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service information - Norsk Motor Import AS

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1. N lt rr 77 gt NH N 22 CDI UNIT BATTERYOCORD WIRE HARNESS THROTTLE CABLE RR BRAKE CABLE CORD CLIP LH FR WINKER CORD H TAIL LIGHT CORD HEADLIGHT FR WINKER COUPLER HEAD LIGHT TAIL LIGHT SERVICE INFORMATION ANTI THRFT SWITCH UNIT OIL TUBE CABURETOR LEADER CORD AIR VENT TUBE S A REED VALVE ASSY 5 AIR C TUBE A SEAT LOCK CABLE i Nd 2 G Sf START RELAY PALA RX ROY BATTERYOCORD AS BATTERY ASSY WIRE HARNESS 2 T 2 CO 5 uo lt ow ow yy DI wit 2 1 nm jo pe qe O 1 StS lt aol ye Ola x Oj lt gt Slul m O gt C en oc e O cc Lu 1 oc lt gt KIS gt 2 lt NAA S Y 2 N 95 e THROTTLE CABLE FUSE CASE RR BRAKE CABLE SEAT LOCK CABLE 1 12 SERVICE INFORMATION START RELAY BATTERY CORD BATTERYOCORD CDI UNIT jaa SIDE STAND SWITCH CORD EN eho Cie LILO F Q ACG CORD DY o 4
2. 17 TROUBLESHOOTING ENGINE DOES NOT START OR HARD TO START 17 1 ENGINE OUTPUT INSUFFICIENT 172 POOR PERFORMANCE AT LOW SPEED AND IDLING 17 3 POOR PERFORMANCE 5 17 3 UNSATISFACTORY OPERATION 17 4 FUEL GAUGE e ee Ss oe a 226 STARTER NOTOR VERO UE ee d 2 7 ENGINE DOES NOT START OR HARD TO START CAUSE OF TROUBLE 1 the drain screw and check Fuel not supplied to 1 Fuel tank empty flow to the carburetor the carburetor 2 Fuel tube up to the fuel tank Fuel clogged or the vacuum tube or fuel ECHTE SES tube up to the inlet pipe clogged 3 Float valve clogged 4 Fuel tank cap air hole clogged 5 Fuel supply pipe frozen 6 Fuel strainer clogged Y 2 Check the spark plug Weak or no spark 1 Faulty spark plug 2 Contaminated spark plug k 3 Faulty CDI unit 4 Faulty A C generator 5 Disconnected or shorted high tension cord 6 Disconnected or shorted ignition coil wire Y 7 Faulty main switch 3 Test cylinder pressure Low cylinder pressure 1 Piston ring size 2 Cylinder and piston ring won 3 Cylinder and cylinder head cracked 4 Crank case air leaks 5 Cylinder head gasket damaged Compression normal 4 Start the engine in the following Engine starts but
3. COLOR BROWN WHITE BLUE DIMMER SWITCH HORN SWITCH HAZARD SWITCH HO PUSH COLOR LIGHT GREEN COLOR GRAY SKYBLUE ORANGE WINKER SWITCH FRONT STOP SWITCH INSPECTION Remove the black wire and green yellow wire terminals inside the speedometer assembly and check the following When the brake level is pulled continuity When the brake levwl is released no continuity 16 4 FRONT COVER HEADLIGHT RUBBER COVER LIGHTS METER SWITCHES BULBS REPLACEMENT HEADLIGHT BULB e Remove the front cover 3 5 e Remove the headlight rubber cover e Replace with new bulb NOTE Before replacing the bulb be sure to check the swtiches for loose connection of the connectors e Install in the reverse order of removal WARNING Headlight bulbs become very hot while the headlight is NO and remain hot for a while after they are turned OFF Be sure to turn the ignition switch OFF and let the bulb cool down before replacement CAUTION If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to prevent early bulb failuer sure to install the dust cover after replacing the bulb FRONT WINKER BULB e Remove the front cover 3 5 e Remove the bulb from the socket replace with new bulb Install in the reverse order of removal 16 5 LIGHTS
4. BATTERY PART Tk S WIRE HARNESS TARL RELAY BATTERYOCORD s Li Ww ACG COUPLER NIN z 5 CDI UNIT EE EE BYSTART CORD COUPLER ARN 2 el S A I REED VALVE ASSY He lt N CORD d gt THROTTLE CABLE JUNCTION CLAMP y R ANTITHEFT SWITCH COUPLER OIL PUMP CABLE H i CARURETOR HEAT CORD THROTTLE CABLE CARB BYSTART CORD TAIL STOP R L RR WINKER COUPLER E RAN A Ava IL V 11 OIL LEVEL SWITCH CORD AM OIL PASS TUBE P a BREATHER TUBE BL THERMOSTAT SWITCH 2 9 SEAT LOCK CABLE a FUEL UNIT COUPLER FUEL CABLE 7 Aid CARBURETOR HEAT CORD lt e eV aN NS ST 1 5 S A l AIR C TUBE A FUEL VENT TUBE FUEL UNIT S A I AIR C TUBE S A l AIR C ASSY 1 13 RR BRAKE CABLE WINKER SWITCH RR BRAKE SWITCH CORD WINKER SWITCH CORD FUEL METER COUPLER HEADLIGHT FR WINKER COUPLER THROTTLE CABLE RR BRAKE CABLE FRAME GROUND CONNECTION FR BRAKE HOSE SERVICE INFORMATION SPEEDOMETER ASSY FR STOP SWITCH CONECTOR HAZARD STARTER SWITCH THROTTLE CABLE lt lt LLI lt LLI 5 SEAT LOCK CABLE COMBO LOCK SWITCH Z RESISTER COMBO AUTOBYSTART 5W 6 7 REGURATOR RECTIFIER HORN SPEE
5. IGNITION COIL PRIMARYCOIL BLACK YELLOW ANDGREEN 0 1 0 5 20 SECONDARY COIL GREENANDGIGHETENSIONCORD ATIACHTHEPLUGCAP 63 103K 000 DETACHTHEPLUG CAP 33 05 14 6 IGNITION SYSTEM TESTING BY CDI TESTER Check the CDI unit spark performance by using a CDI tester NOTE Read tester manual carefully prior to using the tester SIDE STAND IGNITION CUT OFF SWITCH INSPECTION e Remove the plug maintenance cover center cover 3 3 e Remove the coupler of the side stand switch Check for continuity between theminal as shown below TERMINAL SPECIFICATION BLACK WHITE NO AND GREEN CONTINUITY ON Side stand is Retracted OFF Side stand is Lowered BLACK WHITE AND GREEN CONTINUITY REMOVAL e Remove the floor side cover 3 4 e Remove the plug maintenance cover center cover 3 3 e Remove the side stand switch mounting 2 bolts e Release the wire clamps and remove the side stand switch INSTALLATION e Install on the reverse order of removal 14 7 STARTING SYSTEM lt gt lt lt 5 ANTI THEFT SWITCH UNIT e Y 23 FUEL VENT TUBE SEAT LOCK CABLE FUEL UNIT COUPLER OIL LEVEL SWITCH CORD HEAT CORD TAIL STOP R L RR WINKER COUPLER LOCK SWITCH RESISTER COMP SS FA 72 REG RECTIFIER START RELAY st G BATTERY CORD AN TEMO ce TIAR
6. Check the gear for wear damage and leak of each seal e If the oil comes out from the outlet of the oil pump after connecting the oil tube which is connecting between the tank and the oil pump to the inlet and rotating the shaft in the driving direction consider the oil pump is in good condition OIL PUMP GEAR PART LUBRICATION SYSTEM OIL PUMP ADJUSTMENT CAUTION Perform after inspection and adjustment of throttle cable Check to see if the matching mark of the oil pump body and control lever are aligned in a state where the throttle grip is completely rotated Adjustment is performed by loosening the oil pump control cable lock nut and turning the control nut While the engine is running slightly open the throttle and check to see if the control lever operates together with the increase in engine rpms d Ha i THROTTLE GRIP OPEN CAUTION Do not adjust the control lever matching mark to the closed side of the oil pump body matching mark If this is done the amount of pumped oil is reduced negatively affecting the engine Make sure that the open axis stays within an 1mm sphere e The following occurs when the oil pump is adjusted incorrectly When the oil pump lever is excessively opened Emitting of white exhaust gas or starting problems When the oil pump lever is insufficiently opened Clogging of engine NOTE If the oil pump cable stay bolt is removed apply the
7. Loosen the rear brake arm fixing bolt a Remove the rear brake arm rear brake indicator brake BRAKE CAM cam dust seal Remove the rear brake cam REAR BRAKE ASSEMBLY INSTALLATION 4 gt AC Apply small amount of grease to the brake cam m ar Install the brake cam e Install the rear brake dust seal indicator rear brake arm NOTE i BRAKE SHOE 22 3 B Align the punch marks of the brake arm and the brake cam before assembly Remove the excessive grease after assembling the shoe e Install the brake shoe and spring e Install the rear brake shoe to the rear brake cam e Install the rear wheel e Install the washer and U nut e Install the muffler NOTE Check the brake for smooth operation REAR WHEEL BRAKE SUSPENSION REAR CUSHION REMOVAL Remove the luggage box 43 3 Remove the air cleaner Loosen the top and bottom rear cushion setting bolts NOTE Support the frame firmly prior to working DISASSEMBLY e Install the compressor attachment as shown in the figure e Install the cushion on the cushion compressor and compress the spring TOOLS COMPRESSOR ATTACHMENT REAR COMPRESSOR e Fix the bottom metal and loosen the lock nut e Remove the bottom metal e Remove the stopper rubber spring from the damper component INSPECTION Measure the rear cushion spring free length Check the damper
8. Remove the wheel NOTE Single brake disk type To prevent damage to the lt disk place wheel level surface with rn disk facing up sszT729M 5 RM VALVE Remove the valve cap and bleed air by pressing the valve core Remove the valve core after bleeding air completely Remove the valve stem nut and push the valve stem lightly a bead stopper is installed loosen the lock nut and push the bead stopper down Collapse in the bead with a tire bead breaker If no tire bead breaker is available step on the side wall to collapse the bead NOTE Do not step on the rim Collapse the bead into the rim center and slide the tire out of position RIM CENTER NOTE Tire can be easily removed once the beads are collapsed completely Apply a mild detergent solution to the rim and tire mating surfaces Be sure that the bead is completely collapsed Insert the tire lever from the opposite side of the valve and raise the bead over the rim NOTE Be sure to use motorcycle tire levers TIRE LEVER Do not apply the mild detergent solution to the rim and tire mating surfaces of low pressure tire Apply water only RIM PROTECTOR 10 9 FRONT WHEEL FRONT FORK STEERING e Insert another tire lever at 30 50mm from the first tire TIRE LEVER lever and remove the tire from the rim little by li
9. Install the bearing with the carved mark directing to the outside Use special tools to push in the bearing into the case TOOLS DRIVER HANDLE A OUTER DRIVER 52 x 55 mm DRIVER PILOT 20mm Check the LH crank case oil seal for wear or damage 9 3 TRANSMISSION CRANKSHAF T CRANKCASE TRANSMISSION ASSEMBLY e Install the drive shaft on the transmission cover e Install a new drive shaft oil seal Install the thrust washer final gear and counter gear side washer on the LH crankcase e Install new dowel pins e Install a new transmission cover seal on the transmission cover e Install the transmission cover e Tighten the transmission cover with the flange bolts NOTE Tighten bolts diagobally and alterntely and tighten with specified torque in the end e Remove the oil check bolt release the transmission oil filler ACG cap or the LH crankcase until the oil overflow through oil hole and fill the recommended oil slowly Install the oil check bolt and the cap RECOMMENDED OIL SAE 80 90 TRANSMISSION OIL AMOUNT 0 09 TRANSMISSION CRANKSHAFT CRANKCASE CRANKSHAFT REMOVAL Remove the engine from the Frame body Loosen the 6 RH crankcase flange bolts Secure a crankcase puller on the RH crankcase Remove the RH crankcase from the LH crankcase TOOL CRANKCASE PULLER 0751 00003 Secure a crankcase puller on the RH crankcase CRANK CASE PULLEY R
10. Remove the the switch connector of oil tank and the tube on the side of oil pump Remove the oil level switch connector Remove the tube on the side of oil pump Install the tube clip or the valve in the oil tube to avoid the oil from leaking Remove the flange bolt securing the oil tank and press the left and lower rear fender to remove the oil tank Drain the oil from the oil tank Remove the oil level switch Remove the oil strainer INSPECTION Check the oil level switch and the oil tube for proper installation Install in the reverse order of removal CAUTION If the oil enters into the oil pass it may cause abnormal lubrication or engine sticking Always remove the air in the oil pass after maintenance Make sure that the oil tube is connected properly Drain the oil in the clean container Install the oil strainer after cleaning it TRANSMISSION OIL INSPECTION Check the body and the connection of each engine component for any leak Remove the oil check bolt and check to see if the oil overflows from the oil check hole If only the small amount of oil overflows fill the recommended transmission oil through the oil filler hole gradually NOTE 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 e Tighten the oil check bolt TIGHTENING TO
11. if the starter motor rotates because a large AA amount of current flows in this test do not operating noise is emitted from the starter deg use thin wire relay ROTE DOES NOT ROTATE NO CLICK Y Incorrect starter Incorrect starter motor Y motor connection Remove the coupler from the starter replay e Faulty starter switch and inspect the relay coil ground wire NO CONTINUITY e Incorrect connection with the switch terminals or harness disconnection CONTINUITY Y Check the starter relay voltage in the starter relay coupler with the coupler connected NO VOLTAGE Damaged main or starter switch Incorrect connection with coupler connector Disconnection in starter switch wire VOLTAGE MEASURED Faulty brake stop switch Check the operation of the starter relay NORMAL ad contact at starter relay switch E ABNORMAL Faulty starter relay switch Starter motor rotates but crank shaft does t Incorrect starting clutch Incorrect starter gear Weak rotational power in starter motor e Starting clutch slip e Battery is insufficiently charged Incorrect connection of battery terminal cord Starter motor operates in free wheel e Damaged starter motor e Internal fault of starter motor Ground wire is connected incorrectly e Driven gear slips e Brush is damaged or worn Starter motor and crank shaft rotate but d
12. 5W6 70 IMMER S W RESISTER 30W 5 90 SPEEDOMETER LIGHT TAIL LIGHT 12V 3Wx 2EA 12V 5W HEADLIGHT 12V 35 35W 13 0 BATTERY CHARGING SYSTEM 13 BATTERY CHARGING SYSTEM SERVICE INFORMATION 13 1 HEADLIGHT VOLTAGE INSPECTION 13 5 TROUBLE SHOOTING 13 2 REGULATOR RECTIFIER INSPECTION 13 5 BATTERY REMOVAL INSTALLATION 13 3 13 6 BATTERY INSPECTION 13 3 RESISTERINSPECTION gt 13 8 CHARGING SYSTEM INSPECTION 13 3 SERVICE INFORMATION WARNING Do not place flammable materials near battery when charging This can be a fire hazard as hydrogen gas is created during charging battery Do not allow battery acid to come into contact with clothes skin or eyes Battery acid contact can cause burns or loss of eye sight If contact occurs thoroughly clean with water and if acid enters eyes flush with water and see a doctor If battery acid gets on clothing as it can seep through or make a hole through the clothing and make its way to the skin make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes CAUTION This vehicle has maintenance free MF battery Because MF batteries use different charging equipment take special care when performing maintenance and especially when replacing parts Not all regular battery equipment is compatible with MF batteries When charg
13. Jf j by mie ii P n l A A ae d WIRING DRIVER GROOVE SIDE Secure the wire harness firmly using the clamp In case of the weld clamp do not clamp in the welded part When clamping the wire pay attention not to contact with hot part When clamping the wire harness make sure that the harness is not contacted with the shaft or rotating part The wire harness must be routed without contacting with the end of the lamp or any sharp edge The wire harness must be routed without contacting with the end of the bolt or the piece 1 21 SERVICE INFORMATION In case that the wire harness is contacted with the end or The wire must not hang down or be pulled excessively the sharp edge protect both parts with tube or tape If necessary lock the wire harness properly When mounting parts make sure that the wire harness is not pressed by the parts Do not twist the wire harness e Wire the wire harness not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please read the manual care not drop or throw the parts especially fully and understand the contents semiconductor contained parts because these parts may When testing the resistance of the tester the
14. L DIRT Inner walls get contaiminated making visual inspection difficult INSPECTIONS ADJUSTMENTS FUEL LINE FUEL TUBE e Remove the luggage box c 3 3 Check the fuel tube of the fuel pump connected to the fuel tank and carburetor If the fuel tube is cracked damaged or leaks replace it FUEL LINE FOR CLOGGING Check the fuel tank cap and or fuel tank breather tube for clogging e Visually inspect the fuel strainer for contanmination Check the fuel flow with the fuel strainer installed and with the strainer removed e Replace the fuel strainer if it is excessively contaminated or if the fuel flow is not smooth CAUTION Note the installation direction of the fuel strainer Be sure to install it as shown in the drawing 1 with the cap facing down Fuel flows even though the strainer is installed upside down but it contaminates the inner wall of the strainer and prevents visual inspection of the strainer e Remove the fuel valve lock nut and check the fuel strainer screen for contamination Tighten the lock nut to the specified torque INSPECTIONS ADJUSTMENTS THROTTLE GRIP OPERATION Check if the throttle grip operates smoothly in steering 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 removing only the carbon use plug cleaner a
15. REAR WHEEL BRAKE SUSPENSION TROUBLESHOOTING Wobble or vibration in motorcyle Tire pressure incorrect Faulty tire e Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs e Rear damper improperly adjusted oil leakage Hard suspension e Rear damper improperly adjusted e Bent shock absorber rod Suspension noise Loose fasteners Worn shock 11 2 REAR WHEEL BRAKE SUSPENSION REAR WHEEL FLANGE BOLTS REMOVAL Support the motor cycle on the main stand e Remove the muffler 3 8 Loosen the rear wheel U nut e Remove the rear wheel INSPECTION e Turn the wheel and check the rim for wobbles SERVICE LIMIT Radical 2 0mm Axial 2 0mm INSTALLATION e Insert the rear wheel over the final shaft REAR WHEEL BRAKE SUSPENSION Tighten the U nut TORQUE VALUE 6 0 8 0 kgf m Install the muffler NOTE Check the free play of the brake after the rear wheel assembling REAR BRAKE e Remove the rear wheel 11 3 INSPECTION Measure the brake drum of inner diameter SERVICE LIMIT 111mm Measure the thickness of the brake lining SERVICE LIMIT 2 0mm REAR BRAKE DISASSEMBLY e Manually open the brake shoe and remove it e Remove the shoe spring from the brake shoe BRAKE SHOE SHOE SPRING PYS SHOE SPRING a Ving BRAKE CAM BRAKE SHOE REAR WHEEL BRAKE SUSPENSION
16. SERVICE INFORMATION CRANKSHAFT REMOVAL 9 5 SERVICE STANDARD CRANKSHAFT BEARING REMOVAL 9 5 TRANSMISSION CRANKSHAFT CRANKCASE BEARING REMOVAL 9 6 CRANKSHAFT INSTALLATION 9 7 SERVICE INFORMATION GENERAL SAFETY This section describes how to remove the crank case and to maintain the transmission and the crankshaft Always use special tools to change the drive shaft Fix the bearing inner race and install the shaft e The following parts must be removed prior to removing the crank case Follow the removal procedure spcified in each section OIL PUMP c SECTION 4 CARBURETOR SECTION 5 ENGINE gt SECTION 6 CYLINDER HEAD CYLINDER PISTON S SECTION 8 AC GENERATOR SECTION 13 DRIVE PULLEY SECTION 7 CLUTCH DRIVEN PULLEY SECTION 7 REED VALVE SECTION 5 The following parts must be removed prior to changing the L crank case Follow the removal procedure specified in each section TRASMISSION gt SECTION 9 REAR BRAKE SECTION 12 e assemble the crank case and crankshaft set the special tool to the inner race of the crankshaft beaaring and push and assemble Remove the bearing from the crankshaft during disassembling work and insert a new bearing in the case Install the oil seal after the case is assembled SERVICE STANDARD ITEM STANDARD VALUE SERVICE LIMIT Large end side clearance 0 15 0 55mm 0 60mm Connecting rod large end right a
17. e Install the 6 flange bolts NOTE Make sure that there is no adhesion of gasoline to the RH LH crankcase liquid gasket face Do not apply excessive liquid gasket fluid excessively TOOL CRANKSHAFT ASSEMBLER CAUTION Make sure that the crankshaft is rotated smoothly after installation prior to oil seal installation If the smooth rotation is not acquired tap the crankshaft bearing part of crankcase with plastic hammer to ensure proper installation without mismatch e Install a new LH oil seal in the crankcase end portion at 1 0mm depth e Install a new RH oil seal in the crankcase end portion at 5 0mm depth 9 8 FRONT WHEEL FRONT FORK STEERING FRONT FORK FRONT BRAKE DISK FRONT TIRE P di FRONT WHEEL 10 0 FRONT WHEEL FRONT FORK STEERING 10 FRONT WHEEL FRONT FORK STEERING SERVICE INFORMATION 10 1 FRONT WHEEL SPECIFICATION TUBELESS TIRE TROUBLESHOOTING FRONT FORK STEERING HANDLE STEERING STEM SERVICE INFORMATION GENERAL SAFETY CAUTION Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the brakin performance If contaminated replace the pad with a new one and clean the disk Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged This section describes how to remove and maintai
18. the owner s manual INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY R REPLACE L LUBRICATE C CLEAN ODOMETER READING NOTE 1 4 REMARK 6 FUEL LINE FUEL TUBE I I I THROTTLE GRIP OPERATION I I I AIR CLEANER SPARK PLUG CARBON REMOVAL Every 8 000km CARBURETOR IDLE SPEED TRANSMISSION OIL BRAKE SHOE PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT ADJUSTMENT CLUTCH SHOE WEAR SUSPENSION BOLTS NUTS FASTENERS WHEELS TIRES STEERING HEAD BEARING DRIVE BELT WEIGHT ROLLER SLIDE PIECE DRIVEN FACE MOVABLE DRIVE FACE INNER PART rm p j m m om m E E f there are no appropriate type of tools and maintenance data available or if you do not have mechanical technology contact authorized maintenance shops dealers or other designated repair shops for maintenance and inspections To ensure safety inspections and maintenance of these parts must be carried out by authorized maintenance shops dealers or other designated repair shops NOTE 1 After the odometer reading exceeds 12 000km repeat maintenance service at intervals indicated in the table 2 After riding in areas with high humidity or pollution carry out maintenance service more frequently 3 Replace every 2 years Proper technology is required for this job ANTI THEFT SWITCH a
19. Install the thrust washer e Rotate the kick starter spindle using the kick starter arm draw the spindle to the L side cover and assemble the kick starter ratchet NOTE When installing the 14mm external circlip keep holding the spindle manually and install the circlip in the groove correctly Apply the grease to the kick starter ratchet groove and gear Check the kick starter ratchet and the kick starter spindle for smooth operation after installation 7 3 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION VEN QUITE DRIVE FACE El tna w UNIVEBSAIBEIOUDER START PINION DRIVE FACE 7 4 DRIVE BELT REMOVAL e Remove the LH side cover e Remove the 2 dowel pins and gasket CAUTION Use the special tool when loosening the lock nut Holding the rear wheel or rear brake will damage the final reduction system e Hold the clutch outer using the universal holder and remove the nut e Remove the clutch outer TOOL UNIVERSAL HOLDER e Remove the start pinion ass y e Remove the driven pulley clutch with the drive belt in place e Remove the drive belt from the driven pulley groove and drive pulley groove KICK STARTER 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 T E
20. MAINTENANCE INFORMATION SERVICE INFORMATION ITEM STANDARD USE LIMITS 1 2 liters ENGINE OIL TANK CAPACITY FULL CAPACITY Motix 2 Cycle Oil USD OE ed FULL CAPACITY 5 DMC Pure Mission Oil RECOMMENDED TRANSMISSION OIL SAE 80W 90 OIL FILTER TYPE a LUBRICATION TYPE OIL PUMP TYPE Current Filtration Plunger Type COOLING TYPE COOLING TYPE Air Cooled FUEL TANK CAPACITY FULL CAPACITY 5 l AIR CLEANER TYPE Urethane Foam CARBURETOR SETTING MARK PA35 VENTURI DIAMETER 14mm AIR SCREW OPENING 1 1 2 Rotation 1 1 8 Rotation FUEL SYSTEM FLOAT LEVEL 122 IDLING RPMS 2 000rpm NO OF JET NEEDLES 2 MAIN JET 65 SLOW 35 THROTTLE GRIP CLEARANCE 2 6mm PORT OPEN CLOSE PERIODS INHALATION OPEN Auto Control CLOSE Auto Control EXHAUST OPEN 80 5 BBDC CLOSE 80 5 ABDC SCAVENGING OPEN 55 BBDC CLOSE 55 ABDC CYLINDER HEAD COMPRESSION PRESSURE 10Kgf cnj 600rpm CYLINDER ID MARK LOCATION Top of Cylinder INSIDE DIAMETER ID MARK A 40 005 440 010mm NOID MARK 40 010 440 015mm CYLINDRICAL DEGREE 0 10mm OUT OF ROUNDNESS 0 10mm PISTON OUTSIDE DIAMETER ID MARK A 39 955 439 960mm CYLINDER HEAD ID MARK B 639 965 39 970mm CYLINDER NO ID MARK 639 960 39 965mm PISTON CYLINDER AND PISTON CLEARANCE 0 040 0 055mm PISTON PIN HOLE INSIDE DIAMETER 12 002 412 008mm PISTON PIN OUTSIDE DIAMETER 11 994 g12 000mm PISTON AND PISTON PIN CLEARANCE 0 002 0 014mm PISTON RING GAP TOP 0 15 0 3mm SECOND 0 15
21. SERVICE LIMIT 0 4mm NOTE Replace the brake disk if the disk for damage or crack BRAKE CALIPER REMOVAL Remove the brake oil bolts and the brake hose from the brake caliper Remove the caliper from the L H front fork and remove the pad spring hanger pin and brake pad BRAKE SYSTEM CAUTION Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface Wind the hose joint with cloth to prevent the brake fluid from leaking Clean the removed parts with the brake fluid and make sure that the each port isn t clogged with the compressed air Keep the removed parts in order to avoid dust from adhering DISASSEMBLY Remove the slide pin the bracket the pin bush the boot and pin boot and the pin bolt from the caliper e If there is any wear or damage in the boot replace it with a new one Wind the caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the brake hose CAUTION Never use the high pressure air or bring the air gun too close Never touch the inside of the caliper Disassemble the piston seal and the dust seal NOTE Pay attention not to damage the inner surface of the caliper Clean the piston and the inside of the caliper and remove the oil from the seal groove BRAKE CALIPER INSP
22. 10 2 FRONT WHEEL FRONT FORK STEERING FRONT MASTER CYLINDER STE E RI NG HAN D L REMOVAL Loosen the washer bolt of headlight switch Remove the headlight switch Remove the throttle grip Loosen the 2 master cylinder hold bolts and remove the master cylinder oe i 4 2 r gt g CAUTION Support master cylinder properly to prevent brake fluid from leaking If the master cylinder is dropped upside down air may enter the hydraulic system Fix it to the vehicle WINKER SWITCH ASS while maintaining the correct assembled location THROTTLE GRIP Loosen the washer bolt of winker switch Ass y Romove the winker switch Ass y Remove the wind screen Remove the pilot box Remove the speedometer Remove the front cover STEERING HANDLE Loosen the handle setting U nut remove the handle set collar and flange bolt e Remove the rear brake cable front brake hose speedometer cable handle cable from the guide e Remove the steering handle from the steering stem 10 3 FRONT WHEEL FRONT FORK STEERING an am RC DS HA 10 4 INSTALLATION Install steering handle to the steering stem e Install the handle setting bolt U nut handle set collar NOTE When installing the handle setting collar match it with the groove accurately TORQUE VALUE 5 0kgf
23. Always replace bearings in pairs and never use old bearings TOOLS BEARING REMOVER HEAD BEARING REMOVER Apply sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left bearing with its seal surface facing outside TOOLS DRIVER ATTACHMENT 32 x 35mm PILOT 15mm CAUTION The bearing inserted in the last must be inserted until it contacts with the distance collar Excessively inserted bearing can cause damage the opposite side bearing SPEEDOMETER GEAR REPLACEMENT e Remove the speedometer gear and washer from the speedometer gear box Check the gear for wear or damage e Install the washer Apply grease to the speedometer gear prior to assembling SPEEDOMETER GEAR GEARWASHER SPEEDOMETER GEAR BOX 10 7 FRONT WHEEL FRONT FORK STEERING FRONT WHEEL ASSEMBLY Apply grease to the right side dust seal rim Install the right side oil seal Install the brake disk e Install disk bolts TORQUE VALUE 3 9kgf m e Install the front wheel collar A e Install the meter gear box into speedometer gear box e Install the speedometer gear box seal into the wheel hub e Install the speedometer gear box into the wheel FRONT WHEEL FRONT FORK STEERING TUBELESS TIRE REMOVAL
24. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well ventilated area and free of the open fire and spark SERVICE RULES 1 Parts and lubrication oil must be DAELIM genuine or 2 Before maintenance remove deposit or dust from the recommended parts chasis SERVICE INFORMATION 3 Store the parts of each system discriminatively to install 4 After removing gasket O ring piston pin clip and cotter each part in the right place pin always replace them with the new one When removing the snap ring it can be easily missed after transformation or installation 5 Clean the parts after the overhaul and before the test and 6 Check necessary place and measure necessary data remove the cleaning oil with compressed air Apply oil during installation When installing return to the state to seal face during installation before removing 7 Align the bolts to uniform the tightening points before 8 Bolts nuts and pieces must be tightened from the bigger tightening them when you don t know the bolt length diameter to the smaller one from inside to outside and diagonally with the specified torque 9 Check to see if the rubber part is worn out when 10 Recommended grease must be applied to or filled in removing it and replace it if necessary Some rubber part the specified place is weak to gasoline and kerosene so pay attention not to soak with gasoline or oils SERVICE INFORMA
25. Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits and idling ma become unstable SPECIFICATIONS FUEL TANK CAPACITY 5 0 CARBURETOR ITEM STANDARD TYPE THROTTLE BORE PA35 VENTURI DIAMETER 14mm MAIN JET SLOW JET No 65 35 PILOT SCREW OPENING 1 14 FLOAT LEVEL 12 2mm IDLING SPEED 2 000rpm THROTTLE GRIP FREE PLAY 2 6mm TOOL FLOAT LEVEL GAUGE 5 1 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 low quality gasoline Starter is damaged e Throttle cable is working improperly Fuel tank is functioning improperly Idle is unstable and engine turns off after starting Starter is damaged e Ignition system is damaged Using low quality gasoline Suction system is experiencing secondary intake of air e Idle is adjusted improperly Air screw is adjusted improperly Compression pressure is low Air Fuel mixture is either too lean or rich Carburetor is blocked Mis firing occurs when driving at high speeds e Ignition system is damaged Mixture is too lean Back firing e Ignition system is damaged e Mixture is too lean Insuf
26. IDLING ADJUSTMENT e Travel the vehicle 2 3km under the speed of 50km h to stabilize the combustion on normal temperature e Set the main stand on an even place to secure the safety 5 3 FUEL SYSTEM Turn the stop screw to adjust the idling speed to 2 000rpm IDLING RPM 2 000rpm LOW LEFT STOPSCREW RIGHT Turn the air screw as 1 4 turn to find the highest engine rpm and adjust it to 2 000rpm x Turning the air screw right hand the fuel will get thicker and turning left side it will be thinner As engine speed is set to 2 000rpm by use of air screw lower the idling speed 20 50rpm Standard air screw 1 1 2 turn back e Slightly snap 2 3 times and set to 2 000rpm by use of the stop screw e Slightly snap 2 3 times again to increase the stability and smooth the restarting and complete the adjustment as 1 800 2 000rpm AIR CLEANER REMOVAL Loosen the air cleaner connecting bend screw pin Loosen the 2 bottom air cleaner washer bolts e Remove the air cleaner from the carburetor e Install in the reverse order of removal CARBURETOR REMOVAL INSTALLATION 7 Kd r y 5 a Keep the fire away C e Open the drain screw to drain the gasoline in the carburetor chamber DRAIN SCREW INLET PIPE i THROMUEVALVESSEN ig J x o WASHER SCREWS AUTO BYSTARTER AUTO BY
27. m e Install the rear brake cable front brake hose speedometer cable to the handle cable guide Apply specified glue to the inside surface of the grip and to the clean surface of the left handle bar Wait 3 6 minutes and install the grip NOTE Clean the bonding surface to avoid oil grease or gasoline from attatching Leave it for minimum 1 hour until the bond is dried Use the bond according to the bond manual enclosed and install the grip while rotating it before the bond is dried completely e Align the positioning pin with the handle hole and install the L handle bracket TORQUE 1 2kgf m e Clean the throttle grip surface apply the grease and install the grip Connect the throttle cable to the groove of the grip e Tighten the pin screws after assembling NOTE Check the throttle grip for smooth operation and adjust the free play to 2 6mm e Match the master cylinder with the punch mark of the handle install it with the mark in the master cylinder holder facing upwards or front and tighten the rear or front first NOTE Check to see if the cylinder is passing each cable and wire harness directly and make sure that there is any interference by rotating the handle to the right and left FRONT WHEEL FRONT FORK STEERING FRONT WHEEL SPEEDOMETER GEARBOX A 1 d FFONTAXLE FRONT AXLE FRONT WHEEL REMOVAL e Remove screws from the speedome
28. screw locking compound to the bolt thread PUMP BLEEDING CAUTION Air infiltration in the oil pass may cause the engine sticking Always remove the air in the oil pass after maintenance When disassembling the oil tube air can be enter into the oil tube and the oil pump because of the oil leaking in the oil tube Remove the air completely Do not allow foreign substances from entering the oil pass 4 3 LUBRICATION SYSTEM OIL PASS TUBE Pe PUMP OIL TUBE Fill the oil tank with engine oil Cap around the oil pump and the carburetor with dry cloth e Locate the end of the oil tube in the level lower than the oil tank and drain the oil to bleed the air Install the oil tube in the oil pump Incline the oil pump to locate the oil pump shaft at the angle of 45 from the mark with oil tube __ OIL PUMP SHAFT connected MARK In this state locate the oil pump in the level lower than the oil tank and drain the oil to bleed the air Install the oil pump shaft in the oil pump after completing the bleeding Install the pump in the crankcase OIL PASS TUBE e Bend the oil pass tube the U shape keep the two ends parallel with each other and fill the oil oass tube with the oil LUBRICATION SYSTEM Connect the oil pump and then the carburetor quickly with the both ends of the tube pressed to avoid the air
29. two levers up and over and completely install the bead Install the valve core FRONT WHEEL FRONT FORK STEERING Apply a mild detergent solution to the bead again Tap on the tire tread surface with a rubber hammer so that the tire and rim fit evenly around the circumference Be sure that the tire center and rim center are aligned e Inflate the tire to 1 5 times the standard recommended pressure to seat the bead on the rim NOTE When air charging you may hear a loud sound as the bead seats onto the rim This is normal When air charging if air leaks out from between the rim and bead let the wheel stand with the valve at the bottom and put air in while pushing down on the tire Check that the tire bead seats on the tire rim securely and the rim line of the tire is consentric when the rim FRONT WHEEL INSTALLATION Insert the front wheel between the front forks Insert the disk taking precautions not to damage pad and assemble the wheel e Align the slots of the speedometer gear with the tangs of the left fork slider Insert the front axle into the speedometer gear box and the wheel hub 10 13 FRONT WHEEL FRONT FORK STEERING 10 14 FRONT FORK FORK PIPE ad ame FORK BOLTS Install the axle nut Assemble the speedometer cable and tighten with screws Place the front wheel on the ground and tighten the axle nut to the
30. 1 Manifold air leaks procedure stops immediately 2 Inadequate ignition Engine wont start 5 Remove spark plug Plug wet 1 Carburetor flooded 2 Faulty control box y pug 3 Throttle valve excessively opened 17 1 TROUBLESHOOTING ENGINE OUTPUT INSUFFICIENT 1 Gently accelerate engine Engine speed increases 2 Check ignition timing Normal 3 Press the kick starter pedal to check the cylinder pressure Normal 4 Check the carburetor for clogging Not clogged 5 Remove spark plugs Not contaminated or discolored 6 Check for engine overheating Not overheated 7 Accelerate suddenly or run at Engine does not knock 17 2 Engine speed does nt __ gt increase sufficiently Abnormal Clogged 72 Contaminated or discolored Overheated Enginine knocks CAUSE OF TROUBLE 1 Air cleaner clogged 2 Insufficient fuel supply 3 Fuel tank cap air hole clogged 4 Muffler clogged 1 Faulty CDI unit 2 Faulty A C generator 1 Cylinder and piston ring worn 2 Cylinder head gasket damaged 3 Cylinder and cylinder head cracked 1 Unsatisfactory carburetor maintenance 1 Unsatisfactory plug maintenance 2
31. ADJUSTMENTS CYLINDER COMPRESSION PRESSURE Start and warm up the engine Remove the plug maintenance cover Stop engine and remove the spark plug and spark plug Install a compression gauge Open the throttle completely and crank the engine with the starter motor until the gauge reading rising CAUTION Fix the vehicle securely Cut off the engine and lock the high pressure cable While the engine is hot pay attention not to get burned NOTE The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 10 kgf cm 600RPM e If the pressure is low check the following Leakage from the cylinder head gasket Piston cylinder worn If pressure is high check the following Carbon deposits on the piston head and cylinder head TOOL COMPRESSION GAUGE INN IDLING Stand the vehicle on the main stand 4 Heat the engine to make accurate idling inspection 1 adjustment mm x Verify all engine adjustments satisfy specifications Turn the throttle stop screw and make sdjustment to prescribed idling speed STANDARD RPM 2 000rpm AIR SCREW ADJUSTMENT NOTE The air screw 1 factory pre set Adjustment is not necessary unless the carburetor is overhauled or a new air screw is installed e Tightening the air screw against it is set will damage the seat MASTER CYLINDER BODY INSPECTIONS AD
32. Assembly of Drive Shaft Bearing OUTER DRIVER 37 X40mm 07746 00 10200 DRIVER PILOT 17mm 07746 0040400 UNIVERSAL BEARING PULLER 0755 00001 Disassembly of Crank Shaft Bearing CRANK CASE PULLER 0751 00003 Disassembly of R L Crank Case Crank Shaft CRANK ASSEMBLY 0740 00001 Disassembly of R Crank Case Crank Shaft OUTER DRIVER 52 X 55mm 07746 00 10400 Assembly of Crank Shaft Bearing DRIVER PILOT 20mm 07746 0040500 DRIVER HANDLE A 07749 0010000 CRANK ASSEMBLY 0740 00001 Assembly of R L Crank Shaft Oil Seal LOCK NUT WRENCH A 07916 1870101 Disassembly of Top Cone Race LOCK NUT WRENCH B 07916 KM 10000 BALL RACE REMOVER 07946 GA70000 Assembly of Ball Race 10 OUTER DRIVER 42 X 47mm 07746 00 10300 DRIVER HANDLE A 07749 00 10000 SHOCK ABSORBER COMPRESSER 07GM 00 10000 Disassembly Assembly of Rear Cushion COMPRESSER SCREW 55 Y 079GME 0010100 11 SPRING COMPRESSER ATTACHMENT 07967 GA70102 SPRING COMPRESSER ATTACHMENT O7JME GW20100 UNIVERSAL HOLDER 07725 0030000 Disassembly Assembly of Fly Wheel T A G G ROTOR PULLER 0750 00006 Disassembly of Fly Wheel LUBRICATION OIL SERVICE INFORMATION ENGINE PARTS APPLICATION AREAS CAUTIONARY SUGGESTIONS OIL TYPE CRANK CASE JOINING FACE Gasket Fluid TB 1215 CRANK CASE REVOLUTION PART CYLINDER BIG REVOLUTION PART FRICTION PART Ultra 2 Super 2 Cycle Oil Separation Lubrication Use TRANSMISSION FINAL REDUCTION KICK SPINDLE BUSH STARTER PINION STARTER DRIVE GEAR OPERA
33. GEAR INSPECTION e Remove the LH side cover 7 2 e Remove the drive face 7 6 e Remove the starter pinion gear e Install in the reverse order of removal INSPECTION Wear or damage to the pinion reduction gears Replace with a new one Worn journals Replace with a new one Check if the pinion gear moves smoothly along the axis e Pinion gear does not move smoothly Replace with a new one STARTING SYSTEM 15 7 LLL 16 LIGHTS METER SWITCHES SERVICE INFORMATION HANDLE SWITCH ISPECTION 16 4 TROUBLE SHOOTING FRONT STOP SWITCH INSPECTION 16 4 FUEL UNIT BULBS REPLACEMENT gt 16 5 OIL LEVEL SWITCH METER REPLACEMENT 16 6 MAIN SWITCH HORN INSPECTION SERVICE INFORMATION GENERAL SAFETY Refer to tester owner s manuals when performing continuity inspections e Refer to wiring diagram chapterl7 for switch continuity After inspecting and or per performing maintence work make sure the wires and cables are properly placed and connected TROUBLE SHOOTING Fuel meter indicator malfunctioning Cil indicator light not operating Coupler separated when there is oil e Harness disconnected Burned out fuse e Float operation malfuction e Battery insufficently chargde e Fuel unit damaged e Main swtich damaged Meter damaged
34. Install the front fork 10 21 FRONT WHEEL FRONT FORK STEERING e Install the following parts Steering handle 10 3 Front wheel gt 10 5 Front handle cover rear handle cover 3 6 Front fender gt 3 5 Front brake caliper gt 12 6 NOTE Check the cables and wiring for interference Install the front cover 10 22 REAR WHEEL BRAKE SUSPENSION 11 REAR WHEEL BRAKE SUSPENSION SERVICE INFORMATION 11 1 REARWHEEL 11 3 SERVICE STANDARD 11 1 11 4 TROUBLESHOOTING 112 REARCUSHION 11 6 SERVICE INFORMATION GENERAL SAFETY e Ifthe 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 e Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies Use a brake cleaner designed to mininize the hazard caused by airborne asbestos fibers SPECIFICATIONS AXLE SHAFT RUN OUT m REAR WHEEL RIM RUNOUT REAR BRAKE DRUM INNER DIAMETER 110 0 110 3mm REAR BRAKE LINING THICKNESS 4 0mm REAR CUSHION SPRING FREE LENGTH 234 8mm TORQUE VALUES AXLE SHAFT RUN OUT 10 0 12 0kgf m REAR CUSHION UPPER BOLT 3 5 4 5kgf m REAR CUSHION LOWER BOLT 3 5 4 5kgf m 11 1
35. OIL STRAINER SCREEN OIL TANK LIGHTS METER SWITCHES OIL LEVEL SWITCH REMOVAL INSTALLATION e Remove the luggage box 3 3 Remove the body cover Loosen the bolt joined with the fuel tank e Remove the wire of oil level switch e Remove the oil level switch from the oil tank e Install in the reverse order of removal NOTE Disassemble after adjusting the oil level INSPECTION Move the float to farthesting extreme up and down and check the continuity of the terminals It s normal state if there is no continuity when the float is up but continuity when it is down MAIN SWITCH REMOVAL INSTALLATION e Remove the front cover 53 5 e Disconnect the main switch coupler INSPECTION Inspect continuity of each terminal TERMINAL IG E BAI ON LOCK COLOR GREEN BLACK LIGHTS METER SWITCHES HANDLE SWITCH INSPECTION Remove front handle cover Remove the handle switch coupler connector and inspect continuity of each terminal e If abnormal inspect the switch LIGHTING SWITCH STARTER SWITCH HL C1 RE ST PUSH COLOR YELLOWRED GREEN ENGINE STOP SWITCH BLACK DIMMER SWITCH WINKER SWITCH up o HI LO HL fao LO 8 ve S I STARTER SWITCH 7
36. Plugs with incorrect heat value used 1 Rich fuel mixture 1 Cylinder or piston worn 2 Lean fuel mixture 3 Poor quality fuel used 4 Carbon deposit inside the combustion chamber excessive 5 Ignition timing incorrect 1 Carbon deposit inside the combustion chamber excessive 2 Poor quality fuel used 3 Lean fuel mixture TROUBLESHOOTING POOR PERFORMANCE AT LOW SPEED AND IDLING 1 Check the ignition timing Abnormal Normal 2 Check the carburetor air screw Incorrect gt Correct 3 Check the area around the maniford Leaking gt for air leakage No leak Weak or intermittent 3 CAUSE OF TROUBLE 1 Faulty CDI unit 1 Excessive fuel mixture Loosen screw to correct adjustment level 2 Lean fuel mixture Tighten screw to correct adjustment level 1 Faulty insulator packing 2 Loose carburetor 3 Faulty inlet pipe packing 4 Faulty insulator O ring 1 Carbon deposited on spark plugs or 4 Check spark speaks spark plugs contaminated 1 2 Faulty CDI unit 3 Faulty ignition coil 4 Faulty A C generator 5 Faulty main switch CAUSE OF TROUBLE 1 Check the ignition timing Incorrect 1 Faulty CDI unit Correct 2 Faulty A C generator 2 Remove the fuel tube from the fuel Insufficient fuel supply gt 1 Fuel tank empty valve Fuel flows 2 Fuel tube
37. and dowel pin after removing the gasket of the crankcase surface Align the bolts to uniform the tightening location before tightening then when you don t know the bolt length e Tighten the bolts diagonally with specified tightening torque TORQUE 1 0kgf m KICK STARTER REMOVAL Remove the LH side cover Loosen the flange bolt securing the kick starter arm remove the kick starter arm Remove the 14mm external circlip Remove the kick spindle washer Remove the kick starter spondle Remove the kick spindle spring bush KICK STARTER SPINDLE KICK DRIVEN GEAR KICK STARTER SPINDLE KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION KICK RETURN SPRING KICK SPINDLE BUSH FRICTION START GEAR SPRING KICK SPINDLE BUSH KICK DRIVEN GEAR INSPECTION Inspect wear and damage of the kick starter spindle and gear portion Inspect damage to return spring Inspect defects and damage of the kick starter spindle bushing Inspect wear and damage of the kick starter ratchet Inspect damage to friction spring KICK STARTER INSTALLATION Install the kick spindle bush spring in the LH side cover Install the kick starter spindle in the LH side cover Install the kick starter spindle washer Install the 14mm external circlip in the L side cover Install the kick starter arm e Install the kick spindle springn in the groove of the LH side cover
38. any clogged passage with compressed air e Bleed the brake hose after removing it TROUBLE SHOOTING HYDRAULIC DISK BRAKE Braking power unsatisfactory Air in the brake system Moisture in brake fluid e Brake pad and disk contaminated Caliper piston seal worn e Master cylinder piston seal worn e Brake pad worn e Caliper inside contaminated Unsatisfactory caliper sliding part operation Lopsided wear of brake pad and disk Low brake fluid level Clogged brake fluid line Disk bent or distorted Caliper piston seized or worn Master cylinder piston seized or worn Disk worn Master cylinder inside contaminated Brake lever bent 12 6 12 6 12 9 Hard brake lever movement or unsatisfactory return Brake system clogged Caliper piston seized or worn Unsatisfactory caliper sliding part operation Brake fluid line clogged Caliper piston seal worn Master cylinder piston seized or worn Brake lever bent Brakes drag Brake pad and disk contaminated Improper wheel alignment Lopsided wear of brake pad and disk Disk bent or distorted Unsatisfactory caliper sliding part operation Hydraulic system contaminated with dust 12 1 BRAKE SYSTEM MECHANICAL DRUM BRAKE Poor brake performance Improperly adjusted brake Worn brake linings Worn brake drum Worn brake cam Brake cable sticking needs l
39. carburetor and let it cool down for 30 minutes Insert a vinyl tube into the fuel enrichening circuit and blow into the tube Air should flow into the circuit e If air does not flow into the circuit replace the auto bystarter Connect the battery to the auto bystarter terminals and wait for 5 minutes Insert a vinyl tue into the fuel enrichening circuit and blow into the tube Air should not flow into the circuit If air flows into the circuit replace the auto bystarter Check the resister if the auto bystarter is normal but engine is still hard to start e If there 15 a broken wire the resister current will not flow to the PTC and the auto bystarter will not operate e If there 15 a shorted wire the resister current of a higher voltage than specified will reach the PTC this will cause the fuel enrichening circuit to close too soon and starting will be difficult THROTTLE VALVE DISASSEMBLY e Remove the throttle valve e Remove the throttle cable e Remove the throttle valve spring e Remove the needle clip e Remove the clip e Remove the jet needle 5 7 FUEL SYSTEM SPRING THROTTLE VALVE LINK SMALLER DIAPHRAGM AIR VENT VACUUM __ I LINE LARGER DIAPHRAGM SPRING ASSEMBLY Install the jet needle into the throttle valve and secure with the retainer Route the throttle cable through the spring and compress the spring fully Attach the
40. e Meter damaged Oil level switch damaged Fuel meter needle unstable Loose connector Coupler loose Harness disconnection Fuel unit damaged M u e Meter damaged Oil indicator does not turn off when oil is out Oil level switch damaged Headlight hi lo not operating e Green red wire joined e Bulb malfunction e Dimmer switch damaged 16 1 LIGHTS METER SWITCHES FUERUNITIRETAINER 4 FUEL UNIT REMOVAL e Remove the luggage box 3 3 e Remove the fuel unit wire from the wire harness e Turn the fuel unit fixing unit set cap comp to the left and remove it Remove the fuel nit from the fuel tank NOTE Be careful of prevention the fuel unit wire from damaging When disassembling be careful of prevention the float arm from damaging e Remove the base packing NOTE Check for damage INSTALLATION Install the base packing to the fuel tank e Install the fuel unit NOTE Install it aligning the spark of the fuel unit with the ollp park of fuel tank Check the fuel leakage INSPECTION Move the float upward and downward and measure the resistance between the terminals UNIT WIRE TERMINAL YELLOWAWHITE AND GREEN FUEL FULL UPPER LINE 10 RESERVE 71 FUEL LOW LOWER LINE 90 LOWER LINE When the measured value differs greatly from the standard value replace the fuel unit 16 2 OIL LEVEL GAUGE
41. from entering NOTE Make sure that the tubes are arranged correctly e Start the engine NOTE Do not start the engine in the poorly ventilated ares e Open the oil pump control level fully and idle for 2minutes to bleed the air remained in the oil pass tube with the oil drained from the pump NOTE Do not increase the engine RPM more than required e Connect the oil control cable NOTE Adjust the oil pump if the adjustment nut of the oil control lever is loose ENGINE OIL LEVEL INSPECTION Check to see if the matching mark of the oil pump body and control lever are aligned in a state where the throttle grip is completely rotated x 1 ih 9 m 1 i LOLBOX WARNING LOW OILWARNING LIGHT BLINKING LEVEL 0 15 L Remove the oil tank and fill the oil tank with oil to OIL TANK the level of the projected portion RECOMMENDED OIL ULTRA 2 SUPER OIL Reinstall the oil tank and check to see if the pilot lamp turns off when the main switch is turned on PROJECTION PART 4 5 LUBRICATION SYSTEM OIL TANK SW OIL LEVEL SWITCH OIL STRAINER SCREEN AIR GUN CHECKHOLE OIL TANK DISASSEMBLY Remove the luggage box Remove the body cover Loosen 2 flange bolts securing fuel tank seatcatch Loosen 2 washer bolts of setting stay securing luggage carrier
42. harness 15 short circuited battery line and ground line Coupeler is connected incorrectly NORMAL Check the changing coil with the register epee A C generator charging coll rectifier coupler charging coil NORMAL L generator coupler connected incorrectly ABNORMAL CORRECT Damaged charging coil m ABNORMAL Inspect the A C generator charging Check the lighting coil with the register lighting coil rectifier coupler lighting coil NORMAL gt generator coupler connected incorrectly NORMAL ABNORMAL Damaged charging lighting coil Check the headlight lighting control voltage ABNORMAL Damaged register rectifier darkened headlight NORMAL Inspect the headlight register ABNORMAL Damaged headlight register NORMAL Inspect the body of the register rectifier ABNORMAL Damaged register rectifier NORMAL Damaged battery 13 2 MAINT SPECIAL SCREW BATTERY CHARGING SYSTEM BATTERY REMOVAL INSTALLATION Loosen lpcs special screw securing maintenance lid Remove the maintenance lid After removing the negative terminal of battery firsty must remove the positive terminal of battery Install in the reverse order of removal BATTERY INSPECTION CHARGE LEVEL OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and discon
43. shorted or damaged CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Ignition swich damaged or shorted 4 Terminal loose of faulty connection 5 Wire harness damaged 1 Faulty fuel level sensor connection 1 Damper oil inside the meter insufficient 1 Faulty connection between the sliding arm and the resistance 1 Terminal connection loose or faulty connection 1 Balance coil lead shorted or damaged STARTER MOTOR STRTING MOTOR WILL NOT TURN 1 the brake and check the brkae stop light for operaation Light is activated 2 Operate the turn signal to check the battery circuit Signal operates satisfactorily 60 120 signaling second 3 Press the starter switch to check the starter magnetic Satisfactory 4 Connect the starter to battery and check operation Light not activated Starter turns Signal continuously operates dim or does not operate at all Needle moves Needle not moves Unsatisfactory STRTING MOTOR TURNS SLOW OR FAILS TO CRANK MOTOR 1 the turn signal to check the battery circuit Signal operates satisfactorily 2 Connect the starter subwire to the battery Turns slowly with speed not changing 3 Operate the kick starter Signal continuously operates dim or does not operate at all Operates sitisfactor
44. the brake hose to the caliper and install 2 sealing washers and the brake hose bolt TORQUE 3 5kgf m e Install the brake caliper on the front fork e Fill the brake fluid and bleed air OIL BOLT MASTER CYLINDER BRAKE LEVER CIRCLIP N j T MASTER BODY CYLINDER SPRING 2 PISTON BOOT pg 1 a 1 j zi ion DIAPHRAGM DIAPHRAGM PLATE CIR CLIP BR OIL CUP CAP BRAKE SYSTEM MASTER CYLINDER REMOVAL Disconnect the front brake switch wire Drain the brake fluid Remove the brake hose from the master cylinder CAUTION Brake fluid causes damage to the painted plastic or rubber parts Do not spill fluid on these parts If contaminated gently wipe off the fluid with a piece of cloth or wash in water Close hose joints properly to prevent leakage of brake fluid Clean the disassembled parts with brake fluid and use compressed air to verify each passage is not clogged Do not allow the disassembled parts to be contaminated by waste material or dust Remove the master cylinder holder and lift out the master cylinder DISASSEMBLY Remove the front stop switch Remove the piston boot cir clip from the master cylinder TOOL SNAP RING PLIERS Remove the washer piston spring from the master cylinder Clean the master cylinder reserve master piston with t
45. throttle cable end to the bottom of the throttle valve and thread the throttle cable through the slot in the valve Align the cutout in the throttle valve with the throttle stop screw on the carburetor body and install the valve on the carburetor NOTE Be sure that the throttle valve cutaway is toward the air cleaner case side as it determines the volume of air for fuel mixture Operate the valve after installing the throttle valve FUEL AUTO COCK REMOVAL INSTALLATION Remove the luggage box Remove the maintenance lid Remove the rear grip Remove the body cover Remove the fuel tube A B connected to the carburetor Remove the inlet pipe negative pressure tube Remove the fuel tube A B connected to the fuel tank Remove the flange bolt securing the fuel auto cock and the frame Remove the fuel auto cock e Install in the reverse order of removal CAUTION Be sure to remove the diaphragms from the fuel auto valve before using compressed air to blow out of air passages Compressed air wil damage the diaphragms or may force them off the aliminum e Disconnect the fuel line and place it in a clean container as shown NOTE Placea clean contaier under the fuel tube Refer to the Model Specific manual for replacement Connect the fuel auto valve vacuum tube to the vacuum pump and apply vacuum Be sure that the fuel flows out smoothly If the vacuum does not
46. zero be damaged by the impact of the drop adjustment must be performed before testing Is this measurement range or configuration in accord with the manual 1 22 INSPECTIONS ADJUSTMENTS 2 INSPECTIONS ADJUSTMENTS SERVICE INFORMATION 2 1 PAD SHOE 222 MAINTENANCE SCHEDULE 2 2 BRAKE 5 5 2 8 FUEL LINE FUEL TUBE 23 HEADLIGHT ADJUSTMENT 2 8 FUEL LINEFORCLOGGING 2 3 SIDE STAND THROTTLE GRIP OPERATION 2 4 ESSA cane SUSPENSION 2 9 BOLTS NUTS FASTENERS 2 9 Hd 25 WHEELS TIRES 2 9 CYLINDER COMPRESSION PRESSURE 2 6 STEERING HEAD BEARING 2 10 CARBURETOR IDLING 2 6 aes AIR SCREW ADJUSTMENT 2 6 5 7 LUBRICATION POINTS 2 11 SERVICE INFORMATION WARNING e The exhaust gas contains poisonous substance Do not keep engine idling in a closed or poorly ventilated place for long period of time NOTE SPECIFICATIONS ITEM STANDARD VALUE REFERANCE THROTTLE GRIP PLAY 2 6mm SPARK PLUG BPR6HS SPARK PLUG GAP 0 6 0 7mm 936 CARBURETOR IDLE SPEED 2 000rom CYLINDER COMPRESSION PRESSURE 10 600rpm TORQUE VALUES SPARK PLUG 1 4kgf m CYLINDER HEAD COVER BOLTS 1 0kgf m 2 1 INSPECTIONS ADJUSTMENTS REGULAR INSPECTION SCHEDULE Carry out pre operation check at each scheduled maintenance period based on the information described
47. 0 3mm RING MARK Turning up CONNECTING ROD SMALL END PORTION DIAMETER 17 005 417 017mm 17 SERVICE INFORMATION ITEM STANDARD USE LIMITS CLUTCH AUTOMATIC Automatic Centrifugal TYPE Continuously Variable Transmission CLUTCH OUTER DIAMETER 107 0 107 2mm CLUTCH LINING THICKNESS 4 0mm CLUTCH DRIVE BELT WIDTH 15mm MOVABLE DRIVE FACE BUSH INSIDE DIAMETER 20 035 20 085mm BOSS OUTSIDE DIAMETER 20 010 20 025mm WEIGHT ROLLER OUTSIDE DIAMETER 15 92 16 08mm DRIVEN PULLEY FACE SPRING FREE LENGTH 98 1mm FACE OUTSIDE DIAMETER 33 965 33 985mm MOVABLE FACE INSIDE DIAMETER 34 000 34 025mm CRANK SHAFT LARGE END SIDE CLEARANCE 0 15 0 55mm 0 60mm CRANK SHAFT CONNECTING ROD LARGE END RIGHT ANGLE DIRECTION CLEARANCE 0 010 0 022mm 0 04mm CRANK SHAFT SHAKING A 0 05mm 70mm from center 0 15mm B 0 03mm 37mm from center 0 10mm JA m 70mm 37mm WHEELS RIM RUNOUT RADICAL 2 0mm AXIAL 2 0mm AXLE DEFLECTION 0 2 FRONT REAR WHEELS TIRES TYPE TUBELESS TIRE PRESSURE FRONT 1 25kef REAR 2 00kgf cri TIRE SIZE FRONT 90 90 10 50J REAR 90 90 10 50J SERVICE INFORMATION ITEM STANDARD USE LIMITS FRONT BRAKE LEVER FREE PLAY 10 20mm _ BRAKE FLUID DOT3 or DOT4 _ BRAKE PAD THICKNESS to wear line DISK THICKNESS 3 0mm 2 5mm DISK SHAKING 0 3mm DISK WEAR LINE 2 5mm BRAKES MASTER CYLINDER INSIDE DIAMETER 11 000 11 043mm 11 05mm
48. DAELIM SERVICE MANUAL HOW USE THIS MANUAL This manual describes effective maintenance procedure for the BONITA 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 through 2 provide information on overall vehicle section 3 assembly and disassembly procedures for external components and section 4 describes maintenance procedure for the engine frame and electrical systems To facilitate use of this manual each page starts with disassembly and system diagrams service information and troubleshooting guide If you cannot find the cause of trouble refer to Section 18 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be reproduced without written permission of DAELIM Motor Co Ltd CONTENTS FRAME ENGINE GENERAL SERVICE INFORMATION INSPECTIONS ADJUSTMENTS EXTERNAL PARTS ENGINE REMOVAL INSTALLATION mm CYLINDER HEAD CYLINDER PISTON EB REAR WHEEL BRAKE SUSPENSION KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION BRAKE SYSTEM ELECTRICAL SYSTEM CHARGING SYSTEM BATTERY IGNITION SYSTEM STARTER SYSTEM LIGHTS METER SWITCHES TROUBLESHOOTING WIR
49. DOMETER CABLE THROTTLE CABLE BOX CORD TIGHTEN IT FIRMLY AFTER SET UP HAZARD STARTER SWITCH CORD SPEEDOMETER CABLE FR BRAKE TUBE WINKER SWITCH CORD SPEEDOMETER CORD 1 14 SERVICE INFORMATION GENERAL SAFETY WARNING 1 Do not run the engine for a long time in closed or not well ventilated area because the exhaust gas contains toxic substances such as carbon monoxide hydrocarbon nitric oxide 2 The battery fluid lean sulfuric acid is extremely toxic It is dangerous if skin is exposed to it or if it enters into the eye Be careful in handling When exposed to the battery fluid wash it with water and get a medical check up store the battery fluid in a safe place to avoid touching by the children 3 Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must performed in the place free of the open fire or electric spark 5 When more than two person are working always pay attention to other worker s action and alway have safety in mind 6 The skin exposed to used engine oil can be a major reason of the skin cancer Pay attention not to exposed and wash carefully with soap and water after handling 7 If compressed air is used to clean the brake dust scattered in the air can be breathed in by workers Please take action not to scatter dust in the brake cleaner etc 8
50. E RED CORD e When disconnecting the battery the minus terminal must be disconnected first Make sure that the tool such as spanner do not contact with the frame If the fuse is short circuited find out the cause and repair Replace with the fuse having the specified capacity PA DATION 3 OF CAPACITY SERVICE INFORMATION When measuring voltage or resistance of the cord terminal using tester contact the tester plug behind of the coupler Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water proof coupler TESTER PLUG Recheck the condition of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After connecting the terminal apply the grease to the terminal RED STRIPE Connect covers to the terminal after maintenance f there is rust in the terminal remove the rust with sand paper prior to connecting SERVICE INFORMATION Turn off the main switch before connecting dis e When disconnecting the coupler disconnect it while connecting holding the coupler body Pull while holding the wire Release the lock to disconnect the lock of the coupler harness cord and do not remove the coupler connection The lock of the coupler has two types according to releasing method press type and pul
51. ECTION Caliper Cylinder Check the caliper cylinder bore for scoring scratches or other damage Measure the caliper cylinder I D in X and axis at serveral points Replace the caliper cylinder if the largest measurement is beyond the specified service limit SERVICE LIMIT 30 2mm 12 7 BRAKE SYSTEM PISTON LH BRACKET gt 1 PAD SPRING 44 PISTON SEAL BUSH PISTON DUST SEAL SLIDE PIN FRONTIEORK 12 8 Caliper Piston Measure the caliper cylinder O D in X and Y axis at serveral points Replace the caliper piston of the smallest measurement is less than the specified service limit SERVICE LIMIT 30 1mm BRAKE CALIPER ASSEMBLY INSTALLATION Clean the piston seal and the dust seal with the brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad NOTE Make sure that each part is free from dust or dirt before reassembly Replace the dust seals and piston seals as a set whenever they are removed When cleaning with the brake fluid use the specified brake fluid Apply the silicone grease to the pin bush Connect pin bush to the portion of the caliper Install the pad spring in the caliper e Install the caliper pin bolt and the slide pin in caliper e Install the brake pad and the hanger pin in the caliper Connect
52. ER AUTOMATIC BATTERY EHAROER Ri 5 e PATE d SEPERATOR 4 PLATE 13 4 T MAINFUSE TERMINAL CHARGING VOLTAGE CHECK Use the full change battery 12 8 13 2 e In case that charging the voltage is not controled properly the battery cannot be used due to the battery solution dried up by over charging and the deformation caused by the damage of the plates e Battery control voltage 14 5 0 5V 5000rpm NOTE If you have 1EAof rester measure current first CHARGING CURRENT CHECK e Check the charging current passed through the generator assy regulator comp is normal with the discharged battery CHARGING CURRENT 1 5 2 4A 5 000rpm TOOLS DIGITAL CIRCUIT TESTER BATTERY CHARGING e Remove the battery from the frame and connect it to the battery charger Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal NOTE Do not connect the charger to the battery coupler terminals Never open the sealed filler cap WARNING The battery generates hydrogen gas which can be highly explosive Do not smoking or allow flames or sparks near the battery easpecially while charging it Turn power ON OFF at the charger not at the battery terminals If the cable is disconnected or connected at the battery terminal during charging spark may jump and ig
53. ER LO EAS y LOCK SWITCH RESISTER COMP REG RECTIFIER N Lp NE YN lt TS LQ NY SS e 2 pP Kv a 2 gt eae ES CDI UNIT BATTERYOCORD WIRE HARNESS THROTTLE CABLE RR BRAKE CABLE BLUE YELLOW GREEN BLACK YELLOW BLACK RED BLACK WHITE AC GENERATOR SPARK PLUG IGNITION COIL LE PULSE GENERATOR CDI UNIT SIDE STAND MAIN SWITCH SWITCH 7 14 0 IGNITION SYSTEM 14 IGNITION SYSTEM SERVICE INFORMATION gt gt 14 1 EXCITE COIL INSPECTION gt TROUBLE SHOOTING gt 14 2 PULSE GENERATOR INSPECTION 14 5 IGNITION SYSTEM INSPECTION IGNITION TIMING INSPECTION 14 6 VOLRAGE MEASUREMENR 14 3 CDIUNIT 146 IGNITION COIL 14 4 SIDE STAND IGNITION CUT OFF SWITCH 147 SERVICE INFORMATION GENERAL SAFETY Refer to the malfunction diagnosis when inspecting ignition devices Because the ignition devices have installed electrical addevices it is impossible to adjust ignition timing Be careful when handling the ignition devices as they can become easily damaged if dropped or bumped Also do not disconnect or connect the connectors and couplers when the main swtich is turned ON as excessive electric current can cause damage in the unit Always perform maintenance work on the ignition devices with the main switch turned OFE e Ignition d
54. ES S W WINKER DIMMER HORN SW RR STOP SW COMB 5 G Y L1 7 G Y e TIT TT T i iu 5B T eee we 2 m LE B lt sbe gt Ge Yo Y ANTITHEFT DEVICES S W 5 6 7 N HORN DIMMER S W WINKER S W HORN S W FRAME EARTH 12V a BATTERY FUEL REG REC UNIT 2 gt 820 HEATER CARBURETOR RR WINKER 12V 10W Sb Sb G TAIL STOP LIGHT 12V 5W 21W IL D 17 Sb G Y L LH RR WINKER a 12V 10W 2 cc LE L a x 5 gt e 5 SPARK PLUG STARTER MOTER COLOR COMB GROUND MARKING SERVICE MANUAL 2008 12 PRINTED 2008 12 PUBLICATION COPY PROHIBIT DAELIM MOTOR SERVICE MANUAL
55. ING DIAGRAM E 1 SERVICE INFORMATION SERIAL NUMBER LOCATION 141 SPECIFICATIONS MAINTENANCE INFORMATION 1 3 TWISTTORQUE 16 SPECIALIZED TOOLS LUBRICATION OIL SYMBOLS WIRING DIAGRAM GENERAL SAFETY SERVICE RULES CAUTION WHEN WIRING ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION SERVICE INFORMATION SPECIFICATION ITEM SPECIFICATION ITEM SPECIFICATION TYPE OF VEHICLE BONITA BRAKING DISTANCE 8 0m 30km h OVERALL LENGTH 1 795mm OVERALL WIDTH 730mm MIN REVOLUTION RADIUS COOLING TYPE AIR COOLED OVERALL HEIGHT 1 075mm STARTING STARTER MOTOR KICK WHEEL BASE MOTOR TYPE SE50C DISPLACEMENT 1 225mm 49 5 2 CYCLE NO OF CYLINDERS MOUNTING 1 CYLINDER TRANSVERSE VALVE APPARATUS READ VALVE PISTON VALVE COMBINATION FUEL UNLEADED GASOLINE BORE amp STROKE 40 X39 4mm FRONT AXLE DRY WEIGHT REAR AXLE 30kg 45kg COMPRESSION RATIO MAX OUTPUT En 2 95PS 6 000rpm TOTAL 75kg MAX TORQUE 0 35kgf m 5 500rpm PASSENGERS GROUND CLEARANCE 105mm CASTER 2 65kg zr PRIMARY SPEED REDUCTION RATIO 3 077 SECONDARY SPEED 3 461 REDUCTION RATIO l TRANSMISSION NON STAGE TRANSMISSIO TRAIL 73mm TRANSMISSION RATIO 1ST GEAR 2 41 0 76 FRAME TYPE 1 2 UNDER BONE
56. INTS BLUE YELLOW TERMINAL 9 EARTH PEAK VOLTAGE OVER 1 5V 14 3 IGNITION SYSTEM EXCITE COIL CAUTION Assemble the spark plug to the cylinder head inspect in a State having compression pressure WIRE HARNESS UNIT COUPLER e Remove the luggage box 3 3 e Remove the CDI unit 14 7 e Remove the coupler from the CDI unit and contact the peak voltage adaptor to the excite coil wire blue red green of harness coupler EXCITE COIL F MARK Operate the starter motor and measure the excite coil peak voltage CONTACT POINTS BLACK RED TERMINAL EARTH PEAK VOLTAGE OVER 120V CAUTION When measuring voltage do not touch the metal part of the handle rod as there is the danger of receiving an electric shock Perform the following inspections of measured peak voltage on the CDI unit coupler portion isabnormal Disconnect the AC generator cord coupler and connect the adaptor In the same manner as with the unit coupler side measure peak voltage and compare with the girst peak voltage When the measured value in the unit side is abnormal and normal on the pulse generator side the problem is either incorrect coupler connection or disconnection of the wire harness When both measurements are abnormal this indicates a problem with the pulse generator Refer to the malfunction diagnosis are go through each step IGNITION COIL
57. JUSTMENTS Turn the air screw clockwise until it seats lightry then back it out to the specification given This is an initial setting prior to the final air screw adjustment Rev the engine up slightly from the idle apeed and make sure that engine speed rises and returns smoothly Adjust by turning the air screw in or out within a 1 4 turn if necessary If the engine cannot be adjusted by turning the air screw within a 1 4 turn check for other engine problems BRAKE FLUID Remove the brake fluid cover Check the oil level inside the front reservoirs if the oil level is near the lower limit line remove the reservoir diaphragms and fill DOT 3 and DOT 4 brake fluid to the top limit line e the brake fluid reaches the lower limit line check the entire brake system for leaks CAUTION Brake fluid will damage painted plastic or rubber parts Mixing incompatible fluids can impair braking efficiency Foreign materials can clog the system causing a reduction or complete loss of braking ability A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability BRAKE PAD SHOE BRAKE PAD REPLACEMENT Check the brake pads for wear e If the red mark on the pad reaches the brake disk replace the pads NOTE Replace the brake pads as sets BRAKE SHOE REPLACEMENT If the arrow mark of the wear limit aligns with the A mark when the parki
58. KET NUT 2 10 5 0kgf m FRAME SIDE 7 3kgf m EXHAUST PIPE JOINT NUT 3 6 1 2kgf m MUFFLER BRACKET BOLT 3 3kgf m EXHAUST PIPE PROTECTOR SCREW 4 6 O 5kgf m STANDARD TWIST TORQUE TYPE TWIST TORQUE SUBE TWIST TORQUE N m kgf m ft Ib N m kgf m ft Ib 5mm BOLT NUT 5 0 5 4 5mm SCREW 4 0 4 9 6mm BOLT NUT 10 1 0 7 6mm SCREW 9 0 9 7 BOLT NUT 21 2l 15 6mm SCREW FLANGE BOLT NUT 9 0 9 7 10mm BOLT NUT 35 3 5 25 8mm SCREW FLANGE BOLT NUT 27 27 20 12mm BOLT NUT 55 5 5 40 10mm SCREW FLANGE BOLT NUT 40 4 0 29 Bolts not appearing in the following table are tightened using standard torque 1 7 SERVICE INFORMATION SPECIALIZED TOOLS TOOL NAME TOOL NO USAGE CHAPTER FLOAT LEVEL GAUGE 07401 001000 Carburetor Oil Level Measurement 5 BEARING DIRVER 07945 GC80000 Change of Driven Face Outer Bearing BEARING REMOVER 07936 3710300 Disassembly of Driven Face Needle Bearing REMOVER HANDLE 07936 3710100 REMOVER WEIGHT 07741 0010201 DRIVER HANDLE A 07749 00 10000 Assembly of Driven Face Needle Bearing 7 OUTER DRIVER 24 X 26mm 07746 00 10700 CLUTCH SPRING COMPRESSOR 07960 KM10000 Disassembly Assembly of Clutch Driven Face SOCKET WRENCH 39mm 0723 03900 CLUTCH CENTER HOLDER 07724 0050001 Disassembly Assembly of Driven Pulley Driven Face UNIVERSAL HOLDER 07725 0030000 Disassembly Assembly of Clutch Driven Pulley CRANK ASSEMBLY 0740 00001 Assembly of Drive Shaft DRIVER HANDLE A 0749 00 10000
59. M INSPECTION PEAK VOLTAGE MEASUREMENT NOTE When sparks are not emitted from spark plug after checking for disconnection in wires and looseness measure peak voltage gor each wire Connect the peak voltage adaptor to the digital tester DAERIM PVA MULTI TESTER IGNITION COIL PRIMARY VOLTAGE NOTE Make sure each wire is correctly connected to ensure correct measurement Inspect when there is cylinder compression pressure and with the spatk plug cap securely connected to the spark plug e Remove the luggage box 3 3 With the ignition coil wire connected contact the peak voltage adaptor to the initial wire adaptor terminal black yellow and ground on vehicle body Turn the main switch ON operate the starter motor and measure the ignition coil initial side peak voltage CONTACT POINTS BLACK YELLOW TERMINAL EARTH PEAK VOLTAGE OVER 120V CAUTION When measuring voltage do not touch the metal part o the handle rod as there is the danger of receiving a electric shock PULSE GENERATOR CAUTION Inspect with the spark plug assembled and while there is compression pressure e Remove the CDI unit gt 14 7 Remove the coupler from the CDI unit and connect the peak voltage adaptor to the pulse generator wire blue yellow and green of harness coupler Operate the starter motor and measure the peak voltage of the pulsw generator coil CONTACT PO
60. MASTER PISTON OUTSIDE DIAMETER 10 957 10 984mm 10 91mm CALIPER CYLINDER INSIDE DIAMETER 30 230 30 280mm 30 29mm CALIPER PISTON OUTSIDE DIAMETER 30 148 30 198mm 30 14mm REAR BRAKE LEVER FREE PLAY 10 20mm DRUM INSIDE DIAMETER 95mm 95 5mm LINING THICKNESS 4 0mm 2 0mm SPARK PLUG STANDARD BPR6HS OP at low speed BR4HSA OP at high speed BPR7HS PLUG GAP 0 6 0 7mm IGNITION TIMING FMARK BTDC 15 2 000rpm IGNITION PEAK VOLTAGE IGNITION COIL PRIMARY VOLTAGE 300V 25 SYSTEM EXCITE COIL over 100V PULSE GENERATOR over 2 8V IGNITION COIL RESISTANCE VALUES PRIMARY COIL 0 1 0 5 9 SECONDARY COIL PLUG CAP CONNECTION 6 3 10 3 Ko SECONDARY COIL PLUG CAP DISCONNECTION 2 8 EXCITE COIL RESISTANCE VALUE 20 50 200 2 PLUSE GENERATOR RESISTANCE VALUE QO 400 800 9 ACGENERATOR TYPE AC OUTPUT 12V 11A 5 000rpm CHARGING COIL RESISTANCE VALUE 20_ 04 10 9 LIGHTING COIL RESISTANCE VALUE 20 0 2 0 8 9 CHARGING REGULATOR RECTIFIER TYPE Semi conductor BER E CONTROL VOLTAGE LAMP SIDE 12 0 14 0V 5 000rpm CHARGING SIDE 13 0 15 0V 5 000rpm REGISTER RESISTANCE VALUE REGISTER 6 7 Q5W 63 71 9 SERVICE INFORMATION ITEM STANDARD USE LIMITS LIGHTS BULBS HEADLIGHT 12V 35 35W TAIL STOP LIGHT 12V 5 21W WINKER LIGHTS FRONT 12V 10W X 2 ete REAR 12V 10W X2 JETER HIGH BEAM LAMP 12V 3W X1 SWITCHES OIL LEVEL INDICATOR LAMP 12V 3W X1 WINKER PILOTS 12V 3 0W FUSE 7A METER LIGHTS 12V 1 7W X2 LICENCE LAMP 12V 4W TYPE MF BATTE
61. METER SWITCHES WINKER LENS 16 6 REAR WINKER BULB REPLACEMENT Press the winker lens groove and open the winker lens using plain screwdriver Remove the bulb from the socket replace with new bulb Install in the reverse order of removal NOTE Pay attention not to damge the lens Do not apply excessive force when removing the lens TAILLIGHT BULB REPLACEMENT Loosen the 2 pan screws remove the tail light lens NOTE Pay attention not to damge the tail light lens when removing it Replace the tail stop light bulb with the new one METER REPLACEMENT Remove the speedometer cable from the meter Remove the speedometer coupler connected to the wire harness Loosen the flange bolts securing the speedometer stay LIGHTS METER SWITCHES Remove the speedometer assembly Install in the reverse order of removal METER BULB REPLACEMENT e Remove the front handle cover 3 6 Remove the bulb socket replace with new bulb NOTE Check the each switch for proper operation The wire and cable must be connected accurately HORN INSPECTION e Remove the front cover 3 5 e Remove the horn wiring and connect a fully charged 12V battery Check the sound quality for any abnormalities LICENCE LAMP Loosen 2 screws Remove the lamp cover e Replace the lamp 12V5W e Install in the reverse order of removal 16 7
62. MM RAMP PLATE KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION Measure the movable drive face inner diameter SERVICE LIMIT 20 6MM Check the drive face boss for wear or damage and replace as necessary Measure the O D of the drive face boss Replace the boss if the service limit is exceeded SERVICE LIMIT 19 97MM WEIGHT ROLLER MOVABLE DRIVE FACE ASSEMBLY INSTALLATION Install the weight roller on the movable drive face Install the ramp plate e Install the movable drive face boss NOTE Do not get the grease on the pulley face Remove any misplaced grease with a degreasing agent Install the movable face assembly on the crankshaft 7 7 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION DRIVEBELT DRIVE FACE INSTALLATION e Install the drive belt on the crank shaft e Install the drive face the crank shaft serration e Install the washer and install flange nut e Tighten the drive pulley nut to the specified torque TORQUE VALUE 5 5kgf m TOOL CLUTCH CENTER HOLDER NOTE Correctly match the drive pulley face and crank shaft serration when assembling If the universal holder cannot be used remove the cooling fan and hold the flywheel with the universal holder CLUTCH DRIVEN PULLEY DISASSEMBLY e Remove the LH side cover 7 2 e Remove the start pinion gear 7 8 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION Hold the clut
63. NANCE LID 3 3 INNER REARGRIP 3 3 FRONT UNDER COVER BODY COVER 3 3 SPEEDOMETER REAR FENDER 3 4 MUFFLER SERVICE INFORMATION NOTE This section describes external parts removal installation Do not apply unreasonable force when disassembling covers to prevent possible damage A muffler is hot Do not service it immediately after the engine is stopped 3 1 EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF FRAME COVERS TROUBLESHOOTING This chart shows arrows connected in the order of disassembling covers D LUGGAGE BOX 5 REAR FENDER 9 FRONT FENDER 2 BATTERY 6 FLOOR SIDECOVER INNER COVER MAINTENANCE LID r 3 REAR GRIP FLOOR PANEL 1 FRONT WHEEL 4 BODY COVER FRONT COVER 2 FRONT UNDER COVER NOTE Beware that the scooter does not fall down when you remove the front wheel 3 2 _ SPECIAL BOLTS TAPPING SCREW FLANGE BOLTS OIL TANK CAP 3 REAR GRIPS BODY COVER CENTER COVER EXTERNAL PARTS LUGGAGE BOX Open the seat and remove the oil tank cap Loosen 4 flange bolts Remove anti theft switch coupler NOTE Luggage box can be removed with the seat Install the oil tank cap and the fuel tank cap Remove the luggage box e Install in the reverse order of removal NOTE t
64. Piston Outer Diameter Inspection Measure and record the piston O D 90 C to the piston pin bore and at the point specified in the Model Spectific manual near the bottom of the piston skirt e Replace the piston if the service limit is exceeded SERVICE LIMIT 39 90 mm Measure clearance between the piston O D and the cylinder I D SERVICE LIMIT 0 13 mm e Install the needle bearing and piston pin in the connecting rod small end and check for excessive play Piston Pin Inspection Measure the piston pin O D at three points e Replace the piston pin if the service limit is exceeded SERVICE LIMIT 11 98 mm 8 5 CYLINDER HEAD CYLINDER PISTON CYLINDER GAUGE TOP RING SECOND RING PISTON RING MARK STOPPER PIN PISTON RING 8 6 Piston Pin Bore Inspection Measure the piston pin bore I D in an X and axis Take the maximum reading to determine the 1 0 e Replace the piston if I D is over the service limit SERVICE LIMIT 12 03 mm PISTON PISTON RING INSTALLATION Clean the piston ring grooves Lubricate the piston rings and ring grooves with clean 2 stroke oil Install the piston rings on the piston with the marks facing up NOTE Do not confuse the top and second rings Be sure to install them in the proper grooves Some 2 stroke engines use an expander ring behind the second ring e 2 stroke engines the piston has stopper pins that ho
65. REMOVAL INSTALLATION e Remove the luggage box 43 3 2 Remove plug maintenance cover Remove the spark plug cap Loosen the ignition coil Disconnect the ignition coil wire Remove the ignition coil Install in the reverse order of removal CAUTION Arrange the cords in the right place INSPECTION RESISTANCE MEASUREMENT e Remove the luggage box 23 3 Measure primary coil resistance between the green and black yellow terminals STANSARD VALUE 0 1 0 5 20C gt CAP IGNITION SYSTEM Measure the secondary coil resistance between the plug cap and green wire termimals RESISTANCE VALUE SPARK PLUG CAP CONNECTION 6 5 9 5 20 C e The coil which the resistance value indicate oo disconnection remove the plugcap and measure the resistance of secondary coil Measure the resistance between the high tension code and green code terminals RESISTANCE VALUE 2 6 1 25 20 EXCITE COIL INSPECTION NOTE Assemble the spark plug to the cylinder head inspect in a state having compression pressure e Remove the luggage box 3 3 e Remove the connection of the AC generator wire connector black red measure the resistance between the terminal of AC generator and body earth STANDARD VALUE 500 20 20 PULSE GENERATOR INSPECTION NOTE The inspection of pulse gener
66. RQUE 1 3 kgf m Start the engine and check for leak FUEL SYSTEM pp FUEL TANK LAM 2 FUEL AUTO COCK FUEL STRAINER FUEL TUBE CARBURETOR 5 0 5 FUEL SYSTEM SERVICE INFORMATION 5 1 CARBURETOR CLEANNING 5 6 TROUBLESHOOTING 5 2 CARBURETOR INSPECTION 5 6 FUEL TANK gt 5 3 THROTTLE VALVE IDLING ADJUSTMENT 5 3 REMOVAL INSTALLATION 5 7 AIR CLEANER DISASSEMBLE 5 4 FUEL AUTOCOCK CARBURETOR REMOVAL REMOVAL INSPECTION 5 8 INSTALLATION 5 4 INLET PIPE REED VALVE FLOOT CAMBER FLOOT JET REMOVAL INSTALLATION 5 9 REMOVAL INSTALLATION 5 5 REED VALVE INSPECTION 5 9 SERVICE INFORMATION GENERAL SAFETY WARNING e Gasoline is extremely flammable Avoid fire in the work place also paying particular attention to sparks Furthermore the evaporated gasified gasoline 1s highly explosive Work in a well ventilated areas Exhaust gas contains poisonous substance Do not keep engine running for a long period of time in a closed or poorl ventilated area CAUTION Do not excessively bend or twist cable Distorted or damaged cable may lead to mechanical malfunctions Pay particular attention to the position of O ring Replace with new ones when disassembled it is desired to store a vehicle for a period longer than month drain gasoline out of the carburetor float chamber
67. RY CAPACITY 12V 3AH BATTERY TERMINAL VOLTAGE QO 13 0 13 2 CHARGING CURRENT STANDARD 0 4A 5h CHARGING CURRENT RAPID 4A 0 5h ENGINE TWIST PART NUMBER SCREW DIAMETER mm TWIST TORQUE REFERENCE FLY WHEEL NUT 1 10 4 0kgf m DRIVE FACE NUT 1 10 4 0kgf m CYLINDER HEAD BOLT 4 6 1 0kgf m SPARK PLUG 1 14 1 4kgf m DRIVEN FACE NUT 1 28 5 5kgf m CLUTCH OUTER NUT 1 10 4 0kgf m OIL LEVEL CHECK BOLT 1 8 1 3kgf m EXHAUST PIPE JOINT NUT 2 6 1 2kgf m MUFFLER BRACKET BOLT 2 8 3 3kgf m CRANK CASE BOLT 6 6 1 0kgf m SERVICE INFORMATION FRAME PARTS TWIST PART NUMBER SCREW DIAMETER TWIST TORQUE REFERENCE STEERING STEM LOCK NUT 1 7 0kgf m HANDLE POST TWIST NUT 1 10 5 0kgf m FRONT BRAKE LEVER PIVOT BOLT 1 6 1 0kgf m FRONT BRAKE LEVER PIVOT NUT 1 6 1 0kgf m REAR BRAKE LEVER PIVOT SCREW 1 5 0 3kgf m REAR BRAKE LEVER PIVOT NUT 1 5 O Akgf m MASTER CYLINDER HOLDER BOLT 2 6 1 2kgf m MASTER CYLINDER COVER SCREW 2 4 0 2kgf m BRAKE HOSE BOLT 2 10 3 5kgf m CALIPER MOUNT BOLT 2 8 2 7kgf m CALIPER BREATHER VALVE 1 8 0 6kgf m CALIPER PAD PIN 2 10 1 8kgf m CALIPER SLIDE PIN BOLT 1 2 3kgf m BRAKE SWITCH SCREW 1 4 0 12kgf m STEERING STEM BOLT FRONT FORK SIDE 4 10 3 5 4 5kgf m FRONT AXLE NUT 1 12 6 0kgf m REAR AXLE NUT 1 14 11 0kgf m SPEEDOMETER CABLE SETTING SCREW 1 0 2kgf m REAR BRAKE ARM BOLT 1 0 6kgf m FRONT BRAKE DISK BOLT 3 8 3 9kgf m REAR CUSHION UPPER BOLT 1 10 4 0kgf m REAR CUSHION LOWER BOLT 1 10 4 0kgf m ENGINE HANGER BRAC
68. STARTER 8 SETFLATE AIR SCREW THROTTLE STOP SCREW M P FLOAT PIN KON FLOAT FLOAT CHAMBER FLOAT CHAMBER SCREWS FUEL SYSTEM Remove the air cleaner Remove the wiring coupler of the auto bystarter Remove the oil pass tube Remove the throttle valve set Remove 2 flange bolts securing the inlet pipe Remove the carburetor insulator Remove the carburetor e Install in the reverse order of removal NOTE Install the carburetor after aligning the throttle valve cutaway and the throttle stop screw Tighten top set correctly so that it is not released CARBURETOR DISASSEMBLY ASSEMBLY Remove the auto bystarter cover Loosen the 2 washer screws e Remove the auto bystarter set plate e Remove the auto bystarter e Remove the auto bystarter O ring e assembly in the reverse order of disassembly NOTE Install the auto bystarter in the carburetor body after applying grease to the starter O ring and then tighten firmly with set plate piece FLOAT CHAMBER FLOAT JET DISASSEMBLY ASSEMBLY Loosen the 2 float chamber screws Remove the float chamber 5 5 FUEL SYSTEM INSPECTION Check the flot valve and seats for cracks or damage Check the flot valve operation Check the flot valve level FLOAT LEVEL 12 2 mm Remove the main jet needle jet holder an
69. TE ps 77 77 77 SERVICE LIMIT 15 5mm NOTE Use only a genuine DAELIM replacement drive belt Do not get oil or grease on the drive belt or pulley faces Clean off any grease or oil before reinstalling DRIVE BELT INSTALLATION e Turn the pulley clockwise and spread the faces apart while installing the drive belt NOTE Hold the pulley faces apart preventing them from closing e Install the pulley assembly once with the drive belt e Install the clutch outer e Temporarily install the driven pulley with special flange nut and tighten the nut to the specified torque TORQUE 4 Okgf m TOOL UNIVERSAL HOLDER 7 5 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION WEIGHT ROLLER MOVEABLE DRIVE FACE COMP RAMP PLATE WEIGHT ROLLER 7 6 MOVABLE DRIVE FACE REMOVAL e Remove the LH side cover 7 2 Remove the start pinion gear Hold the drive face using the clutch center holder and remove the nut and washer TOOL CLUTCH CENTER HOLDER MOVABLE DRIVE FACE DISASSEMBLY Remove the dirve face boss Remove the movable drive face MOVABLE DRIVE FACE INSPECTION The weight rollers push on the movable drive pulley face by centrifugal force worn or damaged weight rollers will interfere with this force Check the rollers for wear or damage and replace as necessary Measure the O D of each roller replace if the service limit is exceeded SERVICE LIMIT 15 4
70. TEERING Remove the oil seal OIL SEAL NOTE Take precautions not to damage the interior and exterior rim of the bottom case Remove the fork pipe from the bottom case A 4 BOTTOM CASE Remove the seat pipe the piston and rebound spring BOTTOM CASE REBOUND SPRING from the fork pipe N FRONT CUSHION SPRING SFAT PIPE FORK BOLT FRONT FORK INSPECTION Place the fork spring on a level palce and measure the free length FORK SPRING If the free length deviates from the service limit replace the spring with a new one Check components for damage or abnormal wear Replace defective parts with new ones SERVICE LIMIT 231 9mm FREE LENGTH 10 16 FRONT WHEEL FRONT FORK STEERING FORK PIPE Place the fork tube on a V block and measure deflection with a dial gauge SERVICE LIMIT Replace if the deflection is greater than 0 2mm 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 pipe Assemble the fork pipe to the bottom case Wrap the bottom case with a piece of cloth and fix it to the vise Apply screw locking agent to the socket bolt thread and assemble the socket bolt to the fork piston TORQUE VALUE 2 0kgf m NOTE When a vise is used to ho
71. TION 11 Maintenance needed to use the specialized tools must 12 Never reuse the ball bearing removed with the ball performed with the right tool applied pressure when removing press fitted the bearing 13 Check the smooth rotation of inner or outer race of the 14 Pay attention to installation direction in case of the ball bearing by rotating it manually single sided sealed ball bearing Install the open Replace the ball bearing having excessive axial direction or double sided sealed bearing in the way longitudinal hanging that the face marked with manufacturer and size e Wipe the ball bearing likely to have hanging with should direct to the outer axle oil except double sided sealed type ball SINGLE SEALED DOUBLE SEALED Replace the ball bearing of which press fitted part is slacked at the case or shaft 4 MANUFACTURER S NAME BEARING 15 When blowing the ball bearing with compressed air 16 Install the snap ring so that chamfered side directs to after cleaning keep the race from rotating High speed the load applied side After installation check the rotation of the race may damage the bearing Prior to proper installation by rotating the snap ring installation apply oil or grease to the bearing SNAP RING 17 Check each part for proper tightening and operation 18 The brake fluid and coolant can damage the painted after installation plastic or rubber parts Ke
72. TION PART MOVEABLE DRIVEN FACE DRIVEN FACE OPERATION PART Capacity 0 09 Capacity 5 0 5 6g SAE 80W 90 Multi Purpose Grease OIL PUMP DRIVE GEAR Molybdenum Grease FRAME PARTS APPLICATION AREAS CAUTIONARY SUGGESTIONS OIL TYPE FRONT WHEEL DUST SEAL EDGES FRONT PIVOT ARM BUSH FRICTION FACE FRONT PIVOT ARM SEAL EDGES REAR BRAKE CAM AXLE PART CAM PART WHOLE AREA OF REAR BRAKE CAM DUST SEAL REAR BRAKE ANCHOR PIN AXLE PART FRONT BRAKE OIL SEAL EDGES FRONT BRAKE CAM AXLE PART CAM PART WHOLE AREA OF FRONT BRAKE CAM DUST SEAL SPEEDOMETER GEAR PINION INSIDE DIAMETER PART AXLE PART GEAR TEETH PART BALL RACE BEARING REVOLUTION PART Multi Purpose Grease HANDLE GRIP INSIDE AXLE PART Adhesives ROYAL BOND 1300 SERVICE INFORMATION SYMBOLS ABBREVIATIONS The following symbols are used this manual to represent job related warnings or cautions SYMBOL MEANING SYMBOL MEANING WARNING Indicates dangerous area Serious CAUTION accident may result if instructions are not followed Indicates important work Minor injury or vehicle part damage may result if instruction are not followed Indicates general safety matters Provides safety and appropriate handling procedures The following symbols indicate needed lubrication steps the changing of parts and required specialized tools etc when performing maintenance CAUTION Use re
73. TON 8 2 SERVICE INFORMATION GENERAL SAFETY e Take precautions not to damage the joint part with a driver when removing the cylinder or not to damage the cooling pin by striking the cylinder too hard e Take precautions not to damage the inside of the cylinder or the exterior part of the piston Check parts after disassembling and clean and dry with an air hose prior to taking measurements ITEM STANDARD VALUE SERVICE LIMIT Inner diameter 40 005 40 010mm 40 05mm CYLINDER Cylindricality 0 10mm Out of roundness 0 10mm PISTON Piston skirt outer diameter 39 955 39 970mm PISTON PIN Piston pin hole inner diameter 12 002 12 008mm PISTON RING Piston pin outer diameter 11 994 12 000mm CYLINDER TO PISTON CLEARANCE 0 040 0 055mm TROUBLESHOOTING Comperssion low Worn cylinder or piston rings e Leaking valve seats Excessive smoke Worn cylinder or piston e Improper installation of piston rings Scored or scratched piston or cylinder wall Overheating Excessive carbon build up on the piston combustion Incorrect spark plug Knocking or abnormal noise Worn piston and cylinder Excessive carbon build up Low octane fuel 8 1 CYLINDER HEAD CYLINDER PISTON SPARK PLUG FAN COVER SHROUD REMOVAL Remove the plug Remove the 2 flange bolts of fan cover comp Remove the fan cover Loosen the 2 fan cover flange bolts Loosen the 2 flange b
74. YX GY 1 hil H ET VA T SIE NN eee N LLENE Fey DNO ZT CDI UNIT zi BATTERYOCORD WIRE HARNESS THROTTLE CABLE RR BRAKE CABLE RED WHITE RED FUSE MAN S W RED Q QO REAR STOP S W GREEN YELLOW GREEN STARTER RELAY FRONT STOP S W 15 0 STARTING SYSTEM 15 STARTING SYSTEM SERVICE INFORMATION 15 1 STARTER RELAY INSPECTION 15 6 TROUBLE SHOOTING gt gt gt 15 2 STARTER PINION GEAR INSPECTION gt 15 6 STARTER MOTOR gt 15 3 SERVICE INFORMATION GENERAL SAFETY WARNING When performing maintenance on the starter motor and related parts turn the main switch to OFE There is the danger of the starter motor unexpectedly operating if the main switch is not turned to OFE First check connection with battery and battery charge level before begining maintenance on the starter motor It is possible for the starter motor coil to become dmged if the starter is operted when the engine does not turn over 15 1 STARTING SYSTEM TROUBLE SHOOTING Starter motor does not rotate No response from starter motor Check to see if the fuse is burned out Check to turn on the lamp of stop switch Remove the starter moter wire connect PD eS te UENO err in to the battery terminal and check to see the brake lever In this state push the starter CLICKS M
75. alve Check the fluid level often and add fluid if the fluid level is near the lower level e If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Assemble the bleeder valve TORQUE 0 6kgf Add brake fluid up to upper level Install diaphragm and mater cylinder cap TORQUE VALUE 1 0kgf m BRAKE PAD REPLACEMENT Loosen the 2 front brake caliper fixing bolts from the front fork e Remove the front caliper Loosen the hanger pin HANGER RIN BRAKE SYSTEM To install a new brake pad into the brake press the piston to return to the original position Remove the hanger pin pad spring and brake pad Verify that the pad spring is installed in specific position NOTE When replacing brake pads replace whole set Do not remove the brake hose when replacong brake pads Install a new brake pad pad spring and hanger pin Install the brake caliper into the left front fork NOTE Be careful not to damage the brake pad 12 5 BRAKE SYSTEM 12 6 FRONT DISK Tighten the caliper braket bolt TORQUE 2 7kgf m BRAKE DISK INSPECTION Measure the thickness of the disk SERVICE LIMIT 3 0mm NOTE Measure the brake disk thickness at the several points and replace if the smallest measurement 15 less than the specified service limit Check the brake disk for bent and twist
76. an 4 cycle engine because the engine oil is burnt in the 2 cycle engine Excessive carbon deposit may cause self ignition by the zoverheating of the carbon in the combustion chamber and the piston head and may damage the engine Carbon deposit in the exhaust gas port disturbs exhaust gas flow and causes decrease of the output Remove the carbon deposit periodically CYLINDER HEAD CAUTION Pay attention not to damage the combustion chamber the piston and the cylinder when removing the carbon Remove the cylinder head and remove the carbon with the piston being in the top dead center Dismount the cylinder remove the carbon deposited in the exhaust gas port and clean the remaining carbon in the cylinder EXHAUST GAS PORT CYLINDER Cylinder Wear Inspection e Inspect the cylinder wall for scratches and wear e Inspect the area near T D C Center carefully This area is especially subject to wear due to the possibility of borderline lubrication from heat and top ring compression 8 4 HIGH MIDDLE MICRO METER CYLINDER HEAD CYLINDER PISTON Measure and record the cylinder at the three levels in both an X and Y axis e Take the maximum reading to determine the cylinder wear NOTE Avoid the intake and exhaust ports when measuring SERVICE LIMIT 40 05 mm e Calculate the piston to cylinder cleearance Take the maximum reading to detemine the clearance
77. ator is pergormed on a state assembling to the engine e Remove the luggage box 53 3 e Remove the connection of the AC generator 6P coupler and mesure the resistance between the blue yellow of starter and green code STANDARD VALUE 100 20 20 14 5 IGNITION SYSTEM IGNITION TIMING INSPECTION As a CDI device is used in this vehicle there is no need for adjusting ignition timing If ignition timing problems occur inspect the CDI unit and the AC generator and replace if any malfunctions are found in the devices Ignition timing inspection well read the instruction manual of timing light or revolution indicator and handle it exactly Warm up the engone Remove the fan cover Connect timing light to the high tension cord When engine rpms are at 1 800 ignition timing 15 correct if the F mark and crank case index mark are aligned IGNITION TIMING 17 DEGREES 2BTDC 1 800 RPMS NOTE Index mark must face the spark plug CDI UNIT REMOVAL INSTALLATION Remove the maintenance lid e Remove the luggage box 3 3 e Disconnect the coupler from the CDI unit and remove CDI unit Install in the reverse order of removal CIRCUIT INSPECTION e Remove the coupler from the CDI unit and check the ignition system circuits from the wiring coupler side INSPECTION ITEM CHECK POINT STANDARD VALUE PULSE BLUE YELLOW AND GENERATOR GREEN 30 200 000
78. attery acid Make sure to charge battery after the adding of battery water in the following instances When open voltage voltage between terminals does not reach 12 4V after the adding of battery water charge until open voltage reaches at least 12 8 When battery acid temperature is under OC charge normally for 2 3 hours See the part location drawing for the location of charging system parts 13 0 e Follow the trouble shooting for charging equipment inspection 13 2 e The charging equipment may ofter appear to be malfunctioning if the couplers or connectors are incorrectly attached Make sure to check these connection before starting maintenance work on the charging equipment 13 1 BATTERY CHARGING SYSTEM TROUBLE SHOOTING Barrery is Overcharged Headlight bulb is out No headlight beam wire Headlight register is damaged disconnected e Lighting switch is connected incorrectly Regulator retifier is not grounded connected incorrectly Problems with the Charging System ee NNLLA gt Inspect the body of the register rectifier NORMAL NORMAL Short circuited harness ABNORMAL Damaged main switch Register rectifier is switch EN 14V BEEN 14 15 gt Battery is damaged Check the voltage of the register rectifier ABNORMAL Wire
79. ay slip even after the rim and tire are installed Only use the water e If the tire has an light mark yellow paint mark install the tire with this mark aligned with the valve e If the tire has an arrow mark install the tire with the mark pointing in the direction of rotation e Stand the tire upright hold it with one hand and starting from the opposite side to the valve install one side of the tire on the rim as much as you can by hand sure to assemble in the sequence shown e Place the wheel on the level surface and install the remaining portion of the tire using two tire levers 10 11 FRONT WHEEL FRONT FORK STEERING 10 12 PROTECTOR TIRE LEVER VALVE CORE e Install the other side of the bead while holding the assembled portion of the bead with your knee to prevent it from coming off After 1 2 of the bead has been installed insert the two tire levers at a distance of 30 40mm to install it Repeat this procedure until 3 4 of the bead has been installed NOTE Hold one tire lever upright to remove the other lever Check out whether the bead is in the center of the rim when 3 4 of the bead has been installed NOTE The last portion of the bead is more difficult to install The rim and bead may be damaged if the bead on the opposite side of the point where you are working is not in the rim center When the remaining bead is only 50 60mm pull the
80. ch outer using the universal holder and remove the flange nut then remove the clutch outer Remove the drive belt Remove the driven pulley Install in the reverse order of removal cuurcusprnecove DRIVEN PULLY SUB ASS Y DISASSEMBLY The clutch driven face are assembled toward the clutch spring compressor CAUTION Make sure that the boss portions of the clutch driven face are matched with the clutch spring compressor hole TOOL CLUTCH SPRING COMPRESSOR SPRING COLLAR SPECIAL NUT Fix the clutch spring compressor with a vice etc Disassemble the 28mm special nut with a socket wrench Disassemble the clutch driven face form the clutch spring compressor TOOL CLUTCH SPRING COMPRESSOR SOCKET WRENCH 39 x41mm DRIVENFACE SPRING DRIVE FRATE Remove the seal collar from the driven pulley Remove the guide pins and guide pin rollers and the MOVEABLE DRIVE FACE movable driven pulley face SEAL COLLAR DRIVE FACE COMP 7 9 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION 7 10 VERNIER CALIPER GUIDE PIN NOTE Some guide pin can be separated to the roller and the pin Remove the O ring and oil seals from the movable driven face INSPECTION Clutch outer Measure the I D at shoe contact surface of the clutch outer Replace the outer if the service limit is exceeded SERVICE LIMIT 107 5mm Clutch Shoe Inspection Measure the thickness of each
81. commended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease with the ratio 1 1 SYMBOL Use multi purpose grease Lithium based multi purpose grease NLG 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Apply a locking agent Use the agent of the middle strength unless otherwise specified Apply sealant Replace the parts with new ones before assembly Use brake fluid DOT3 or DOT4 Use the recommended brake fluid unless otherwise specified Use Fork or Suspension Fluid Use special tool Use option tool These tools are obtained as you order parts Indicates reference page Example Refer to page 3 1 Special grease etc that do not correspond to the above are indicated without using symbols 1 10 SERVICE INFORMATION TOES ANTI THEFT SWITCH UNIT pee pu NS o TL Im RO FUEL VENT TUBE SEAT LOCK CABLE FUEL UNIT COUPLER OIL LEVEL SWITCH CORD PETC R L RR WINKER COUPLER lt 21 0 Mel HE L J DENNI gt LOCK SWITCH RESISTER COMP IGNITION COIL RECTIFIER dec NS ii Ji Co Cm JA ZMN 7 gt
82. d needle jet and remove the slow jet Remove the air screw spring washer O ring Remove the throttle stop screw spring O ring CARBURETOR CLEANING After removing all parts blow open air and fuel passage in the carburetor body with compressed air CAUTION Cleaning the air and fuel passage with a piece of wire will damage the carburetor body or fuel pump e Install in the reverse order of disassembly CAUTION Tightening air screw against its seat will damage the seat NOTE NEEDLE JET HOLDER Be sure to install the needle jet with the smaller hole toward the float chamberr WASHER Install the air screw and its O ring and washer in the order as shown in the drawing If the air screw and carburetor body are replaced with the new ones N MAIN JET adjustment is necessary AIRSCREW SLOW JET CARBURETOR INSPECTION Connect an ohmmeter to the auto bystarter wire connector terminals and measure the resistance If the resistance is greatly out of specification it indicates a faulty PTC in the auto bystarter Replace the auto bystarter NOTE The auto bystarter might be normal if the resistance is only slightly out of specification However be sure to check all related parts for trouble Refer to the Model specific manual for specified resistance AC GENERATOR SPRING h NEEDLE JET NEEDLE CLIP FUEL SYSTEM e Remove the
83. e retainer plate instead of three washers Check the shoe springs for damage or loss of tension Check the damper rubbers and shoe springs for damage or deformation replace as necessary KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION PIVOT PINS DAMPER RUBBER OIL SEAL GUIDE PIN 7 12 Apply a small amout of grease on the pivot pins Install new clutch shoes on the pivot pins and push them into place Use a small amount of grease on the pivot pin and keep grease off of the brake shoes Replace the brake shoes if there is any grease on them CAUTION Grease or oil damages chutch shoes and can lead to a loss of engaging ability Use pliers to hook the springs to the shoes e Install the E clip and washers or retainer plate into the pivot pins NOTE Apply only to the belt type gearless transmission Wipe the grease came out from the pivot pin thoroughly CLUTCH DRIVEN PULLEY ASSEMBLY Install new oil seals and O rings on the movable driven pulley face Lubricate the inside of the movable face with the specified amount of grease GREASE APPLICATION 5 0 5 5g Install the movable face on the driven pulley face e Install the guide pins or guide pins and guide pin rollers KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION Install the seal collar SEAL COLLAR Assemble the driven pulley spring and clutch in the clutch spring compressor Compr
84. emove the crankshaft from the RH crankcase TOOL CRANKCASE PULLER 0751 00003 RH CRANK CASE Secure a crankcase puller on the LH crankcase Remove the crankshaft from the LH crankcase TOOL CRANKCASE PULLER 0751 00003 NOTE Be careful not to distort the mating surface of the crank case during disassembly Do not force to disassemble by pounding on the crankshaft CRANKSHAFT BEARING REMOVAL e If the radial ball bearing is left on the crankshaft remove the bearings out of the crankshaft using a bearing puller TOOL UNIVERSAL BEARING PULLER 0755 00001 9 5 TRANSMISSION CRANKSHAF T CRANKCASE ie Ex FEELER GAUGE a DIAL GAUGE BEARING RH CRANK CASE 9 6 CRANKSHAFT INSPECTION Place the crankshaft on a stand or V block and check the journal vibration SERVICE LIMIT RIGHT SIDE 0 1mm LEFT SIDE 0 15mm Measure the side gap between the connecting rod big end and the crank weight SERVICE LIMIT 0 6mm Check the vertical shaft play of the connecting rod big end from the X and Y direction SERVICE LIMIT 0 05mm CRANKCASE BEARING REMOVAL e Remove the RH LH transmission INSPECTION e Manually turn the bearing inner race to see if it rotates smothly Check the outer race to see if it is accurately pressed into the case e If the outer race is excessively loose or 15 loosely pressed into the case remove in and replace with a
85. emporarily to prevent the foreign material from entering after removing the luggage box BATTERY MAINTENANCE LID Loosen 1 special screw and remove maintenance cover REAR GRIPS Loosen 4 special bolts and remove the rear grip Install in the reverse order of removal BODY COVER Remove the center cover with the body cover Remove the luggage box 3 3 Remove the maintenance lid Remove the rear grips EXTERNAL PARTS Loosen 4 tapping screw on the center cover and floor panel Remove 4 the body cover clips RH LH FLOOR SIDE COVER COUTION f removal is difficult recheck each connection and try removing again Loosen 4 socket bolts on the fuel neck cap and remove the fuel neck cap Remove the tail light coupler of winker Remove the body cover Install in the reverse order of removal REAR FENDER Luggage box Rear grips Body cover Loosen 2 washer bolts on the frame body Remove the secondary in the groove of the rear fender airfilter tube Remove the rear fender e Install in the reverse order of removal WASHER SCREWS FLOOR SIDE COVER Loosen 2 washer screw located in the side of the RH LH floor side cover Remove the floor side cover Install in the reverse order of removal FLOOR SIDE COVER EXTERNAL PARTS FLOOR PANEL Remove the plug maintenance cover Remove the center cover Loos
86. en pairs of commutator bars Make a continuity check between individual commutator bars and the armature shaft There should be no continuity Check the bearings Do not rotate smoothly Replace with a new one Damage oil seal Replace with a new one STARTER MOTOR ASSEMBLY Carefully insert the armature shaft into the front bracket e Align the front bracket notch with the brush CAUTION The sliding surfaces of the brushes can be damaged if they are not installed properly STARTING SYSTEM Insert the brush spring into the brush holder and install the front bracket NOTE Insert the brush spring with care so that it does not lean in the holder Apply grease to both ends of the armature shaft APPLY GREASE e Install the starter motor cover NOTE The coil my be damaged if the maganet pulls the armature against the case STARTER MOTOR COVER Align the front bracket with the cover e Tighten the washer screw WASHER SCREW 15 5 STARTING SYSTEM DRIVE FACE RETURN SPRING OUTER 15 6 eee STARTER RELAY INSPECTION Remove the maintenance lid When battery voltage is applied between the starter relay green yellow wire and yellow red terminals there should be continuity between the red and red white terminals The terminals are distinguished by the corresponding wire color of wire harness connector STARTER PINION
87. en the tapping screw securing the battery cover to remove the battery cover Disconnect the battery wire to remove the battery loosen 1 washer bolt Remove the CDI winker relay coupler fuse Loosen the 4 washer bolts securing the floor panel Remove the floor panel from the connecting groove of the inner box by lifting the rear part of the panel slightly Draw the floor panel moving it to the right and left to remove it Install in the reverse order of removal FRONT COVER Loosen 2 special screws R L in the inner cover Loosen a special screw in the front of the front cover e Draw the upper part of the front cover to remove it e Disconnect the head light wiring and remove the front COVer e Install in the reverse order of removal COUTION e Check for proper alignment of the connection hook before performing installation EXTERNAL PARTS FRONT FENDER FRONT FENDER A FRONT FENDER Loosen the special screw R L securing the front fork Loosen 2 tapping screws securing the front fender B e Remove the front fender B from the front fender A e Remove the front fender A e Install in the reverse order of removal INNER COVER e Remove the luggage box e Remove the body cover e Remove the floor side cover e Remove the floor panel e Remove the front cover Loosen the 4 tapping screws R L securing the inner COVer Loosen the 1 set screw securi
88. ep these parts from contacting with them and wash these parts with water in case of contact SERVICE INFORMATION 19 Install the oil seal so that the manufacturer marked 20 Connect the tube until the tube fully inserted in the surface directs outer surface direction not covered joint Install the clip if it is supplied Replace the tube with oil having slacked end Pay attention not to bend or damage the lip Apply the grease to the lip CAVITY MANUFACTURER S NAME CLIP FITTING 77 A A 21 Keep the pneumatic system interior or the engine 22 Install the gasket mounted in the contact surface of interior from the infiltration of dust each case of the engine while removing gasket material completely Remove damaged contact surface by wiping with the oil stone equally 23 Pay attention not to bend the cable excessively 24 Install the boots with the installing groove by inserting Transformed or damaged cable may cause malfunction the boots into the groove or damage CAUTION WHEN WIRING 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 WHITE COUPLER WHITE TUBE BLACK TUBE WHITE STRIPE BLACK CORD WHIT
89. ess the assembly by turning the tool handle until the lock nut can be installed Clamp the clutch spring compressor in a vise and tighten the lock nut to the specified torque using the lock nut wrench TORQUE VALUE 4 0kgf Install the spring compressor Install the clutch driven pulley and drive belt onto the drive shaft TOOL CLUTCH SPRING COMPRESSOR SOKET WRENCH 39mm Install the drive belt on the driven pully subass y mount on to the drive shaft Install the drive belt on the assemblying area of the movable drive face Rotate the driven pully ass y to the right side and enlarge the belt groove 7 13 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION 7 14 After assemblying the clutch outer install the flange nut temperarily Fix the clutch outer with the universal holder tighten the flangenut with standard torque STANDARD TORQUE 4 0kgf m Install the 2 dowel pins and gasket Install the LH crank case cover and tighten the bolts CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD BOLT CYLINDER HEAD CYLINDER TOP RING SECOND RING gt CYLINDER GASKET STOPPER PIN PISTON PIN CLIP NEEDLE BEARING 8 0 8 CYLINDER HEAD CYLINDER PISTON SERVICES INFORMATION 6 1 TROUBLESHOOTING 8 1 FAN COVER SHROUD REMOVAL 82 CYLINDER HEAD CYLINDER PIS
90. evices can often appear to be malfuctioning when the couplers or connectors are disconnected Check these connections before working on Use recommended spark plug Using incorrect spark plug may make the engine run bodly or damage the engine e This manual gives explanations on inspections to receive peak voltage As inspections for coil resistance values are also included it may be difficult to make a correct determination Conduct inspection on the main switch by referring to the wiring diagram continuity chart chapter 16 14 1 IGNITION SYSTEM TROUBLE SHOOTING Spark plug does not emit sparks UNUSUAL CONDITION POSSIBLE CAUSES START FROM 1 AND GO THROUGH LIST IN ORDER ASIVIAT Id TOO NOLLINDI Maximum voltage is low No or almost no peak voltage 1 Using a tester with a low internal resistance 2 Cranking speed is low Battery is low or kick power is weak 3 Influence of tester sampling time normal state if measured a number of times and show over the set voltage 4 Problem in ignition system wiring disconnected damaged 5 Ignition coil is damaged 6 Excite coil is damaged when no problem peak voltage 7 CDI unit is damaged when no problems in 1 6 and spark plug does not emit sparks 1 Adaptor is connected incorrectly 2 Main switch damaged 3 CDI unit coupler is connected incorrectly 4 CDI unit ground wire disconnection 5 Damage to excite coil measure
91. ficient power and high fuel consumption Air cleaner is blocked e Ignition system is damaged Mixture 15 too rich Air Fuel mixture is extremely lean e Fuel jet 1s blocked e Float valve is damaged Oil level is low Bad ventilation of air in tank cap Fuel strainer screen is blocked Fuel tube is bent creased or blocked Suction system is receiving secondary suction of air Air Fuel mixture is extremely rich Air jet is blocked e Float valve is damaged Oil level is too high Starter is damaged Air cleaner is blocked FUEL SYSTEM FUEL TANK REMOVAL WARNING Gasoline is extremely flammable Avoid fire during work and pay particular attention to electric sparks Furthermore the evaporated gasified gasoline is highly explosive Work in a well ventilated areas Remove the following parts Luggage box Plug maintenance lid Rear grips Body cover 3 4 Remove the fuel tube from the fuel strainer NOTE Use the tube clip or the cap to prevent the gasoline from leaking Remove the fuel unit wire coupler Loosen the 2 flange bolts and remove the seat catch Loosen the 2 flange bolts of the rear grip stay Remove the fuel tank INSTALLATION Install in the reverse order of removal NOTE e Check for gasoline leakage e Gasoline mark is on fuel tank cap e Check this mark when filing gasoline
92. ge bolt NOTE Take action to prevent oil from leaking Install the clip in the oil tube Take precautions not to damage the engine when removing the engine from the chasis ENGINE REMOVAL INSPECTION Remove the engine with the muffler and rear wheel attached Install in the reverse order of removal Check the following after the engine is assembled Electric systems Adjust of the rear brake free play Inspection of the throttle cable operation Inspection of the oil pump cable operation NOTE Take precautions not to damage wiring and cable Take precautions not to damage the threaded part of bolts Arrange the cable tubes and wiring in the right positions 6 3 KICKSTARTERCONTINUOUSLY VARIABLE TRANSMISSION SHOE SPRING GUIDE PIN MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE SPRING SO DRIVEN FACE DRIVE BELT 4 WEIGHT ROLLER DRIVE FACE BOSS RAMP PLATE MOVABLE DRIVE FACE KICK STARTER SPINDLE KICK STARTER RETURN SPRING 7 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION SERVICE INFORMATION DRIVE 7 4 SERVICE STANDARD MOVABLE DRIVE FACE 7 6 TROUBLESHOOTING gt DRIVEN PULLY 7 8 LH SIDE COVER REMOVAL CLUTCH DRIVEN PULLY ASSEMBLY 7 12 KICK STARTER SERVICE INFORMATION GENERAL SAFETY Do not allow oil to contact the drive belt
93. he recommended brake fluid MASTER CYLINDER INSPECTION Check the piston periphery for kink or scratch Check the primary and secondary cups for wear 12 9 BRAKE SYSTEM PISTON 3m CYLINDER GAUGE STOP SWITCH MASTER BODY CYLINDER SPRING MASTER PISTON PRIMARY CUP 12 10 Measure the O D of the master pin SERVICE LIMIT 10 90m m NOTE If there is any leak of fluid when installing new piston it may indicate the side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Check the master cylinder for scores scratches or nicks and replace if necessary Measure the moster cylinder LD in X and Y axis at serveral points SERVICE LIMIT 11 08mm MASTER CYLINDER ASSEMBLY INSTALLATION CAUTION Replace the piston spring cups and snap ring as a set Be sure that each part is free from dust or dirt before reassembly When cleaning with the brake fluid use the specified brake fluid 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 CAUTION When installing the cups do not allow the lips to turn inside out Refer to the drawing Note the installation direction of the snap ring certain that the snap ring is seated firmly in the groove e Install the rubber boo
94. heck tire pressure CAUSE OF TROUBLE 1 Streering head adjuster excessively tightened 2 Streering cone race or steel ball damaged 1 Excessive wheel bearing play 2 Rim bent 3 Axle nut loose 1 Front wheel and rear wheel not aligned 2 Front fork bent POOR FRONT REAR SUSPENSION PERFORMANCE 1 Suspension excessively soft gt 2 Suspension excessively hard gt 3 Noise from the suspension gt POOR BRAKE PERFORMANCE gt gt 1 If the arrow were mark the brake panel mark match with each other 2 Brake noise H 3 Poor braking TROUBLESHOOTING Check tire pressure CAUSE OF TROUBLE 1 Cushion spring weak 2 Over loaded 3 Damper oil leaks 1 Fork pipe or cushion rod bent 1 Slider stuck 2 Cushion stopper rubber damaged Check tire pressure CAUSE OF TROUBLE 1 Brake shoe worn 2 Brake cam worn 2 Shoe and cam contact surface worn 2 Brake drum worn 1 Brake shoe worn 2 Foreign matter in the brake lining 3 Brake drum worn 1 Brake wire defectiver or expanded 2 Only part of the brake shoe makes contact with the brake drum 2 Clay or moisture inside the brake drum 2 Brake lining contaminated by grease or oil 17 5 TROUBLESHOOTING FUEL GAUGE GAUGE READING INACCURATE IGNITION SWTICH ON 1 the turn signal to check the battery circuit Signal operates satisfacto
95. ic cord interferes with the handle If the handle moves satisfactorily adjust the steering head bearing BATTERY Remove the battery cover Check to see if the terminal has loosed If the terminal is loose check the contact clean then tighten Apply grease thinly after tightening If the terminal is corroded remove the battery pouring the hot water clean with wire brush Full charging voltage 13 0 13 2V Low charging voltage Less Than 12 3V NOTE Check the chaging condition using the voltmeter Pay attention not to transfotm the battery terminal Never remove the filler cap INSPECTIONS ADJUSTMENTS LUBRICATION POINTS Unless specifically designated use generd grease to lubricate the lubrication points For stiding parts not shown here add oil or grease CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable and apply oil If the cable has expanded replace it BRAKE HOSE M ES THROTTLE GRIP OR STEERING BEARING SPEEDOMETER GEAR BOX WHEEL BEARING SPEEDOMETER GEAR SIDE MAIN STAND PIVOT m T BEARING 2 11 3 EXTERNAL PARTS EXTERNAL PARTS SERVICE INFORMATION 3 1 FLOOR SIDE COVER MAINTENANCE PRECEDURE 3 2 FLOOR PANEL TROUBLE SHOOTING 3 2 FRONT COVER LUGGAGE BOX 3 3 FRONT FENDER BATTERY MAINTE
96. ing the battery remove the battery from the frame and do not open stopper There is the possibility of damaging the regulator rectifier etc if the terminal or coupler 1s separated connected when electricity is over flowing through the electrical devices Make sure to turn the main switch OFF when performing maintenance to the charging equipment e If the battery is allowed to repeatedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to note here that the battery will naturally last 2 3 years of normal use and although it will re charge its load is reduced leading to a loss in battery strength It is possible for the battery to become overcharged from battery body load If a battery cell becomes short circuited and if a state develops where voltage is not created between the terminals the regulator will not operate and excessive 12 voltage will develops where voltage is not created between the terminals the regulator will not operate and excessive voltage will develop in the battery and normal cell electrolytes will decrease the vehicle is not used for a long period make sure to chage the battery every three months If not so the battery ability to store electricity is reduced A new ME battery will not necessarily be ready for use in the vehicle with only the adding of b
97. ixing flange bolts Remove the grommet from the crankcase cover Remove the connector couler on the wire harness or starter motor Remmove the ground wires Remove the stator NOTE Insert the puller shaft and remove the flyweel after inserting the ACG rotor puller and securing it with spanner The flyweel may easily removed if you rotate the puller while topping the roller shaft with metal hammer Always use a holder and a puller to remove the flywheel Do not try to remove the flyweel by hammering directly on it The crankshaft or components could be damaged Remove the wooddruff key with care not to lose it BATTERY CHARGING SYSTEM STATOR FLYWHEEL STATOR INSTALLATION Note the direction of stator and install the stator on the crankcase Install the grommet to crankcase cover Install AC generator wire couler to wire harness Install the connector to starter motor then install the ground wire FLYWHEEL INSTALLATION Clean the tapered portion of the crankshaft If the flywheel is installed with dust or dirt on the taper the taper will not make secure contact with the flywheel and there will be excessive force on the woodruff key Insert the woodruff key into the key groove in the crankshaft Set the flyweel groove to the woodruff key and install the flyweel on the crankshaft CAUTION Before installing the flyweel chec
98. k that no nuts or bolts are magnetically attached to the flywheel Installing the flywheel with anything attached to it could damage the stator coil COOLING FAN Hold the flywheel rotor with a holder and tighten the bolt nut to the specified torque TORQUE 4 0kgf Install the colling fan e Install the fan cover 13 7 BATTERY CHARGING SYSTEM A C GENERATOR CHARGING COIL INSPECTION NOTE This test 15 done with the starter mounted to the engine Remove the luggage box Disconnect the AC generator coupler Measure the resistance of the charging coil between the white wire and ground and the lighting coil between the yellow wire and ground STANDARD RESISTANCE 20 BETWEEN WHITE WIRE AND GROUND 0 4 1 0 o BETWEEN YELLOW WIRE AND GROUND 0 2 0 8 o RESISTER INSPECTION e Remove the front cover 3 5 Measure the resistance between the register lead wire and ground STANDARD VALUE 20 C RESISTER 6 7 0 5W GREEN BLACK BODY GROUND 6 3 7 1 0 RESISTER 5 9 30W PINK BODY GROUND 5 6 6 5 0 NOTE Problems with the resister are caused by operational problem of the starter 13 8 lt A 2 ANTI THEFT SWITCH UNIT m nn FUEL VENT TUBE SEAT LOCK CABLE FUEL UNIT COUPLER OIL LEVEL SWITCH CORD TAIL STOP ALISE Ss 22 R L RR WINKER COUPL
99. l type so release it properly according to the shape Typical releasing method of the coupler is illustrated in the following xg uw _ im a a EN 8 Insert the lock of the coupler until the lock is fully secured Dx _ BER Release the lock by inserting the coupler slightly Pay attention not to damage the vinyl cover of the then narrowing connection to remove the coupler coupler Check to see if there is bended terminal and secure it to If the wire harness coating is damaged repair by avoid disconnecting winding vinyl tape or replace it Prior to connecting the connector make sure that the cover is not damaged and the mess terminal is not opened 1 20 Insert the connector until the vinyl cover is fully inserted into the terminal The opening of the vinyl cover must face at the ground direction but in case of the plain connector the draining opening must face at the sky direction DRAINING HOLE 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 SERVICE INFORMATION e When removing T start broaden the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked e When removing T start from the frame replace it with the new one M V
100. ld the bottom case do not insert the case itself but insert the bracket Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed TOOLS FORK SEAL DRIVER FORK SEAL DRIVER BODY Install the oil seal stopper ring Accurately assemble the oil seal stopper ring to the bottom case 10 17 FRONT WHEEL FRONT FORK STEERING pum Install the dust seal e Fill a prescribed amount of automatic transmission fluid AFT into fork pipe CAPACITY 58 Slowl the fork pipe 2 3 times to discharge air FORK OIL owly press the fork pipe im g y p FORK OIL Assemble the spring to the fork pipe NOTE Install the spring with the smaller pitch side facing downward Assemble the fork bolt to the fork pipe FRONT FORK INSTALLATION Install the front fork to the steering stem Install the front fork setting bolt Install the front fork cover TORQUE VALUE 4 0kgf m FORK COVER 10 18 FRONT WHEEL FRONT FORK STEERING Install the following parts Front wheel gt 10 5 Brake caliper gt 12 6 Front fender 3 6 Front cover 3 5 STEERING STEM REMOVAL Front cover 3 5 e Front fender 3 6 e Steering handle 10 3 e Front wheel gt 10 5 e Front brake caliper gt 12 6 e Front fork g
101. ld the piston rings away from te intake and exhaust ports e Align the piston ring end gaps with the stopper pins Check the fit of each ring in the groove by pressing the ring into the groove Make sure that it is flush with the piston at several points around the ring e If the ring rides on the stopper pin it is damaged during assembly Coat the needle bearing 2 stroke engine only piston pin with the recommended oil Lubricate the piston pin e Install the needle bearing into the connecting rod e Install the piston and insert the piston pin PISTON PIN CLIP PISTON PIN CLIP 49 CYLINDER HEAD CYLINDER PISTON NOTE The mark that is stamped on the piston head should be facing the correct direction MARK TO INTAKE SIDE MARK TO EXHAUST SIDE A MARK TO ONGOING SIDE MARK TO INTAKE SIDE Install the new piston pin clips CAUTION Take care not to drop the piston pin clip into the crankcase Make sure to set the piston pin clip in the groove properly Do not align the clip s end gap with the piston cutout CYLINDER CYLINDER HEAD INSTALLATION Apply the engine oil inside of cylinder piston ring and install them 8 7 TRANSMISSION CRANKSHAF T CRANKCASE 2 COUNT GEAR FINAL GEAR MISSION COVER DRIVE SHAFT 9 0 TRANSMISSION CRANKSHAFT CRANKCASE 9 TRANSMISSION CRANKSHAFT CRANKCASE
102. mbled place a tube clip or band on the oil tube to prevent oil from leaking out TROUBLE SHOOTING Overheating or engine clogging e Faulty adjustment of oil pump insufficient amount pumped e Bad quality of engine oil Engine oil not being injected or blocked bent strainer screen or oil tube Entering of air in oil tube system e Faulty oil pump Engine oil not being supplied from oil tank Blocked oil tank cap air hole Blocked oil strainer screen Excess exhaust smoke accumulation of carbon on spark plug e Faulty adjustment of oil pump over pumped amount e Bad quality of engine oil 4 1 LUBRICATION SYSTEM BOIL PUNPDISASSEMBLY ASSEMBLY E e Remove the luggage box ul Remove air cleaner OI 4 Remove 2 bolts of oil pump cable stay Remove oil tube on the side of oil pump Remove oil pass tube Remove setting plate of oil pump Remove oil pump Install in the reverse order of removal CAUTION When assembling disassembling the oil pump do not allow foreign substances from entering the engine and oil tube by cleaning around the oil pump If the air enters into the oil line it may cause faulty lubrication or engine sticking Always remove the qir in the oil line after maintenance Pay attention not to damage the O ring when assembling the oil pump OIL PUMP INSPECTION e Rotate the shaft and check for proper rotation
103. n assemblying the muffler and Ex pipe comp S A I PIPE e Remove 2 flange bolts securing the exhaust muffler ass y e Remove the upper flange bolt securing the muffler comp e Remove the hose clip and tube e Install in the reverse order of removal EXTERNAL PARTS AIR FILTER ASS Y SECONDARY HOSE CLIP tai N Remove the seat Remove the luggage box Remove the hose clip and tube e Install in the reverse order of removal 4 AIR FILTER ASS Y SECONDARY SCREW GASKET Kaos Pw FLANGE BOLT LUBRICATION SYSTEM OIL SYSTEM DRAWING OIL TANK OIL PUMP OIL PASS TUBE PUMP CONTROL CABLE 4 0 4 LUBRICATION SYSTEM SERVICE INFORMATION 4 1 OIL PUMP BLEEDING 4 3 TROUBLE SHOOTING 4 1 ENGINE OIL LEVEL INSPECTION 4 5 OIL PUMP DISASSEMBLY ASSEMBLY 4 2 OIL TANK DISASSEMBLY 4 6 OIL PUMP ADJUSTMENT 4 3 TRANSMISSION OIL INSPECTION 4 6 SERVICE INFORMATION CAUTION e Remove air from oil tube and oil pump if the oil tube is taken off or if air enters the oil tube e If the oil tube 15 disassembled remove the air in the oil pass tube e Maintenance on the oil pump is done without the engine being removed from the vehicle when disassembling the oil pump do not allow foreign substances from entering the engine or oil pump e Do not disassemble the oil pump assembly e If the oil tube 15 disasse
104. n front wheels front fork and steering system For information on th front brake system refer to section 10 Place a jack underneath the engine to support the 2 wheeled vehicle SPECIFICATIONS ITEM STANDARD VALUE SERVICE LIMIT a 2 0mm FRONT WHEEL RIM RUNOUT AXIAL FFRONT FORK TUBE DEFLECTION FRONT FORK OIL LEVEL FORK SPRING FREE LENGTH TORQUE VALUES STEERING STEM LOCK NUT 7 0kg m BRAKE DISK BOLT 3 9kef m FRONT AXLE NUT 6 0kgf m 10 1 FRONT WHEEL FRONT FORK STEERING TROUBLESHOOTING Hard steering Steering bearing adjustment nut too tight Faulty steering stem bearings Damaged steering stem bearings Insufficient tire pressure Steers to one side or does not track straight Unevenly adjusted right and left shock absorbers e Bent front forks e Bent front axle wheel installed incorrectly Front wheel wobbling e Bent rim Worn front wheel bearings e Faulty tire Axle nut not tightened properly Wheel out of balance Soft suspension Weak fork springs e Insufficient fluid in front forks Hard suspension Incorrect fluid weight in front forks Front fork air pressure incorrect e Bent fork tubes Clogged fluid passage e Clogged anti dive orifice Front suspension noise Worn slider or guide bushings e Insufficient fluid in forks Loose front fork fasteners Lack of grease in speedometer gear box
105. nd wire brush to clean the plug Always use a feeler gauge to check the gap THROTTLE GRIP FREE PLAY 2 6 mm e If the throttle grip doesn t move smoothly adjust the free play e Take off the rubber boots loosen the lock nut and turn the adjuster to control the free play e After adjusting tighten the lock nut check the operation of grip and then put on the rubber boots THROTTLE CABLE ADJUST NUT LOCK NUT AIR CLEANER Loosen 5 setting screw assembled to the air cleaner case cover and then remove air cleaner case cover Remove the air cleaner element Wash away any accumulated dust or dirt by gently Squeezing it in non flammable or high flash point solvent WARNING Using gasoline or low flash point solvents for cleaning parts may result in a fire or explosion CAUTION Cleaning the element with gasoline or any acid alkaline or organic volatile type oil may cause improper ignition deterioration of the element or V sa loosening of the element adhesive dd INSPECTIONS ADJUSTMENTS Be sure to allow the element to dry thoroughly before applying oil Otherwise the oil will be diluted by the and the filtering ability of the filter will be much less effective Spread clean 80 90 gear oil on the element rubbing inthoroughly over the surface with both hands and ES 9 DRY m 9 then squeeze out a
106. nect the battery terminals Measure the voltage between the battery terminals FULLY CHARGED 12 8 13 0V INSUFFICIENTLY CHARGED UNDER 12 3V NOTE Use a digital voltmeter when measuring charge level e Measure 30 minutes later TOOLS DIGITAL TESTER CHARGING SYSTEM INSPECTION LEAK TEST e Trun off the main switch and remove the earth cable from the battery Connect an ampere meter between the battery terminal and the earth cable and check current when the main switch is turned off CAUTION Use an ampere meter while sequentially changing its measuring range from large to small If the current level greater than the measuring limit is measured the ampere meter fuse may be cut Do not turn on the main switch while current is being measured LEAK CURRENT Not to exceed 1mA BATTERY ADJUSTMENT VOLTAGE CHECK Connect the voltmeter between the battery terminals Connect the amperemeter between the main fuse termanals Start the engine and measure the charging voltage and ampere while incresae the rpm gradually CONTROL VOLTAGE CHARGING SIDE 14 5 0 5V 5 000rpm LAMP SIDE 13 1 0 5V 5 000rpm NOTE Check with fully charge the battery which has the voltage between terminal of 12 8V 13 0V In case that the engine is started by the starter motor measurement must be performed after accelating charging for 10 seconds 13 3 BATTERY CHARGING SYSTEM VOLT MET
107. new one TRANSMISSION CRANKSHAFT CRANKCASE BEARING REMOVER BEARING OIL SEAL RH CRANK CASE LH CRANK CASE REPLACEMENT LH Crankcase Use special tools to remove the drive shaft bearing TOOLS BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD Apply clean engine oil to a new bearing and assemble it to the crank case Install a new final gear oil seal CRANKSHAFT INSTALLATION Replace the bearing if necessary Apply clean engine oil to the new RH crankshaft bearing and press in the bearing into the RH crank case TOOLS DRIVER HANDLE A OUTER DRIVER 52 x55mm DRIVER PILOT 20mm Use special tools to assemble the crankshaft bearing to the LH crank case TOOLS DRIVER HANDLE A OUTER DRIVER 52 x55mm DRIVER PILOT 20mm Clean the crankcase using cleaning oil and check for rack and damage to each area 9 7 TRANSMISSION CRANKSHAF T CRANKCASE NOTE After removing the liquid gasket from the joining face of the crankcase amend the scratched areas using oil ston Apply 2 cycle oil to the radial ball bearings and the connecting rod large end portion e Install the crankshaft to the LH crankcase NOTE Install not to interfere with the case with being careful of connecting rod location TOOL CRANKSHAFT ASSEMBLER LH CRANK CASE Apply a liquid gasket to the LH crankcase joining face CA NOSSA TU install the dowel pins e Install the RH crankcase
108. ng bag holder Loosen the 2 tapping screws R L securing the front cover Remove the inner cover e Install in the reverse order of removal EXTERNAL PARTS FRONT UNDER COVER Remove the following parts Luggage box Body cover Floor side cover Floor panel Front cover Inner cover Front fender 1 Front wheel E Loosen the flange bolts securing the lower end of the UNDER COVER inner cover e Remove the front under cover e Install in the reverse order of removal NOTE Pay attention not to turn over the vehicle UNDER COVER SPEEDOMETER Loosen the 2 special screws securing the wind screen Remove the wind screen Loosen the 2 flange bolts securing the speedometer SPEEDOMETER Slay Remove the front cover Remove the speedometer wire Remove the speedometer cable EXTERNAL PARTS FLANGE BOLTS Remove the speedometer e Install in the reverse order of removal MUFFLER Loosen the muffler flange bolt securing Ex pipe comp Loosen the 2 bolts securing the muffler comp e Remove the Ex muffler comp WARNING Never performing the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot EX PIPE Loosen the 2 cap nuts securing the cylinder comp e Pull the Ex pipe comp downward to remove it e Install in the reverse order of removal NOTE Replace the packing whe
109. ng brake lever is tightly depressed it indicates the brake lining has reached the service limit Replace the brake shoes INSPECTIONS ADJUSTMENTS BRAKE SYSTEM Check the front brake hose for cracks or damage If any leaks are found replace immediately Check the brake rod for looseness or damage and replase it if necessary BRAKE LEVER FREE PLAY Check the free play after pulling the lever FREE PLAY JEN FRONT 10 20mm REAR 10 20mm REAR BRAKE FREE PLAY ADJUSTMENT Turn the adjuster nut to adjust the free play After initial adjustment Check the operation of the rear brake light switch Make additional adjustments if necessary HEADLIGHT ADJUSTMENT Adjust the headlight beam level by operating the adjusting screw located on the upper side of the front fender NOTE e Adjust the beam level according to local laws and regulations e Improper beam level adjustment may blind oncoming drivers or may incorrectly light the road ahead SIDE STAND Do not ride motorcycle with an unsatisfactory INSPECTIONS ADJUSTMENTS SIDE STAND Erect the main stand e Pull the lower end of the side stand and see if it moves freely If the side stand does not move smoothly apply grease to the pivot area If the side stand moves too freely check the side stand spring Check the axial movement of the side stand SUSPENSION NOTE suspension Loose or worn suspensi
110. ngle direction clearance 0 010 0 02mm 0 04mm Crank shaft shaking 9 1 TRANSMISSION CRANKSHAF T CRANKCASE 9 2 DRIVE SHAFT DRIVE SHAFT TRANSMISSION CRANKSHAFT CRANKCASE DISASSEMBLY e Remove the LH side cover 7 2 e Remove the continuously variable transmission SECTION 7 e Remove the exhaust muffler 3 7 e Remove the rear wheel gt 11 3 Install the oil sump under the cover of transmission Loosen the 5 transmission cover flange bolts e Drain the oil of transmission e Remove the transmission cover e Remove the final shaft gear e Remove the thrust washer e Remove the counter shaft e Remove the counter shaft gear e Remove the side washer e Remove the drive shaft from transmission cover with the press NOTE Take precautions not to damage the cover joints e Remove the oil seal of the drive shaft INSPECTION e Inspect the drive shaft for wear or damage TRANSMISSION CRANKSHAFT CRANKCASE FINAL SHAFT COUNTER GEAR COUNTER SHAFT THRUST WASHER SIDE WASHER BEARING e Inspect the final shaft for wear or damage e Inspect the counter shaft for wear damage Bearing Inspection e Manually turn the bearing inner race installed inside the transmission cover and check if the race is turning smoothly Verify the outer race is accurately installed in the case e Replace the bearing if necessarry NOTE
111. nite the flammable gas Always remove the battery from the frame when charging it If the battery 1s charged while installed in the frame the electrolyte may spill and corrode the frame components CHARGING CURRENT 0 3A CHARGING TIME 8 10h WARNING Do not let the electrolyte temperature rise above 45 C 113 F If the electrolyte temperature becomes too high lower the charging current e Quick charging will shorten the battery life and cause battery damage It chould only be done in emergency slow charging is prefered BATTERY CHARGING SYSTEM HEADLIGHT VOLTAGE INSPECTION e Remove the front cover 3 5 CAUTION Check voltage with the headlight coupler connected After starting the engine place the dimmer switch to HI and check the boltage between the blue and green wires of the headlight coupler CAUTION Measurement is performed in ACarea CONTROL VOLTAGE 12 6 13 6V 5 000rpm COURUER If voltage is incorrect check the regulator rectifier REGULATOR RECTIFIER INSPECTION HARNESS CIRCUIT INSPECTION e Remove the front cover 3 5 lf e Remove the 4P coupler of the regulator rectifier and SIREGUIATORIREGIIFIER inspect the wiring circuit in the main harness side a ie gt terminal ITEM MEASUREMENT LOCATION AREAS OF INSPECTION IF INCORRECT BATTERY WIRE Voltage between red 4 green There must be battery vol
112. ny excess oil gt E gt E un Y CAUTION Using air filter oil when riding in extremely dusty WASH SQU ULTRAII or OUT OIL conditions prevents premature engine wear due to MOTIX 2 dust dirt drawn into the engine Apply air filter oil to the entire surface of the element and rub it with both hands to saturate the element with oil Squeeze out excess oil 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 removing only the carbon use plug cleaner and wire brush to clean the plug Always use a feeler gauge to check the gap ENCH SPARK PLUG GAP 0 6 0 7mm CHECK GAP DEPOSITS CAUTION Make sure there 15 no dirt or debris on the seat of the spark plug hole before inserting the spark plug To prevent damage to the cylinder head hand tighten the spark plug before using a wrench to tighten to the CHECK WASHER specified torque FOR DAMAGE e Do not overtighten the spark plug CHECK FOR CRACKS HIGH SPEED Spark plug specification change HIGH SPEED STANDARD LOW SPEED BP6HS BPR7HS BPR6HS BRAHSA STANDARD BPR7HS BPROHS BR4HSA O C The specification changes according to the speed B4HSA LOW SPEED INSPECTIONS
113. olts of shroud comp Remove the shroud comp gt FRANGE BOLTS attention not to damage certain part when removing Remove according to the working precedure Install in the reverse order of romoval CYLINDER HEAD CYLINDER PISTON REMOVAL e Remove the luggage 3 3 e Remove the exhaust muffler assembly gt 3 7 Remove the fan cover shroud 8 2 CYLINDER HEAD CYLINDER HEAD CYLINDER PISTON Cylinder head Loosen 4 cylinder head bolts NOTE Bolts are loosened by rotating 2 3 times and alternating to a diagonal bolt Remove the cylinder head Remove the cylinder head gasket Cylinder Remove the cylinder Piston Piston Ring Remove the piston pin clip Remove the piston pin NOTE Be careful not to bend pins Be careful not to damage the cylinder and crankcase gasket face when cleaning Remove the piston Remove the needle bearing from the small end of the connecting rod 8 3 CYLINDER HEAD CYLINDER PISTON NOTE Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the clip fall into the crankcase Mark and store the pistons and piston pins so that they can be reinstalled in their original positions INSPECTION There is more carbon deposit whitin the engine in case of 2 cycle engine th
114. on parts will lead to deterioration in the vehicle s safety and operation efficiency 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 for several times to check the operating conditions Check the rear fork for oil leakage parts damage or looseness BOLTS NUTS FASTENERS Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value Check all pins clips hose clamps and cable stays INSPECTIONS ADJUSTMENTS WHEELS TIRES NOTE Check the tire pressure when the tires have been cooled off Check the tread the part making contact with the road surface and side for wear cracks or damage Replace damaged tires STANDARD PRESSURE ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 1 75 175 2 00 200 DRIVER ANDA PASSENGER 2 00 200 2 25 225 Chec the tread depth at the tire center e If the tread depth has reached the service limit replace the tire INDICATOR LOCATION MARKING STEERING HEAD BEARING NOTE e Check the cable if it interferes with the handle operation e Lift the front wheel and check if the handle moves right and left smoothly If the handles move heavily check if the cable or electr
115. or fuel filter clogged 3 Fuel tank cap air hole clogged 3 Remove the carburetor and check Clogged gt 1 Clean for clogged jet Not clogged 17 3 TROUBLESHOOTING UNSATISFACTORY OPERATIION CLUTCH DRIVE DRIVEN PULLEY Engine start but motorcycle does not move Y 2 Vehicle moves slow engine starts but stops immediately 3 Engine weak at start Y 4 Engine weak at high speed 9 5 Abnormal noise or odor CLUTCH DRIVE DRIVEN PULLEY Steering is heavy 2 Wheels wobbling 3 Motorcycle pulls to one side 17 4 CAUSE OF TROUBLE 1 Drive belt worn or slips 2 Ramp plate samaged 3 Drive face spring damaged 4 lining came off 5 Driven pulley shaft spline damaged 6 Faulty transmission 7 Transmission seize 1 Shoe spring damaged 2 Clutch outer and weight seize 3 Pivot seize 1 Drive belt worn or slips 2 Weight roller worn 3 Drive pully bearing seized 4 Weak drive face spring 5 Drive pully bearing worn or seized 1 Drive belt worn or slips 2 Weight roller worn 3 Drive pully bearing worn 1 Oil or grease spilled on the drive belt and inside pulley 2 Drive belt worn 3 Weak drive face spring 4 Drive pully bearing worn or seized C
116. or the pulley face The transmission rate of driving force 15 reduced with oil contact Do not operate starter motor while the LH crank case front cover is removed NOTE Take precautions not ot apply the grease oil to the movable drive face or weight roller SPECIFICATIONS STANDARD SERVICE LIMIT MOVABLE DRIVE FACE BUSHING INNER DIAMETER 20 035 24 0520 085mm 20 60mm DRIVE FACE BOSS OUTER DIAMETER 20 011 20 025mm 19 97mm DRIVE BELT WIDTH 15 0mm 15 5mm WEIGHT ROLLER OUTER DIAMETER 15 920 16 080mm 15 40mm CLUTCH OUTER AND INNER DIAMETER 107 0 107 2mm 107 50mm DRIVEN FACE OUTER DIAMETER 33 965 33 985mm 33 94mm DRIVEN FACE INNER DIAMETER 34 000 34 025mm 34 06mm TROUBLESHOOTING Engine starts but motorcycle does not work Vehicle unable to run at the maximum speed Drive belt worn or lack of output Ramp plate damaged Drive belt worn Clutch shoe worn or damaged Defective movable driven face spring Movable driven face spring cut Weight roller worn Pulley face contaminated Engine stops or the vehicle runs suddenly after starting Clutch shoe spring cut 7 1 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION DOWEL PIN DRIVE FACE KICK STARTER SPINDLE 7 2 LH SIDE COVER REMOVAL Remove the rear brake cable Remove the 9 flange bolts securing LH side cover Remove the LH side cover Remove the gasket and the dowel pin NOTE Install the new gasket
117. orcycle 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 be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 9 GENERATOR SECTION 13 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION SECTION 7 CYLINDER HEAD CYLINDER PISTON SECTION 8 CARBURETOR SECTION 5 OIL PUMP SECTION 4 e Items to be worked after removing engine CRANKSHAFT CRANKSHAFT BEARING CRANK CASE BEARING TORQUE VALUES ENGINE HANGER BOLT ENGINE 5 0kef m FRAME 7 3kgf m 6 1 ENGINE REMOVAL INSPECTION ENGINE REMOVAL Remove the luggage box Disconnect the A C generator coupler Disconnect the carburetor auto bystarter coupler Remove the spark plug cap Remove the oil pump cable Remove the oil tube connected to the oil pump Remove the vacuum tube connected to the inlet pipe Remove the fuel tube connected to the carburetor and the auto cock Loosen the carburetor cap top remove the throttle valve MUFFLER Loosen the rear brake adjust nut and remove the brake arm joint B and rear brake cable Loosen the under bolt at the end of rear cushion e Remove the muffler e Remove the rear wheel REAR WHEEL Loosen the engine hanger U nut REARICUSHION Loosen the engine hanger flan
118. ose not turn engine over Incorrect starting system e Faulty engine 15 2 STARTING SYSTEM STARTER MOTOR REMOVAL INSTALLATION e Remove the luggage box 43 3 e Remove the body cover 53 3 Disconnect the starter wire connector remove the wire from the wire fixing clamp Loosen the 2 starter motor fixing bolts e Remove the starter motor e Install in the reverse order or removal NOTE Accurately tighten the earth wire Turn off the main switch prior to servicing the starter motor If power is connected the starter motor may be activated and damaged DISASSEMBLY e Remove the starter motor screws and remove the motor cover NOTE Record the order so the parts can be installed correctly later INSPECTION Check for continuity of the starter motor case Between cord terminal gt and bracket normal if no continuity Between cord terminal and brush normal if there is continuity If abnormal replace with a new one Measure the brush length Replace the brush if it is worn beyond the service limit SERVICE LIMIT 3 mm 15 3 STARTING SYSTEM 15 4 COMMUTATOR FRONT BRACKET Check the commutator for Damage or abnormal wear Replace with a new one Discoloration of the commutator bar Replace with new one Metallic debris between commutator bars Clean it off Check for continuity betwe
119. peak voltage 6 Pulse generator is damaged measure peak voltage 7 Peak voltage adaptor is damaged 8 CDI unit is damaged when no problems 1 7 and no sparks emitted from spark plug Spark plug peak voltage is normal but spark plug dies not emit sparks 1 Damage to spark plug or leakage of ignition coil secondary current 2 Damaged ignition coil MOO LLIOXH Peak voltage is low 1 Using a tester with a low internal resistance 2 Cranking speed is too low Battery 1s insufficiently charged or kick power is weak 3 Influence of tester sampling time normal state if measured a number of time and shows over the set voltage 4 Excite coil is damaged when 1 3 is okay No almost no peak voltage 1 Peak voltage adaptor is damaged 2 Excite coil is damaged AS 14 2 Maximum voltage is low 1 Using a tester with a low internal resistance 2 Cranking speed is low Battery is low or kick power is weak 3 Influence of tester sampling time normal state if measured number of times and show over the set voltage 4 Pulse generator is damaged when 1 3 is okay No almost no maximum voltage 1 Maximum voltage adaptor is damaged 2 Pulse generator is damaged DIGITAL TESTER ADAPTOR IGNITION COIL INITIAL WIRE ADAPTOR TERMINAL m 74 NN m m IGNITION SYSTEM IGNITION SYSTE
120. prescribed torque TORQUE VALUE 6 0kgf m FRONT FORK REMOVAL e Remove the front cover 3 5 e Remove front fender 3 6 e Remove the front brake caliper 12 6 e Remove the front wheel 10 5 e Remove the front fork cover Loosen the front brake hose stay bolt remove fork e Remove the speedometer cable from R fork speedometer cable guide e Loosen the R fork securing bolt remove the speedometer cable and guide Loosen the 2 steering stem front fork R L stay bolts e Remove the front fork FRONT FORK DISASSEMBLY e Wrap the fork pipe with a piece of cloth and fix it to the vise e Remove the fork pipe cap bolt FRONT WHEEL FRONT FORK STEERING NOTE If the screw is completely loosened the fork tube cap bolt may spring out by the force of the spring Take due precautions SPRING Remove the fork spring and expand and release the fork pipe several times to drain fork oil nem 3 e Wrap the bottom case with a piece of cloth and remove the socket bolt NOTE If the socket bolt turns idle but cannot be removed temporarily assemble the spring and the fork tube cap bolt first Hold the bottom case firmly with a vise taking precautions not to distort or damage it e Remove the dust seal DUST SEAL e Remove the oil seal stopper ring a IL SEAL STOPPER RING _ OIL SEAL STO c S 10 15 FRONT WHEEL FRONT FORK S
121. remain steady it indicates the diaphragm is incorrectly installed or damaged If the vacuum remains steady but the fuel flow is not smooth it indicates a clogged filter or incorrectly installed diaphragm e If the fuel flows without the vacuum applied the diaphragm is incorrectly installed FUEL SYSTEM FLANGE BOLT INLET PIPE REED VALVE REMOVAL INSTALLATION Remove the luggage box Remove the air cleaner Remove the carburetor Remove the vacuum tube connected to the inlet pipe Remove the oil pump cable Remove the fan cover and shroud Remove the inlet pipe securing 4 flange bilts connected to the LH crank case Remove the inlet pipe Remove the reed valve e Install in the reverse order of removal NIECES F INSPECTION Check the reed valve for fatigue or damage and replace the reed valve assembly 1f necessary Check the reed valve seat for cracks damage clearance from the reed and replace the reed valve assembly 1f necessary NOTE e Be sure to replace the reed valve as an assembly Disassembling or bending the reed stopper will cause engine trouble 5 9 ENGINE REMOVAL INSPECTION 6 0 ENGINE REMOVAL INSPECTION 6 ENGINE REMOVAL INSPECTION SERVICE INFORMATION 6 1 ENGINE REMOVAL INSPECTION 6 2 SERVICE INFORMATION GENERAL SAFETY NOTE Use a jack to remove or install the engine Support the mot
122. rily 2 Remove the fuel level sensor and move float to check the status of operation Float up Full position Float down Empty position Needle not moving 3 Short circuit the tank unit terminal on the wire harness side Needle not moving 4 Terminal joints loose or faulty connection Y Signal continuously 3 operates dim or does not operate at all Needle moves Needle not moves Unsatisfactory Check GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit Signal operates satisfactorily 2 Remove the tank and operate the float Needle moving Y 3 Move the float rapidly One up down motion per second Needle moving 4 start the engine and measure the fuel level sensor resistance Resistance not changed 5 Check each joint Signal continuously operates dim or does not operate at all Needle not moves Needle not moves Resistance changed significantly Unsatisfactory Satisfactory 17 6 CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Faulty ignition swich 4 Faulty terminal connection 5 Wire harness damaged 1 Faulty float 1 Balance coil damaged or shorted 1 Terminal loose 2 Faulty terminal connection 1 Balance coil lead
123. rod for deflection or damage SERVICE LIMIT 229 6mm REAR WHEEL BRAKE SUSPENSION REAR CUSHION ASSEMBLY INSTALLATION Assemble the spring spring guide and stopper rubber Apply thread locking agent to the lock nut and install the rear cushion compressor attachment on the damper rod e Fix the upper joint and tighten the lock nut TORQUE VALUE 4 0kgf m TOOLS REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT INSTALLATION Install the rear cushion Install the luggage box e Tighten the top and bottom of the cushion with bolt e Install the air cleaner TORQUE VALUE UPPER SIDE 3 5kgf m LOWER SIDE 3 5kgf m 11 7 BRAKE SYSTEM 12 0 12 BRAKE SYSTEM BRAKE SYSTEM SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID BLEEDING BRAKE PAD REPLACEMENT 12 1 12 1 12 3 12 4 SERVICE INFORMATION GENERAL SAFETY BRAKE DISK INSPECTION BRAKE CALIPER MASTER CYLINDER Do not allow foreign material to enter the system when replenishing brake fluid e prevent chemical changes do not mix different types of brake fluid Do not use the old brake fluid again e Brake fluid can cause damage to painted plastic and rubber surfaces Take precaution not to allow parts to be contaminated by the brake fluid Do not reuse sealing washers e Clean the disassembled parts with brake fluid and check for
124. shoe replace if the service limit is exceeded SERVICE LIMIT 2 0mm Movable Driven Face Spring Inspection Measure the free length of the driven pulley spring and replace if the service limit is exceeded SERVICE LIMIT 96 1mm KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION GUIDE PIN 7 uj oU E 2 ES ay m MOVEABLE DRIVEN FACE DRIVEN FACE INNER NEEDLE BEARING DRIVE FRATE CLUTCH SHOE DAMPER RUBBER Driven Face Inspection Check the following Both faces for damage or excessive wear Guide pin groove for damage or deformation e Replace damaged or worn parts an necessary e Measure the of the driven face and I D of the movable dirven face Replace either part if the service limit is exceeded Driven face outer diameter service limit 33 94mm Movable driven face inner diameter service limit 34 06mm 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 e Turn the inner race of the outer bearing with your finger Check that the bearing turns smoothly and quietly and that the bearing outer race fits securely Replace the bearing if necessary CLUTCH SHOE REPLACEMENT e Remove the E clip and washers then remove the clutch shoes and shoe springs from the drive plate NOTE Some models use on
125. t 10 14 Loosen the steering stem lock nut Remove the speedometer cable and front brake hose from the steering stem bracket Loosen the steering top cone race Remove the steering stem 10 19 FRONT WHEEL FRONT FORK STEERING UNDER aa 10 20 UNDER STEERING BALL RACE Check the steel ball cone race and ball race for wear or damage Replace worn or damaged ones Remove the steering steel ball Ass y Remove the steering steel ball Ass y Bottom Remove the upper under ball race TOOL BALL RACE DRIVER NOTE Check all of the races and balls for damage or abnormal wear and replace as necessary If the vehicle has been involved in a collision the steering stem may be damaged STEERING STEM INSTALLATION Insert the upper under ball race into the steering head pipe FRONT WHEEL FRONT FORK STEERING Using a steering stem driver drive the steering stem bottom cone race into the steering stem Insert the ball race after applying grease e lemporarily tighten the top cone race on the steering stem e Check for smooth left and right movement and completely tighten the top cone race again TORQUE VALUE 1 5kgf m 4 Loosen by 1 4 turn and check the top and bottom free play Temporarily install the R L front forks first and tighten the steering stem nuts TORQUE VALUE 7 0kgf m TOOLS LOCK NUT WRENCH EXTENSION BAR e
126. t in the groove properly TOOL SNAP RING PLIERS e Install the boot master to the cylinder BRAKE SYSTEM Install the brake hose to the master cylinder with 2 new sealing washers and the hose bolt Install the stop switch Install the brake lever e Install the master cylinder into the master holder NOTE Install the holder with its UP mark facing upwards and align the holder joint with the punch mark on the handle bar Tighten the holder upper bolt first TORQUE VALUE 2 5 3 5 kgf m Connect the brake stop swtich wire e Fill the brake fluid and bleed air e Replenish the brake fluid if necessary 12 11 BATTERY CHARGING SYSTEM ANTI THEFT SWITCH UNIT Ly ip S SEAT LOCK CABLE LOCK SWITCH RESISTER COMP FUEL VENT TUBE FUEL UNIT COUPLER OIL LEVEL SWITCH CORD a 5 TEAOR Ss R L RR WINKER COUPLER A AX ANN REG RECTIFIER START RELAY A BATTERY CORD n Mi Fil 4 6 WY 2 S 55 lt _ lt 84 2m 54 i I p xis 75 es m N 5 2 X A SC ae ay CDI UNIT J BATTERYOCORD WIRE HARNESS THROTTLE CABLE RR BRAKE CABLE WHITE GREEN RED RED AC GENERATOR FUSE GREEN A 7 REGULATOR um 0400 BYSTARTER RESISTER
127. tage Damaged disconnected main fuse harness CHARGING Resistance between white wire and mM COIL earth wires Disconnect the starter 4 10 9 AC generator charging lighting coil coupler connection damage resister 6 7 Q Resistance between yellow wire and 5W headlight li circuit earth wires Disconnect dimmer 0 2 0 8 Q0 C ghtlightng switch connection LIGHTING COIL Inspect gt part after at least 10 minutes later REGULATOR RECTIFIER INSPECTION BATTERY TERMINAL LAMP TERMINAL B e If the inspection of the harness side proves to be L TERMINAL ARRANGEMENT satisgactory check the regulator rectifier coupler for T faulty connection and measure the resistance between lt lt the terminals of the regulator rectifier RESISTANCE VALUE Tester Tester Q R B Y G A 3 50 L ap ee A E CHARGING TERMINAL EARTH TERMINAL B is Se E oo 5 100 BATTERY CHARGING SYSTEM COOLING FAN STATOR A C GENERATOR REMOVAL Remove the plug Loosen the 2 flange bolts remove the fan cover Loosen the 4 cooling fan fixing flange bolts remove the cooling fan Hold the flywheel with a universal holder TOOL UNIVERSAL HOLDER Remove flyweel with a ACG rotor puller TOOL ACG ROTOR PULLER 0750 00004 Loosen the 2 pulse generator fixing flange bolts remove the pulse generator Loosen the 2 stator f
128. ter gear box and separate the speedometer cable NOTE Loosen axle nuts Support bottom of engine with a jack until the front wheel is lifted Loosen the axle nut e Remove the front axle e Remove the front wheel NOTE Do not operate brake lever after the front wheel is removed e Remove the speedometer gear box INSPECTION Check the front axle for deflection e Place the front axle on a V block and measure deflection with a dial gauge SERVICE LIMIT 0 2mm e Place the front wheel on an inspection stand e Slowly turn the wheel and check the rim runout with a dial gauge SERVICE LIMIT Radial 2 0mm Axial 2 0mm 10 5 FRONT WHEEL FRONT FORK STEERING ROTATION SPEEDOMETER GEARBOX go A 10 6 BEARING INSPECTION Manually turn the bearing inner race and replace if it makes noise or is worn Check if the bearing outer race is accurately fitted into the wheel hub and replace worn ones NOTE Replace bearings in pairs left and right set FRONT WHEEL DISASSEMBLY Remove the speedometer gear box dust seal and speedometer gear retainer Remove the front wheel collar A Remove te oil seal and brake disc Check the disc for defects FRONT WHEEL FRONT FORK STEERING WHEEL BEARING REPLACEMENT Install the bearing remover head and the remover shaft on the wheel and remove the bearing and distance collar NOTE
129. the upper level CAUTION To prevent chemical changed do not use different types of brake fluid Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this operation until the brake fluid flows out of the brake bleeder NOTE BRAKE FLUID Check the fluid level often and replenish fluid if the amount of fluid is reduced to the lower level Read the user s manual carefully prior to disassembling or using the brake bleeder Protect the bleeder valve with tape to prevent air from entering the bleeder valve e Repeat the above opration until there is no air flowing out of the bleeder hose Squeeze the bleeder valve and operate the brake lever to check the ingress of air Add brake fluid 12 3 BRAKE SYSTEM BRAKE LEVER If the brake bleeder is not used do the following First fill the brake fluid up to the upper limit line Connect the hose to the bleeder valve to receive brake fluid D Squeeze the brake lever completely loosen the bleeder valve 1 2 turn and tighten it again NOTE Do not release the brake lever until the bleeder valve is tightened 2 Release the brake lever slowly to its fullest extent and leave it unattended for a few seconds 3 Repeat the process specified in iteam until there is no more air bubbles coming out of the bleeder v
130. ttle NOTE Do not try to remove the bead too much at one time e Repeat the above procedures until half of bead is removed Then remove the remaining bead by hand Remove the another tire from the rim according to the same procedures TIRE LEVER RIM VALVE REPLACEMENT Cut off the rim valve at its base Apply mild detergent solution to a replacement rim valve and insert it from inside of the rim NOTE Be sure to use the recommended rim valve Do not damage the valve hole Replace the rim valve whenever installing a tubeless tire 10 10 FRONT WHEEL FRONT FORK STEERING RIM INSPECTION e If using a solution brake cleaner gasoline thinner when removing the rust and dirt wipe off the remainder when reassembling It may damage the rubber parts e If there 1s serious deformation twist or crack the air may be leaked Replace the damaged parts immediately e If there is scratch on bead contacting face more than 0 5mm in depth or 1 0mm in width replace the damaged parts immediately WARNING If the combination of tubeless tire and rim isn t proper the tire may come off It will cause a serious accident Pay attention to deal it TUBELESS TIRE INSTALLATION CAUTION Always use the exclusive tire lever for two wheeled vehicles Use the rim protector to prevent the scratch of rim case of low pressure tire if vegetable soapy water is used it m
131. ubrication Contaminated brake linings Contaminated brake drum Worn brake shoes at cam contact areas Improper engagement between brake arm and camshaft serrations brake lever hard or slow to return Worn broken return spring Improperly adjusted brake e Sticking brake drum due to contamination Worn brake shoes at cam contact areas e Brake cable sticking needs lubrication Worn brake cam e Improperly installed brake linings Brakes squeaks Worn brake linings Worn brake drum Contaminated brake linings Contaminated brake drum 12 2 BRAKE SYSTEM BRAKE FLUID BLEEDING BRAKE FLUID CHANGE CAUTION FUA SCR MASTER CYLINDER CAP A contaminate disk or pad reduces braking power Do not allow the disk or pad to be contaminated by oil Replace contaminated pads and remove pollutants from the disk completely NOTE Check the brake fluid level often and replenish new fluid as required Do not spill fluid on painted plastic or rubber parts Remove the master cylinder cap master cylinder holder and diaphragm from the master cylinder Connect the bleeder hose to the bleeder valve Loosen the bleeder valve and pump the brake lever repeatedly When there 15 no more fluid flowing out of the bleeder valve stop pumping the brake lever M BIEEDER SCREWS AIR BLEEDING e Fill the reservoir with DOT 3 or 4 brake fluid up to
132. y Operates heavy Operates light STRTER ROTATE WITHOUT STOPPING 1 Turn off the ignition switch Will not stop p TROUBLESHOOTING CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Faulty ignition swich 4 Faulty terminal connection 5 Ignition swich damaged or shorted 1 Battery totally discharged 1 Faulty starter switch connection 2 Starter magnetic damaged or shorted 3 Connector and terminals loose 1 Worn brush worn 2 Faulty connection between the rotor and brush 3 Faulty the starter motor subwire connection 4 Terminals loose 1 Wire harness damaged CAUSE OF TROUBLE 1 Battery totally discharged 1 Connector terminals loose 2 Faulty starter relay connectior 1 Engine seized 1 Faulty connection between the rotor and brush CAUSE OF TROUBLE 1 Pinion seized Starter relay connection seized 17 7 18 WIRING DIAGRAM HAZARD START KILL SW Lu gt SPEEDOMETER ILLUM 12V 1 7W PILOT BOX OIL PILOT 12V 3W WINKER PILOT 12V 3W HIGH BEAM 12V 3W oooO RH FR WINKER SB SB 12V 16W G HEAD LIGHT W B 12V 35W 35W L G FR WINKER 12V 16W G WINKER RELAY HAZARD S W KILL S W ANTITHEFT DEVIC

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