System Inspection

    14-4 charging system ● remove the frame center cover. ● disconnect the a.C. Generator connector. ● measure the resistance between the yellow wires. ● replece the stator if resistance value is high or there is continuity between each yellow wire and ground. ● resistance : yellow~yellow 0.6~1.6Ω charg...

  • Page 160

    14-5 charging system regulator rectifier inspection ● remove the luggage box. ● remove the regulator rectifier coupler. ● measure each terminal. ● replace the regulator rectifier unit if the resistance value between the terminals is abnormal. Resistance value tester ⊕ tester ⊖ unit : ㏀, ( 20 ℃) r b ...

  • Page 161

    15-0 ignition system cdi unit ignition coil green spark plug blue/yellow green ac.Generator pulse generator (12v 10ah) battery + _ side stand switch main switch fuse (15a) black/white pink black blue/yellow black/yellow green green/red red green to.Light relay battery regulator rectifier ignition un...

  • Page 162: 15. Ignition System

    15-1 spark plug spark plug gap ngk cr8eh-9 0.8~0.9mm 15. 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 ...

  • Page 163: Troubleshooting

    15-2 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 164: Cdi Unit Inspection

    15-3 ignition system cdi unit inspection cdi ignition circuit inspection ● release the seat lock with the main key. ● remove the luggage box. (⇨3-3) ● disconnect the coupler from the cdi unit, and check the ignition system circuits from the wiring coupler side. Inspection items ● if there are a norm...

  • Page 165: Ignition Coil Inspection

    15-4 ignition system ignition coil inspection ● remove the seat lock with the main key. ● remove the luggage box. ● remove the center cover. ● remove the primary wire. ● measure the resistance between the two terminals of the ignition primary coil. ● if the resistance value is within the specified r...

  • Page 166: Ignition Timing Inspection

    Ignition timing inspection ● start and warm up the engine. ● remove the plug maintenance cover. ● connect the timing light to the high-tension cord. ● remove the timing hole cap from the rh. Shroud, and start the engine. ● if the f mark on the rotor is aligned with the index mark on the case at the ...

  • Page 167

    15-6 ignition system removal ● remove the floor mat. ● remove the center cover. (⇨3-3) ● remove the rh. Floor side cover. (⇨3-4) ● remove the coupler of the side stand switch. ● remove the lh. Floor side cover. (⇨3-4) ● loosen the side stand switch mounting 2 bolts. ● release the wire clamps and rem...

  • Page 168: Memo

    Memo.

  • Page 169

    16-0 starter system (12v 10ah) battery + _ starter relay m starter motor greem/yellow cable fuse (15a) black main switch rr.Stop switch fr.Stop switch green stop lamp starter switch yellow/red green greem/yellow cable battery main switch starter motor stop switch.

  • Page 170: Service Information

    Service information general safety ● the starter motor can be maintained without removing the engine from the vehicle. ● a weak battery may be unable to turn the starter motor quickly enough, or, supply adequate ignition current. ● the starter motor may be damaged if current is allowed to flow to it...

  • Page 171: Troubleshooting

    16-2 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 172: Starter Motor

    16-3 starter system disassembly ● remove the starter motor cable. ● before disassembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later. ● loosen the starter motor case bolts and remove the motor cover. Inspection ● check for continuity of t...

  • Page 173

    16-4 starter system ● check the commutator for : -damage or abnormal wear. → replace with a new one. -discoloration of the commutator bar. → replace with a new one. -metallic debris between commutator bars.→ clean it off. ● check for continuity between pairs of commutator bars. ● make a continuity c...

  • Page 174

    16-5 starter system ● push and hold the brush inside the rear bracket, and insert the armature into the rear bracket groove. ● align the case mark with the rear bracket mark, and install the case. ● insert the thrust washer (0.5t), thrust washer (0.2t), slip washer and thrust support. ● align the fr...

  • Page 175: Starter Magnetic Switch

    16-6 starter system starter magnetic switch voltage ● measure the voltage between the yellow / red wire (+) and ground at the starter magnetic switch connector. ● if battery voltage appears only when the starter switch is pressed, it is normal. Starter magnetic switch ground line ● disconnect the wi...

  • Page 176

    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 between battery and moto...

  • Page 177: Memo

    Memo.

  • Page 178: 17. Lights/switchs/horn

    17-1 17. Lights/switchs/horn 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 charg...

  • Page 179: Main Switch

    17-2 lights/switch/horn main switch ● remove the front covers. ● disconnect the ignition switch wire couplers. ● check for continuity between the wire terminals. Handle switch ● remove the headlight. ● disconnect the connector of handle switch. ● check for continuity between teminals. ● remove the f...

  • Page 180: Horn

    17-3 lights/switch/horn horn ● remove the horn from the wire connector. ● connect the horn terminal with 12v battery. ● normal if it sounds. Fuel unit ● remove the foor panel. ● be cover full not to be damaged for the wire. ● check the base packing for damage. ● measure the resistance between the fu...

  • Page 181: Headlight Bulb Replacement

    17-4 lights/switch/horn headlight bulb replacement ● remove the front cover. ● remove the headlight coupler and winker coupler. ● remove the bulb socket of rubber boots. ● remove the rubber boots. ● replace the headlight bulb. Front winker bulb replacement ● loosen the 2 screws, remove the winker le...

  • Page 182: 18. Wiring Diagram

    Y/w yy y y y y yy y y y yy y/w y/w y/r y/r y/w y/w y/r y/r y/r y/r gr gr gr gr gr p p/w p/w p p/w p p b b b b w w w w w w g/y g g g g g g g g g g g g g g g g/y g g/y g/y g g r / g g r / g g g g g g g g g/y g g/y g g g g g g g g g g g g g g/y g g g/y g/y g lg lg lg br br/l br br/w br br br/w br/w br ...

  • Page 183

    Service manual 2004. 11. Printed 2004. 11. Publication no copy.

  • Page 184

    Sm51-0411-01e 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.