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caution - Hyosung

1. 19921 eng U8819 79 1991 YOR G MOJA 1991 MUM GM UMOIg Jg 19921 POY U8919 YO SIM M 18921 M8 18921 SUM MOIS A MA eng 1 ped uee6u6r 61 J89E1 POY MA enig PUM IM aniq 417 qS U9819 9 4 13921 enig SHUM TM Jeoenenig YM 18 19 0 407109 MYN UTHOLIMS SIGNVH MWS 1 6 AS DImo pec ETE prox OL3NOVN TOT WNOIS NENL j uis eE NO Tavis ao NOH _ oo EET snd H e ciol TES i 2 H alot ge Ecc sel I Za HIN SOION Tara n ge 3NION3 amava VS ts I 425 22 24 NE lt lt lt m LM EE Q gar 1 ojo i osPogg i O 48 a LI P 9 4 q 1 c XOH3Snd 32 3s 2 109 g 7 5 NOILINO m 1 TNENL HE T an o 3 1 a _ E S Nousog gt O 015 1 1 x a 7 J
2. Disconnect the breather hose and remove the oil return tank with hose 3 3 ENGINE Remove the carburetor with throttle cable Disconnect the starter motor lead wire and ground lead wire Remove the engine sprocket cover ENGINE 3 4 Remove the clutch cable bracket f Disconnect the clutch cable 2 end out of the clutch lever Disconnect the clutch cable 2 end out of the clutch release arm Remove the clutch release Disconnect the magneto lead wire couplers and gear position switch lead wire coupler Remove the reverse gear cable bracket O Disconnect the reverse gear Remove the engine sprocket with drive chain 3 5 ENGINE Loosen the muffler connecting bolt Remove the muffler mounting bolts Remove the exhaust pipe nuts Remove the muffler Remove the radiator Remove the engine mounting bolts and nut Remove the engine mounting brackets Remove the engine from the left side ENGINE 3 6 ENGINE REMOUNTING Remount the engine in the reverse order of engine removal Pay attention to the following points Install the exhaust pipe and muffler 3 7 ENGINE Tighten the exhaust pipe nuts muffler mount ing bolts and connecting bolt to the
3. FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS BREAK IN EXTERIOR ILLUSTRATION lt lt SPECIFICATIONS eee 1 1 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words A WARNING Indicates a potential hazard that could result in death or injury A CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instructions cleaner Please note however that the warning and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the vehicle In addition to the WARNING and CAUTION stated you must use good judgement and basic mechanical safety principles If you are unsure about how to per form a particular service operation ask a more experienced mechanic for advice GENERAL INFORMATION 1 2 GENERAL PRECAUTIONS A WARNING Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attenti
4. EX 9 PISTON AND CYLINDER Apply MOLY PASTE onto the piston pin and small end of the conrod Au MOLY PASTE NOTE Install the piston with the punch mark D on the piston head facing toward the exhaust side Place a clean rag over the cylinder base to vent the piston pin circlip from dropping into the crankcase and then fit the piston pin circlip with long nose pliers CAUTION Use a new piston pin circlip to prevent circlip fail ure with a bent one Apply engine oil to the sliding surface of the piston and big end of the conrod Install the dowel pins and new gasket 3 onto the crankcase ENGINE 3 54 CAUTION Use a new gasket to prevent oil leakage Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt NOTE When mounting the cylinder after attaching the cam chain keep the cam chain taut The cam chain must not be caught between the cam chain sprocket and crankcase when the crankshaft is rotated 3 55 ENGINE Install the cam chain NOTE Make sure that the guide 1 is inserted properly or binding of the cam chain and guide may result Install the dowel pins and new gasket CAUTION Use a new
5. 30 40 mm PERIODIC MAINTENANCE 2 22 m CLEANING AND LUBRICATING Clean the drive chain with kerosine If the drive chain tends to rust quickly the inter vals must be shortened A CAUTION Do not use trichloroethylene gasoline or any sim ilar solvent These fluids have too great a dissolv ing power for this chain and they can damage the O rings Use only kerosine to clean the drive chain A CAUTION Some drive chain lubricants contain solvents and additives which could damage the O rings in your chain Use Hyosung chain lube or an equivalent that is specifically intended for use with O ring chains After washing and drying the chain oil it with engine oil or chain lubricating oil CAUTION The drive chain for this vehicle is made of the special material The standard drive chain is a RK 520EXW recom mends to use this standard drive chain as a replacement Use of another chain may lead to premature chain failure 2 23 PERIODIC MAINTENANCE SUSPENSIONS Inspect Interval Inspect Every 6 months Support the vehicle with a jack or wooden blocks Remove the front and rear wheels Refer to page 7 8 Inspect the suspension arm bearing and bushing for scratches wear or damage If any damages are found replace the suspension arm bearing or bushing with a new one Refer to page 7 24 25 Inspect the s
6. 09915 74511 Oil pressure gauge Measure oil pressure of 4 stroke engine 09923 74510 Bearing remover 20 35mm Used to remove bearing with the rotor remove sliding shaft 09915 74532 Oil pressure gauge adaptor Used with oil pressure gauge 09930 30102 Rotor remove sliding shaft Used to with bearing remover 8 11 SERVICING INFORMATION Special tools Part Number Part Name Description 09930 30164 Rotor remover Used to remove rotor SERVICING INFORMATION 8 12 TIGHTENING TORQUE 9 ENGINE Water temperature switch Coolant drain bolt Cooling fan mounting bolt Cooling fan motor mounting bolt Cooling fan thermo switch Radiator mounting bolt Magneto rotor nut Magneto cover bolt Muffler connecting bolt Muffler mounting bolt Exhaust pipe nut Thermostat case bolt Starter clutch bolt Cylinder head bolt Cylinder head cover bolt Cylinder head base bolt Cylinder base nut Engine sprocket bolt Engine oil check plug Crankcase Oil tank Engine oil drain plug Engine oil inlet hose union bolt Engine mounting nut Engine mounting bolt Spark plug Camshaft housing bolt Cam chain tensioner mounting bolt Cam chain tension adjuster mounting bolt Cam chain tension adjuster bolt Crankcase bolt Clutch sleeve hub nut Prima
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8. Apply THREAD LOCK 1324 to the sprocket mounting bolts THREAD LOCK 1324 Tighten the sprocket mounting bolts to the speci fied torque V Rear sprocket mounting bolt 18 28 N m 1 8 2 8 kgf m AXLE HOUSING Apply SUPER GREASE to the bearings and dust seals before installing AG SUPER GREASE CHASSIS 7 70 7 71 CHASSIS Install the axle housing from the swingarm s right side Install the rear axle shaft Install the chain adjuster bolt Install the chain adjuster Tighten the axle housing bolts nuts and wrench bolts temporarily m REAR AXLE SHAFT When the rear axle shaft is replaced with a new one install the right axle nut onto the new axle shaft Apply THREAD LOCK 1324 to the axle shaft THREAD LOCK 1324 Install the brake disk to the rear axle shaft Apply THREAD LOCK 1324 to the disk bolts and tighten them to the specified torque THREAD LOCK 1324 V Disk bolt 18 28 N m 1 8 2 8 kgf m NOTE Make sure that the brake disk is clean and free of any grease matter Install the rear axle shaft into the axle shaft housing Apply SUPER GREASE to the spline of the axle shaft AGI SUPER GREASE Install the sprocket flange to the axle shaft Apply BOND 1215 to the axle shaft BOND
9. Remove the engine sprocket cover Refer to page 3 3 Disconnect the reverse cable by removing the cable mounting screw REMOUNTING Remount the reverse cable in the reverse order removal Pay attention to the following points e Install the spring with the spring end matched the groove on the housing Apply SUPER GREASE to the O ring a SUPER GREASE Install the O ring to the reverse cable Connect the cable to the spool through the hole of the housing CHASSIS 7 52 7 53 CHASSIS NOTE When installing the spool hook the spring end D on the concave portion of the spool Make sure that the reverse cable is routed cor rectly CABLE PLAY ADJUSTMENT After installing the reverse cable adjust the cable play The cable adjuster is located at left downside of the crankcase assembly Loosen the lock 3 Turn the adjuster in or out until the cable play should be 1 2 mm 0 04 0 08 in at the reverse lever Tighten the lock nut securely After adjustment be sure to check for reverse function CHASSIS 7 54 REAR SHOCK ABSORBER 9 CONSTRUCTION DX N W AY __ e duque 2 9 REMOVAL Raise the rear wheel off the ground and support the vehicle with jack or wooden block Rem
10. CAUTION Care not to cause scratch on the cylinder bore Do not reuse the piston seal and dust seal that have been removed BRAKE CALIPER INSPECTION Inspect the brake caliper cylinder wall and piston sur face for scratch corrosion or other damages If any abnormal condition is noted replace the caliper CHASSIS 7 16 7 17 CHASSIS BRAKE CALIPER REASSEM BLY AND REMOUNTING Reassemble and remount the brake caliper in the reverse order of removal and disassembly proce dures and observe the following points CAUTION Wash the brake caliper components with fresh brake fluid before reassembly Do not wipe off brake fluid with a rag after washing the compo nents Replace the piston seal and dust seal into new ones with brake fluid applied Brake fluid specification and classification DOT 4 Install the brake pad spring Apply SILICONE GREASE to the brake caliper holder pin SILICONE GREASE Install the brake pads Refer to page 7 14 Tighten the brake pad mounting pins D brake caliper mounting bolts and brake hose union bolts 3 to the specified torque V Front brake pad mounting pin 18 28 m 1 8 2 8 kgf m Front brake caliper mounting bolt 18 28 m 1 8 2 8 kgf m Front brake hose union bolt 40 60 N m 4 0 6 0 kgf NOTE Before remounting the brake caliper push th
11. gt zm 2 o lt m gs zi E m5 e Org n 5 ELECTRICAL SYSTEM 6 16 BATTERY CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas If you don t follow the instruction in the below there may be a explosion and severe accident Therefore pay attention to the following points Positively prohibit battery from contacting to short spark or firearms The recharge of battery should be done in the wide place where the wind is well ventilated Don t recharge it at the sight of windproof 9 CAUTION OF BATTERY ELECTROLYTE TREATMENT Pay attention to the battery electrolyte not to stains the chassis or the humanbody If stains the chassis or the humanbody at once wash a vast quantity of water When they were stained clothes will come into being a hole or painting will take off Consult a doctor When the battery electrolyte was dropped to the surface of land wash it with a vast quantity of water Neutralize by hydroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape to seal the bat tery electrolyte filler hole until use as battery of complete seal type Do not use it except the battery electrolyte Pouring into the battery electrolyte necessarily use the electrolyte of the specified capacity Do not open the sealing cap after recharging the batter
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13. Number of cylinder 1 Bore 96 mm 3 78 in Stroke 62 mm 2 44 in Piston displacement 448 80 27 4 in Carburetor BDS42 TYPE Starter system Electric starter Lubrication system Wet sump 9 TRANSMISSION ITEM Rapier450 Clutch Wet multi plate type Transmission 5 forward and 1 reverse Gearshift pattem Forward 1 down 4 up foot operated Reverse Foot hand operated Final reduction 3 143 1st 2 538 2nd 1 684 Gear ratio Pu 1 29 4th 1 040 5th 0 885 Reverse 2 231 Drive chain RK 520EXW 102 Links 1 9 GENERAL INFORMATION 9 CHASSIS ITEM Rapier4so Front suspension Independent double wishbone coil spring and oil damped Rear suspension Swingarm type coil spring and oil damped Steering angle 37 right amp left Caster 7 3 Trail 34 mm 1 34 in Toe in when apply to a load 75 kg 165 Ibs 0 5mm 0 0 2 in Camber 0 Front brake Disk brake twin Rear brake Disk brake Front tire size 21 x 7 10 Rear tire size 20 x 11 9 9 ELECTRICAL ITEM Rapier450 Ignition type gniter type Ignition timing 6 B T D C at 1 500 rpm Spark plug CR8E Battery 12V 8Ah MF Fuse 15A 55W Head lamp LO 55W POSITION 5W Brake Tail lamp LED type Turn signal lamp 10W x 4 Speedometer lamp LCD type
14. 3 45 ENGINE GEARSHIFT CAM FORK AND REVERSE LOCK SHAFT Install the gearshift forks into the gearshifting grooves in the correct position and direction D Gearshift fork No 1 Gearshift fork No 2 8 Gearshift fork No 3 Install the gearshift Install the gearshift fork shaft NOTE After the gearshift fork shaft and gearshift forks have been fitted make sure that the gears engage normally Set the transmission gears to the neutral posi tion 9 CRANKCASE Thoroughly remove the sealant material and oil stains on the mating surface of the right and left crankcases Install the dowel pins to the crankcase Apply engine oil to the conrod big end and to the transmission gears Apply BOND 1215 to the mating surface of the crankcase BOND 1215 Tighten the crankcase bolts to the specified torque V Crankcase bolt 11 N m 1 1 kgf m After the crankcase bolts have been tightened check if the crankshaft countershaft and drive shaft rotate smoothly If a large resistance is felt to rotation try to free the shafts by tapping them with a plastic hammer ENGINE 3 46 3 47 ENGINE GEAR POSITION SWITCH Install the springs D contacts and new O ring 9 Install the gear position switch and tighten the bolts to the specified torque V Gear position switch bo
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16. Engine coolant capacity 1 40 8 21 SERVICING INFORMATION 9 ELECTRICAL Ignition timing STANDARD BTDC 6 1 500rpm Unit mm in Spark plug CR8E Hot type 0 7 0 8 0 028 0 032 CR7E Standard type CR8E Cold type CR9E Spark performance Over 8mm 0 32 Magneto coil resistance Magneto no load voltage Pick up coil 90 1109 Charging coil 0 3 0 8Q Over 70V 5 000 rpm Battery standard charging voltage 13 5 15 0V 5 000 rpm Battery Type YTX9 BS Capacity 12V 8Ah Standard elec trolyte S G 1 320 at 20 C 68 F Fuse size 15A WATTAGE Head lamp License plate lamp HI SERVICING INFORMATION 8 22 Unit W SPECIFICATION LO POSITION SW Brake Tail lamp LED type Turn signal lamp 10W x 4 Speedometer lamp LCD type Neutral indicator lamp 3 4W Turn signal indicator lamp Right amp left High beam indicator lamp 3 4W Coolant temperature indicator lamp Fuel indicator lamp Reverse indicator lamp LED Light Emitting Diode LCD Liquid Crystal Display CAUTION Do not use except the specified bulb Wattage 8 23 SERVICING INFORMATION 9 SUSPENSION Unit mm in ANDARD Swingarm pivot shaft runout 0 6 0 024 Maximum Softest 280 11 0 Front suspension spri
17. e Tighten the exhaust pipe nuts 2 muffler connect ing bolt 3 and muffler mounting bolts 4 to the specified torque V Exhaust pipe nut 23 m 2 3 kgf m Muffler connecting bolt 23 N m 2 3 kgf m Muffler mounting bolt 23 N 2 3 kgf PERIODIC MAINTENANCE 2 4 2 5 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect Interval Inspect Initially at 1 month and Every 6 months thereafter Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification if necessary Remove the seat Refer to page 7 3 Remove the center front fender D center rear fender and front fender Remove the fuel tank Remove the spark plug Disconnect the oil tank overflow hose 4 breather hose Remove the cylinder head cover The valve clearance specification is different for both intake and exhaust valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are removed for servicing Remove the valve timing inspection plug Remove the magneto cover cap 2 using the special tool Cap plug wr
18. 1215 Apply THREAD LOCK 1324 to the thread portion of the rear axle shaft THREAD LOCK 1324 Tighten the inner axle shaft inner nut to the specified torque 9 Axle shaft nut inner 120 150 N 12 0 15 0 kgf Apply THREAD LOCK 1324 to the thread portion of the rear axle shaft THREAD LOCK 1324 e Tighten the rear axle outer nut 3 to the specified torque V Axle shaft nut outer 120 150 N m 12 0 15 0 kgf CHASSIS 7 72 T T3 CHASSIS Install the rear wheel hubs Refer to page 7 11 Install the rear wheels Refer to page 7 12 Adjust the chain slack Refer to page 2 21 Tighten the rear axle housing nuts and wrench bolts to the specified torque in the described order Refer to page 2 21 V Rear axle housing nut 70 100 N m 7 0 10 0 kgf Rear axle housing wrench bolt 40 60 N m 4 0 6 0 kgf m Install the rear caliper and tighten the caliper mounting bolts to the specified torque V Rear caliper mounting bolt 18 28 N m 1 8 2 8 kgf m SERVICING INFORMATION CONTENTS TROUBLESHOOTING RR RR mmm SPECIAL TOOLS fetu ded Fallon ee TIGHTENING TORQUE ent edo WIRE AND CABLE ROUTING WIRING mnm 8 1 SERVICING INFORMATIO
19. 7 9 CHASSIS m REAR WHEEL HUB Remove the rear wheel Remove the cotter pin and loosen the wheel hub nut by applying the rear brake Remove the wheel hub nut and washer Remove the rear wheel hub INSPECTION AND DISASSEMBLY DUST SEAL Inspect the dust seal lips for wear or damage If any damages are found replace the dust seal with a new one Remove the spacer Remove the dust seal with the special tool Oil seal remover 09913 50121 A CAUTION Replace the removed dust seal with a new one HUB BEARINGS Inspect the inner race play of the hub bearing by hand while it is in the wheel hub Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If there is anything unusu al replace the bearing with a new one play play Remove the hub 1 CHASSIS 7 10 CAUTION Do not reuse the removed bearings REASSEMBLY AND REMOUNTING FRONT WHEEL HUB Apply SUPER GREASE A to the hub bearing AG SUPER GREASE Install the hub bearings and spacer into the front wheel hub NOTE Install the inner bearing first and then install the spacer and the outer bearing 2 Install the dust seal 5 into the front wheel hub with fabric portion facing to outside Apply SUPER GREASE to the d
20. I TOOL 79 ocket tester 09900 25002 ELECTRICAL SYSTEM 6 8 cvi E 6 9 ELECTRICAL SYSTEM STARTER SYSTEM STARTER SYSTEM DESCRIPTION Sr Clutch lever position A Ignition switch SWitc switch Starter relay Battery This ATV can only start the engine with pulling the clutch lever STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire With loosening the bolts D remove the starter motor Remove the starter motor STARTER MOTOR INSPEC TION m CARBON BRUSH Inspect the carbon brush for abnormal wear crack or smoothness in the brush holder If any damage are found replace the brush assembly with a new one COMMUTATOR Inspect discoloration abnormal wear or undercut of the commutator If the commutator is abnormally worn replace the armature with a new one When surface is discolored polish it with 400 sand paper and clean it with dry cloth E ARMATURE COIL INSPECTION Check continuity between each segment Check continuity between each segment and the armature shaft If there is no continuity between the segments or there is continuity between the segment and shaft replace the starter motor with a new one Pocket tester 09900 2
21. IG switch A C generator Battery 1 1 1 1 1 LOAD 2 INSPECTION m CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the DC voltage between the battery terminal andO If the voltage is not within the specified value check the magneto no load performance and regulator rectifier A CAUTION When making this test be sure that the battery is full charged condition IG switch Nei 13 57 15 0V at 5 000 rpm Pocket tester 09900 25002 Regulator Rectifier m MAGNETO NO LOAD PERFORMANCE Disconnect the three lead wires from the magneto terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the voltage is under the specified value replace the magneto with a new one Standard NO load per Over 70 V at 5 000 rpm for mance of magneto Pocket tester 09900 25002 E REGULATOR RECTIFIER Remove the rear fender Refer to page 7 5 Remove the regulator rectifier Using the pocket tester 1 MQ range measure the resistance between the terminals in the follow ing table If the resistance checked is incorrect replace the regulator rectifier Unit Tester probe a
22. Low air pressure in front tires Adjust heavy or stiff Tie rod ends tending to seize Replace Linkage connections tending to seize Repair or replace Unequally inflated tires Regulate Loose front wheel hub nuts Tighten Damaged or worn front wheel hub bearings Replace P Worn or loose tie rod ends Replace or tighten Steering wobbles Defective or incorrect front tires Replace Damaged or worn suspension arms and related bearings Replace Distorted front wheels Replace Loose chassis nuts and bolts Tighten Unequally inflated tires Regulate Steering pulls to Improper front wheel alignment Adjust Worn front wheel hub bearings Replace Repair or replace Replace Shocks felt in the steering Tires rapidly or unevenly wear High tire pressure Worn steering linkage connections Loose suspension system bolts Worn or loose front wheel hub bearings Improper front wheel alignment Regulate Replace Tighten Replace Adjust Steering too noisy Front suspension too soft Loose nuts and bolts Damaged or worn front wheel hub bearings Insufficiently lubricated Shock absorber leaks oil Tighten Replace Lubricate Replace Replace Front suspension too stiff Bent shock absorber rod Worn upper or lower suspension arms and related bearings Tighten Replace Suspension too noisy Loose suspension system bolts Worn suspension arms and related bearings Wor
23. N PERIODIC MAINTENANCE 2 12 2 13 PERIODIC MAINTENANCE 5 Install the radiator cap securely 6 After warming up and cooling down the engine several times add the engine coolant until the level is between the upper and lower lines on the engine coolant reservoir tank A CAUTION Repeat the above procedure several times and make sure the radiator is filled with the engine coolant to the upper line of the engine coolant reservoir tank Engine coolant capacity 1 40 including reserve RADIATOR HOSES Inspect Interval Inspect Every 6 months Replace Every 4 years Inspect the radiator hoses for damage and engine coolant leakage If any damages are found replace the radiator hoses with new ones SPARK ARRESTER Inspect Interval Clean Every 6 months Remove the spark arrester 1 Clean the spark arrester pipe by brush Reinstall the spark arrester pipe A WARNING Only clean the spark arrester in an open area away from combustible materials Exhausted hot carbon particles can start a fire CLUTCH Inspect Interval Inspect Initially at 1 month and Every 6 months thereafter basis adjustment be allowed by the clutch lever adjuster Loosen the clutch lever adjuster lock nut and turn the clutch lever adjuster in or out to pro vide the specified play e After adjustment tighten the lock
24. ON 248 113 235 Multi circuit tester set 09900 25008 If the resistance noted to show infinity or too much different resistance value replace the water tempera ture switch with a new one INSTALLATION Install the water temperature switch in the reverse order of removal Pay attention to the following points Install a new O ring and apply engine coolant to the O ring Tighten the water temperature switch to the speci fied torque V Water temperature switch 13 N 1 3 kgf m Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Install the front fender CAUTION Take special care when handling the water temperature switch It may cause damage if it gets a sharp impact Do not contact the water temperature switch 1 and the column thermometer with a pan 5 9 COOLING SYSTEM THERMOSTAT REMOVAL Remove the front fender Refer to page 7 3 Drain engine coolant Refer to page 2 12 Place a rag under the thermostat case Remove the thermostat case cap Remove the thermostat 9 INSPECTION Inspect the thermostat pellet for signs of cracking Test the thermostat at the bench for control action in the follwing manner Pass a string between flange as shown in the photograph Immerse the thermostat in the WATER contained in
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26. 2 Weakened or broken valve springs 3 Worn down piston pin or piston pin bore 4 Piston rings or ring groove worn Noise seems to come from camshaft drive chain 1 Stretched camshaft drive chain 2 Worn camshaft sprockets 3 Cam chain tensioner adjuster not working Noise seems to come from clutch 1 Worn splines of countershaft or hub 2 Worn teeth of cluth plates 3 Distorted clutch plates driven and drive Noise seems to come from crankshaft 1 Worn or broken bearings 2 Big end bearings worn and broken 3 Thrust clearance too large Clean Clean Clean Adjust Replace Adjust Replace Replace Replace Replace Replace Replace Replace Replace Repair or replace Replace Replace Replace Replace Replace Replace Complaint Noisy engine SERVICING INFORMATION 8 2 Symptom and possible causes Noise seems to come from transmission 1 2 Gears worn or rubbing Badly worn splines 3 Primary gears worn or rubbing 3 Badly worn bearings Noise seems to come from water pump 1 2 Too much play on pump shaft bearing Worn or damaged impeller shaft Contact between pump case and impeller Replace Replace Replace Replace Replace Replace Replace Slipping clutch Clutch control out of adjustment or too much play Weakened clutch springs Worn or distorted pressure plate Distorted clutch pl
27. 7 bear ings from the suspension arm Remove the dust caps dust seals 7 bearings and spacers from the suspension arm INSPECTION AND DISASSEMBLY m FRONT SHOCK ABSORBER Inspect the shock absorber for oil leakage or dam age If any damages are found replace the front shock absorber with a new one Inspect the bearings spacers and dust seal for wear or damage If any damages are found replace the shock absorber with a new one CAUTION Do not attempt to disassemble the front shock absorber It is unserviceable KNUCKLE Inspect the knuckle for damage If any damages are found replace the knuckle with a new one KNUCKLE END Inspect the knuckle end boot for wear or damage If any damages are found replace the knuckle end with a new one Inspect the knuckle end for smooth movement If there are any abnormalities replace the knuckle end with a new one m SUSPENSION ARM Inspect the suspension arm for wear or damage If any damages are found replace the suspension arm with a new one CHASSIS 7 24 7 25 CHASSIS SUSPENSION PIVOT BEARING Inspect the dust seal lips and spacers for wear and damage If any damages are found replace them with new ones Inspect the bearings for play If excessive play is found replace them with a new one BRAKE DISK COVER Ins
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29. ON ON OFF CAUTION Take special care when handling the thermo switch It may cause damage if it gets a sharp impact Do not contact the cooling fan thermo switch D and the column thermometer 2 with a pan 5 7 COOLING SYSTEM 9 INSTALLATION Install the cooling fan thermo switch in the reverse order of removal Pay attention to the following points Install a new O ring 1 and apply engine coolant to the O ring Tighten the cooling fan thermo switch to the speci fied torque 9 Cooling fan thermo switch 13 N 1 3 kgf Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Install the front fender COOLING SYSTEM 5 8 WATER TEMPERATURE SWITCH 9 REMOVAL Remove the front fender Refer to page 7 3 Drain engine coolant Refer to page 2 12 Disconnect the water temperature switch lead wire coupler Remove the water temperature switch 1 9 INSPECTION Check the engine coolant temperature by testing it at the bench as shown in the figure Connect the water temperature switch 1 to a circuit tester and place it in the WATER contained in a pan which is placed on a stove Heat the water to raise its temperature slowly and read the column thermometer and the ohmmeter Water temperature switch Standard operating temperature Approx 120 C OFF
30. Radiator Thermostat 5 Cooling fan thermo switch 6 Water temperature switch RADIATOR 9 REMOVAL Remove the front fender Refer to page 7 3 Drain engine coolant by removing the drain bolt Disconnect the cooling fan thermo switch lead wire coupler and water temperature switch lead wire coupler 3 Disconnect the radiator inlet hose and outlet hose 4 5 3 COOLING SYSTEM Disconnect reserve tank hose Disconnect the cooling fan motor lead wire cou pler Remove the radiator by the mounting bolts INSPECTION AND CLEANING Road dirt or trash stuck to the fins must be removed Use of compressed air is recommended for this cleaning Fins bent down or dented can be repaired by straightening them with the blade of a small screw driver INSPECTION OF WATER HOSE Remove the front fender Refer to page 7 3 Any water hose found in a cracked condition or flat tened or water leaked must be replaced Any leakage from the connecting section should be corrected by proper tightening REMOUNTING The radiator reassembly can be performed in the reverse order of disassembly procedures However the following points must be observed in the reassembly operation Install the radiator with the specified torque V Radiator mounting bolt 8 12 m 0 8 1 2 kgf m Pour engine coola
31. to the brake disk bolts and tighten them to the specified torque THREAD LOCK 1324 V Brake disk bolt 18 28 N m 1 8 2 8 kgf m 7 19 CHASSIS MASTER CYLINDER DISAS SEMBLY Drain brake fluid out of the master cylinder Disconnect the brake lamp switch lead wire cou pler Remove the union CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts Remove the two mounting bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm Detach the dust seal boot 2 and remove the cir clip Pull out the piston cup set 3 and spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston surface for any scratches or other damage MASTER CYLINDER REASSE MBLY AND REMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly Pay attention to the following points CAUTION Wash the master cylinder components with new brake fluid before reassembly When washing the components use the speci fied brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Brake fluid specification and classification DOT 4 NOTE When installi
32. to thread part of the throttle stop screw then install the throttle stop screw to the carburetor AG SUPER GREASE REMOUNTING Remount the carburetor assembly in the reverse order of removal Pay attention to the following points Align the lug on the carburetor with intake pipe s cutout Connect the carburetor hoses properly After the carburetor assembly has been remount ed onto the engine perform the following adjust ment Throttle cable adjustment Refer to page 2 9 Idle speed adjustment Refer to page 2 9 COOLING SYSTEM CONTENTS ENGINE COOLANT 226645 Stee Gas COOLING CIRCUIT rre ae COOLING THERMO SWITCH WATER TEMPERATURE SWITCH OIL TANK AND HOSES 5 eem 5 1 COOLING SYSTEM ENGINE COOLANT At the time of manufacture the cooling system is filled with a 50 50 mixture of distilled water and ethylene glycol anti freeze This 50 50 mixture will provide the optimum corro sion protection and excellent heat protection and will protect the cooling system from freezing at tempera tures above 31 C 24 If the vehicle is to be exposed to temperatures below 31 C 24 F this mixing ratio should be increased up to 5596 or 6096 according to the figure CAUTION Use a high quality ethylene glycol base anti freeze mixed with distilled water Do not
33. window or the upper limit line Replace the master cylinder cap to prevent dirt from entering Attach a hose to the air bleeder valve and insert the free end of the hose into a receptacle Squeeze and release the brake lever or the brake pedal several times in rapid succession and squeeze the lever or push down the pedal fully without releasing it Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip or the brake pedal reaching bottom of the stroke Then close the air bleeder valve pump and squeeze the brake lever or push down the pedal and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles NOTE While bleeding the brake system replenish the brake fluid in the master cylinder as necessary Make sure that there is always some fluid visible in the master cylinder Close the air bleeder valve and disconnect the hose Fill the master cylinder with brake fluid to the top of the inspection window or the upper limit line 9 Brake caliper air bleeder valve 9 44N m 0 9 1 4 kgf A CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc PERIODIC MAINTENANCE 2 18 BRAKE HOSES Inspect Interval
34. CHAIN GUIDE Check the cam chain for wear damage and kinked or binding links If any defects are found replace it with a new one Check the cam chain guide for wear and damage If it is found to be damaged replace it with a new one PISTON AND PISTON RING PISTON DIAMETER INSPECTION Measure the outside diameter of piston in the direc tion perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer If the measurement is found less than the service limit replace the piston Service limit Piston diameter 95 88 mm 3 7748 in Micrometer 75 100 mm 09900 20204 f PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calcu late the difference between the cylinder bore and out side diameter of the piston Standard Service limit 0 050 0 060 mm 0 120 mm 0 0020 0 0024 in 0 0048 in Piston to cylinder clearance 18mm 0 71 PISTON PIN HOLE BORE Using a dial calipers measure the piston pin hole bore both the vertical and horizontal directions If the measurement exceeds the service limit replace the piston with a new one Piston pin hole bore 19 030 0 7492 Dial calipers 09900 20605 PISTON PIN DIAMETER INSPECTION Using a micrometer measure the piston pin outside diameter at three position both the ends and the cente
35. CHASSIS CONTENTS EXTERIOR PARTS n Re n LN PRIMER FRONT AND REAR WHEELS FRONT BRAKE se eos E EU Lastest tu FRONT SUSPENSION RII STEERING aS fos DAN REAR BRAKE nie bn REAR SHOCK REAR SUSPENSION 7 1 CHASSIS EXTERIOR PARTS 9 CONSTRUCTION CHASSIS 7 2 7 3 CHASSIS REMOVAL SEAT Remove the seat by pulling the lock release lever which is located behind the rear fender FRONT FENDER Disconnect the head lamp coupler Remove the seat Refer to above Remove the center front fender mounting bolts Remove the center front fender 3 Remove the fuel tank cap Remove the center rear fender mounting bolts Remove the center rear fender 5 Remove the four steering head cover bracket bolts Remove the front fender mounting bolts Remove the front fender D Remove the side 2 left and right m FOOTREST MUDGUARD Remove the mudguards CHASSIS 7 4 7 5 CHASSIS m FOOTREST Remove the footrest mudguards Refer to page 7 4 Remove the footrests REAR FENDER Remove the seat Refer to page 7 3 Remove the
36. IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in procedures BREAK IN ENGINE SPEEDS Initial 10 hours Less than 1 2 throttle After the engine has been operated for 10 hours the engine to full throttle operation for short periods of time Do not maintain constant engine speed for an extended period during any portion of the break in Try to vary the throttle position 1 7 GENERAL INFORMATION EXTERIOR ILLUSTRATION HLGIM L 1 265mm WHEEL BASE 1 810mm LENGTH Sr W r NE CE i i LHOIZH SPECIFICATIONS DIMENSIONS AND DRY MASS GENERAL INFORMATION 1 8 ITEM Rapier450 Overall length 1 810 mm 71 3 in Overall width 1 160 mm 45 7 in Overall height 1 165 mm 45 9 in Wheelbase 1 265 mm 49 8 in Ground clearance 290 mm 11 4 in Dry mass 220 kg 485 Ibs ENGINE ITEM Rapier4so Type Four stroke DOHC Liquid cooled
37. Inspect Every 6 months Replace Every 4 years Check the brake hoses for leakage crack wear and damage If any damages are found replace the brake hoses with new ones TIRES Inspect Interval Inspect Every 3 months m TIRE TREAD CONDITION Operating the vehicle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification Front and Service limit tire tread depth 4 mm 0 16 in ui TIRE PRESSURE If the tire pressure is too high or too low steering will be adversely affected and tire wear will increase Therefore maintain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows COLD INFLATION TIRE PRESSURE To minimize the possibility of tire damage from inflation l h ONE PERSON TWO PERSONS over inflation strongly recommended t at a manual type air pump be used rather than a high 0 3 kgf cm 0 35 kgf cm pressure air compressor as found in service sta FRONT 30 kPa 35 kPa tions When filling air into the tires never exceed 4 4 psi 4 9 psi 250 kPa 2 5 kgf cm 36 psi 0 3 kgf cm 0 35 kgf cm REAR 30 kPa 35 kPa 4 4 psi 4 9 psi AN CAUTION VEHICLE LOAD CAPACITY LIMIT 150 kg 330 7 Ibs The standard tire fitte
38. License plate lamp 5W CAPACITIES ITEM Rapier4so Fuel tank 80 change 2 500 ml With filter change 2 600 ml Overhaul 2 700 ml Coolant 1 40 The specifications are subject to change without notice PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 1 PERIODIC MAINTENANCE CHART d LUBRICATION POINTS ient tse DoD MAINTENANCE PROCEDURES 2 2222 2 3 P TER imr TTE I Qm I UTE EXHAUST PIPE NUTS AND MUFFLER BOLTS o 2 4 VALVE CLEARANCE erae pae Lee geld dre tit ii M SPARK PLUG dirai reine v eria dei Dak THROTTLE CABLE PLAY 5 rti diana a ear iiir 2 ENGINE IDLE SPEED tierna xen a nta ek 250 ENGINE OIL AND OIL FILTER cs 2 10 ENGINE OIL HOSES i rinm le o pel i bx i e Ree 211 ENGINE COOLANT nda de bed veh Ded RADIATOR HOSES a ae e equ iens 2219 SPARK ARRESTER HH eMe eee 2 13 BRAKE FLUID dh natio has FC sa ok Adare ones nave 216 BRAKE HOSES etit Np RR eb or rd vie e esa 19978 DRIVE CHAIN 68 hem cum tbc TE HR sities GR SENATE CAR YET endo bn tus 2520 SUSPENSIONS tonne tante Bebe apud e ica Ma Ke 2229 CHASSIS BOLTS AND NUTS HIR IH 2 23 COMPRESSION PRESSURE
39. The engine serial number is stamped on the left downside of the crankcase assembly These numbers are required especially for registering the machine and ordering spare parts FRAME SERIAL NUMBER 9 ENGINE SERIAL NUMBER GENERAL INFORMATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATIONS FUEL Gasoline used should be graded 91 octane Research Method or higher An unleaded gasoline type is recom mended 9 ENGINE OIL ENGINE OIL SPECIFICATION Classification system Over SL 10W 40 ENGINE OIL X If an SAE 10W 40 motor oil is not available select an alternative according to the following chart 30 20 40 0 10 20 30 40 22 4 14 32 50 68 86 104 Temperature Use a premium quality 4 stroke motor oil to ensure longer service life of your vehicle A WARNING Don t mix the unrecommended oil It could damage the engine lt When refilling the oil tank don t allow the dust to get inside Wipe the spilled oil up immediately Don t put the patch on the cap It could disturb the oil to be provided and damage the engine BRAKE FLUID m Specification and classification Front brake DOT4 Rear brake DOT4 WARNING Since the brake system of this vehicle is filled with a glycol based brake fluid by the manufacturer do not use or mix different types of fluid such as silicone based and petroleum based fluid f
40. a amp Ww f OU 09407 20406 SPEEDO SENSOR BRAKE HOSE HORN r vm zy 8 29 SERVICING INFORMATION HEAD LAMP 09407 22402 POSITION LAMP lt N THERMO SWITCH x FAN MOTOR A N FAN SWITCH OI DS xxm SANGLIER Le We Crea ST 52 CN MNAM WS NN NT Y NN N THERMO SWITCH NUR N SET Ge WATER TEMP SWITCH RADIATOR FAN HARNESS WELDING CLAMP HARNESS WELDING CLAMP HARNESS 09407 20406 SPEEDO SENSOR pic b T 5 SPEEDOMETER SENSOR SENSOR MAGNETO VIEW A HANDLE LOCK KEY HANDLE LOCK POSITION ILLUSTLATION SERVICING INFORMATION 8 30 09407 14403 RR BRAKE S W 09407 14403 RR BRAKE S W VIEW C REAR BRAKE POSITION ILLUSTLATION HANDLE S W LH SPEEDOMETER 09407 20406 FRONT BRAKE SWITCH 09407 20406 HANDLE SWITCH LH CLUTCH LEVER SWITCH 8 31 SERVICING INFORMATION WELDING CLAMP 36618 30610 TUBE TAIL amp STOP LAMP LICENSE LAMP TURN SIGNAL LAMP RH TURN SIGNAL LAMP LH SERVICING INFORMATION 8 32 WIRING DIAGRAM
41. a beaker as shown in the illustration Note that the immersed thermostat is in suspen sion Heat the water by placing the beaker on a stove and observe the rising temperature on a ther mometer 3 Read the thermometer just when opening the ther mostat This reading which is the temperature level at which the thermostat valve begins to open should be within the standard value Thermostat valve Standard operation temperature Valve opening 76 C 169 F Valve closing 71 C 160 F COOLING SYSTEM 5 10 Keep on heating the water to raise its tempera ture Just when the water temperature reaches speci fied value the thermostat valve should have lifted by at least 8 0 mm 0 32 in Standard Over 8 0 mm at 90 C Over 0 32 in at 194 F Thermostat valve lift thermostat failing to satisfy either of the two requirements start to open temperature and valve lift must be replaced with a new one 9 INSTALLATION Install the thermostat in the reverse order of removal Pay attention to the following points Apply engine coolant to the rubber seal on the thermostat Install the thermostat Install the thermostat case cap Tighten the thermostat case bolts to the specified torque V Thermostat case bolt 10 N m 1 0 kgf m Pour engine coolant Refer to page 2 12 Bleed air from the cooling c
42. and lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft sprocket The exhaust camshaft sprocket has arrow marked 1 D Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head Engage the cam chain with the exhaust camshaft sprocket The other arrow marked 2 should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 2 count out 15 roller pins from the exhaust camshaft side going towards the intake camshaft side Engage the 15th roller pin on the cam chain with the arrow marked 3 on the intake sprocket Refer to the following illustrations NOTE The cam chain should now be on all three sprockets Be careful not to move the crankshaft until the camshaft housing and cam chain tensioner are secured 3 57 ENGINE SHAFT ROTATIONAL DIRECTION a E Install the dowel pins Place each camshaft housing and cam chain guide into the correct position ENGINE 3 58 NOTE Camshaft housing marked EX are for the exhaust side and those marked IN are for the intake side Tighten the camshaft housing bolts to the speci fied torque V Camshaft housing bolt 10 N m 1 0 kgf m NOTE When tightening the camshaft housing bolts the piston p
43. brake switch so the brake light comes on when the brake pedal is depressed 7 10 mm 0 3 0 4 in PARKING BRAKE Parking brake adjustment may be required if the parking brake does not work properly Every time the brake pads are replaced adjust the parking brake Park the on level ground Check the front wheels e Lift the rear end of the and place a block under swingarm Loosen the parking brake adjuster lock nut Q Loosen the parking brake adjuster Loosen the parking brake cable adjuster lock nut D 9 Turn the adjuster Y so that the cable length D is 54 58 mm 2 1 2 3 in PERIODIC MAINTENANCE 2 16 Tighten the parking brake cable adjuster lock nut Then turn the parking brake adjuster 1 8 1 4 back Tighten the parking brake adjuster lock nut while holding the parking brake adjuster in position V Parking brake adjuster lock nut 18 N m 1 8 kgf A CAUTION After adjusting the parking brake check that there is no dragging when turning the rear wheel with the wheel off the ground BRAKE FLUID Inspect Interval Inspect Every 3 months Replace Every 2 years BRAKE FLUID LEVEL Place the handlebar straight Check the brake fluid level by observing the lower limit line on the front brake master cylinder When the brake fluid level is below the
44. lever holder aligned with punch mark on the handlebar Connect the clutch cable rear brake cable and clutch switch Adjust each cable play Refer to page 2 9 2 13 and 2 15 Install the throttle case to the handlebar with the mating surface of throttle case aligned with the punch 5 Tighten the throttle case bolts to the specified torque V Throttle case bolt 5 N m 0 5 kgf m Install the brake master cylinder Refer to page 7 20 CHASSIS 7 40 9 TOE IN ADJUSTMENT Adjust the toe in as follows Place the vehicle on level ground and set the han D 2 2 D dlebar straight Make sure all the tires are inflated to the standard pressure Refer to page 2 18 Place 75 kg 165 Ibs of weight the seat eS EN me Loosen the lock nuts D on each tie rod 7 ARD r A CAUTION The lock nuts D have left hand threads Tire side Forward Tire side Measure the distances and B between the front wheels Subtract the measurements of from the measurements of to find the toe in If the toe in is not within specification adjust the tie rod to the right or left until the toe in is within the specified range Standard Toe in 0 5 mm 0 0 2 in When apply to a load 75 kg 165 Ibs NOTE amp Toe in Temporarily tighten the four
45. links Missing O ring seals If any defects are found the drive chain must be replaced Damage to the drive chain means that the sprocket may also be damaged If any defects are found the sprocket must be replaced PERIODIC MAINTENANCE 2 20 Normal wear Excessive wear NOTE When replacing the drive chain replace the drive chain and sprockets as a set CHECKING Place the vehicle on a level ground Loosen the two rear axle housing nuts and two rear axle housing wrench bolts Tense the drive chain fully by turning chain adjuster 2 21 PERIODIC MAINTENANCE Count out 21 pins 20 pitches on the chain and measure the distance between the two points If the distance exceeds the service limit the chain must be replaced Drive chain 20 pitch length 319 4 mm 12 58 in ADJUSTING Loosen or tighten chain adjuster until there is 30 40 mm 1 2 1 6 in of slack at the middle of the chain between the engine and rear sprockets as shown Standard Drive chain slack 30 40 mm 1 2 1 6 in After adjusting the drive chain tighten the rear axle housing nuts and wrench bolts in the described order to the specified torque V Rear axle housing nut 70 100 N m 7 0 10 0 kgf m Rear axle housing wrench bolt 40 60N m 4 0 6 0 kgf m
46. lock nuts Check that the distances O and D are equal as pU shown If the distances are not equal adjust the tie rod to the right or left until the toe in is within specifica tion Check the toe in again by measuring distances ae Right Ta L 2 D If the toe in is not within specification repeat the Forward adjustment as above until the proper toe in is obtained and distances and D become equal After adjustment has been made tighten the four lock 1 to the specified torque 9 Tie rod lock nut 29 N m 2 9 kgf 7 41 CHASSIS REAR BRAKE 9 CONSTRUCTION s WARNING This brake system is filled with an ethylene glycol based DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When cleaning brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disk or brake pad reduces braking performance Discard contaminated pads and clean the disk with high quality brake cleaner or neutral detergent CAUTIO
47. lower limit line replenish with brake fluid that meets the fol lowing specification Specification and classification DOT 4 WARNING The brake system of this vehicle is filled with a glycol based brake fluid Do not use or mix dif ferent types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unsealed contain ers Never reuse brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted sur faces Check the brake hoses and hose joints for cracks and oil leakage before riding 2 17 PERIODIC MAINTENANCE AIR BLEEDING OF THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cush ion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever pedal and also by lack of braking force Considering the danger to which such trapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake System to the normal condition the brake fluid circuit be purged of air in the following manner e Fill the front or rear brake master cylinder with the specified brake fluid to the top of the inspection
48. measure the camshaft runout using the dial gauge If the runout exceeds the service limit replace the camshaft with new one Camshaft runout 0 10 mm 0 004 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 CYLINDER CYLINDER DISTORTION Check the gasketed surface of the cylinder for distor tion using a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straight edge exceeds the limit replace the cylinder Cylinder distortion 0 05 0 002 Thickness gauge 09900 20806 m CYLINDER BORE Measure the cylinder bore diameter at six place If any one of the measurements exceeds the limit overhaul the cylinder and replace the cylinder Standard Service limit Td IEEE 96 000 96 015mm 96 075 mm 3 7795 3 7801 in 3 7825 in Cylinder gauge set 09900 20508 CAM CHAIN TENSION ADJUS TER AND TENSIONER m CAM CHAIN TENSION ADJUSTER Check that the push rod slides smoothly with the lock shaft handle clockwise If it does not slide smoothly replace the cam chain tension adjuster with a new one m CAM CHAIN TENSIONER Check the contacting surface of the cam chain ten sioner If itis worn or damaged replace it with a new one ENGINE 3 28 3 29 ENGINE m CAM CHAIN AND CAM
49. mix an alcohol base anti freeze and different brands of anti freeze Do not put in more than 60 anti freeze or less than 50 Refer to Right figure Do not use a radiator anti leak additive 50 Engine coolant including reserve tank capacity Anti freeze 0 70 Water 0 70 Anti freeze density 55C 67 F 32 0 14 10 4 20 e D 22 30 D 40 40 o 58 50 76 60 we 94 70 n 20 40 60 80 100 Density 96 Fig 1 Engine coolant density freez ing point curve CE CO 302 150 284 140 158 2 S 266 130 o9 9 24 248 120 05 o 230 110 212 100 0 10 20 30 40 50 60 Density Fig 2 Engine coolant density boiling point curve A WARNING Coolant is harmful x Keep it away from children You can be injured by scalding fluid or steam if you open the radiator cap when the engine is hot After the engine cools wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allow pressure to escape and then turn the cap all the way off The engine must be cool before servicing the cooling system x If it comes in contact with skin or eyes flush with water x If swallowed accidentally induce vomiting and call physician immediately COOLING SYSTEM 5 2 COOLING CIRCUIT CD Impeller Radiator cap
50. nut and cover the rubber boot D If not adjust by the adjuster loosen the clutch cable adjuster lock nut Turn the clutch cable adjuster in or out to pro vide the specified play After adjustment tighten the lock nut The clutch cable should be lubricated with a light weight oil whenever it is adjusted CE 10 15 mm 0 4 0 6 in BRAKES Inspect Interval Inspect Initially at 1 month and Every 3 months thereafter E BRAKE PADS Remove the front and rear wheels Refer to page 7 8 The extent of brake pad wear can be checked by observing the limit line on the side of brake pads When the wear reaches the limit line replace the pads with new ones Refer to page 7 14 and 7 42 A CAUTION Replace the brake pads as a set otherwise brak ing performance will be adversely affected m REAR BRAKE PEDAL The procedure for adjusting the rear brake pedal is as follows PERIODIC MAINTENANCE 2 14 REAR BRAKE 2 15 PERIODIC MAINTENANCE Remove the rear master cylinder pin Turn the adjuster in or out until the pedal play to the specification after loosening the lock nut D Make sure to tighten the lock nut D securely 0 10 mm 0 0 4 in 9 Rear brake master cylinder rod lock nut 10 20 N 1 0 2 0 kgf Adjust the
51. pad spring and pads Refer to page 7 42 CHASSIS 7 46 7 47 CHASSIS Tighten the caliper mounting bolts and brake hose union bolt V Brake caliper mounting bolt 18 28 N m 1 8 2 8 kgf Brake hose union bolt 40 60 N m 4 0 6 0 kgf m NOTE Before remounting the brake caliper push the brake caliper piston all the way into the caliper CAUTION The removed brake hose washers should be replaced with new ones in order to prevent leakage of brake fluid Bleed air from the system after after reassem bling the brake caliper Refer to page 2 17 Install the parking brake housing and new gas ket Apply THREAD LOCK 1324 to the parking brake bolts and tighten them to the specified torque THREAD LOCK 1324 9 Parking brake housing bolt 28 N m 2 8 kgf m When replacing the boot with a new one apply SILICONE GREASE to the groove of parking brake axle AH SILICONE GREASE Loosen the lock nuts 4 6 and turn the adjusters in completely so that the cable play is max imum Connect the parking cable Install the adjuster and the lock nut Adjust the parking brake Refer to page 2 15 BRAKE DISK REMOVAL AND REMOUNTING Remove the rear wheel Refer to page 7 8 Remove the rear axle Refer to page 7 67 Remove the brake disk Install the brake disk to the re
52. piston rings Piston ring groove clearance Service limit 0 150 mm 0 006 in 0 150 mm 0 006 in Piston ring groove width Standard 1 21 1 23 mm 0 0476 0 0484 in 1 01 1 03 mm 0 040 0 041 in 2 01 2 03 mm 0 079 0 080 in Standard 1 170 1 190 mm 0 0461 0 0469 in 0 970 0 990 mm 0 0382 0 0390 in Piston ring thickness Micrometer 0 25 mm 09900 20201 Thickness gauge 09900 20806 CONROD CONROD SMALL END INSIDE DIAME TER INSPECTION Using a dial calipers measure the conrod small end inside diameter both in vertical and horizontal direc tions If any of the measurements exceeds the service limit replace the conrod Standard 19 006 19 014 mm 19 040 mm 0 7483 0 7486 in 0 7496 in Dial calipers 09900 20605 Conrod small end I D CONROD DEFLECTION INSPECTION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod Turn the conrod and see if it moves smoothly without play and noise This method can also be used to check the extent of wear on the parts of the conrod s big end Conrod deflection 3 0mm 0 12 in ENGINE 3 32 Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 CONROD BIG END SIDE CLEARANCE INSPECTION Push the big end of the conrod to one side and mea sure the side clearance using a thickness gau
53. s right side INSPECTION AND DISASSEMBLY i SPROCKET Inspect the sprocket teeth for wear If they are worn as shown replace the engine sprocket rear sprocket and drive chain as a set Normal wear Excessive wear 7 69 CHASSIS m REAR AXLE SHAFT Measure the rear axle shaft runout If the runout exceeds the service limit replace the rear axle shaft with a new one Rear axle shaft runout 6 mm 0 24 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 NOTE _ Dial gauge When measuring the runout support the rear axle shaft at 34 mm 1 34 in diameter of the rear axle shaft as shown in illustration Measure the runout at 40 mm 1 57 in diameter of the rear axle shaft as shown in illustration DUST SEAL Inspect the dust seals for wear or damage If any defect are founds replace the dust seal with a new one m AXLE BEARINGS Inspect the play of the wheel bearings by finger while they are in the axle housing Rotate the inner race by finger to inspect for abnor mal noise and smooth rotation Replace the bearing with a new one if there is any thing unusual REASSEMBLY AND REMOUNT ING Reassemble the rear axle shaft and rear axle hous ing in the reverse order of removal and disassembly Pay attention to the following points m REAR SPROKET Install the rear sprocket to the sprocket flange
54. specified torque V Exhaust pipe nut 23 N m 2 3 kgf Muffler mounting bolt 23 N m 2 3 kgf Muffler connecting bolt 23 m 2 3 kgf Install the engine sprocket with drive chain after loosening the chain adjuster Apply THREAD LOCK 1324 to the sprocket bolts THREAD LOCK 1324 Tighten the engine sprocket bolts to the specified torque V Engine sprocket bolt 11 7 13 N m 1 1 1 3 kgf Install the engine coolant hose Install the O ring to the engine oil outlet hose Tighten the engine oil outlet hose bolt securely Tighten the engine oil inlet hose union bolts to the specified torque V Engine oil inlet hose union bolt 23 N m 2 3 kgf m After installing the engine route the wiring har ness cables and hoses properly Refer to page 8 26 to 8 31 Adjust the following items x Engine Refer to page 2 1 Necessary amount of engine oil Oil change 2 500 m Oil and filter change 2 600 md Engine overhaul 2 700 m0 Engine oil type Over SL Adjust the drive chain slack Refer to page 2 21 Throttle cable play 2 9 Engine idle Refer to page 2 9 Clutch cable play Refer to page 2 13 ENGINE 3 8 3 9 ENGINE ENGINE DISASSEMBLY Remove the starter m
55. system Replace the battery Recharge the battery fully and adjust electrolyte specific gravity Replace the electrolyte recharge the battery and then adjust specific gravity Replace the battery Reversed battery polarity Battery sulfation The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction 1 Charging rate too low or too high When not in use batteries should be recharged at least once a month to avoid sulfation 2 Battery electrolyte excessive or insufficient or its specific gravity too high or too low 3 The battery left unused for too long in cold climate Replace the battery and be sure to connect the battery properly Replace the battery Keep the electrolyte up to the prescribed level or adjust the specific gravity by consulting the battery maker s directions Replace the battery if badly sulfated Battery discharges too rapidly 1 Dirty container top and sides 2 Impurities in the electrolyte or electrolyte specific gravity is too high Clean Change the electrolyte by consulting the battery maker s directions 8 7 SERVICING INFORMATION 9 CHASSIS Complaint Symptom and possible causes one side Distorted frame or suspension Defective shock absorber Improper front wheel alignment Adjust Handling is too Insufficiently lubricated Lubricate
56. the level is below upper limit line add oil to that level The vehicle must be in a level position for accurate measurement 2 11 PERIODIC MAINTENANCE A CAUTION Necessarily confirm and clean the oil strainer when replace the engine oil specially when first replacement A CAUTION More frequent servicing may be performed on vehicle that are used under severe conditions OIL FILTER REPLACEMENT Drain the engine oil as described in the engine oil replacement procedure Replace the oil filter 1 with a new one Add new engine oil and check the oil level as described in the engine oil replacement proce dure Necessary amount of engine oil Oil change 2 500 ml Oil and filter change 2 600 ml Engine overhaul 2 700 mQ Engine oil type SA WAM API Over SL A CAUTION When reassembling the oil filter make sure that the oil filter is installed If the filter is installed improperly serious engine damage may result ENGINE OIL HOSES Inspect Interval Inspect Initially at 1 month and Every 3 months thereafter Inspect the engine oil hoses for damage and oil leak age If any damages are found replace the engine oil hoses with new ones ENGINE COOLANT Inspect Interval Replace Every 2 years m ENGINE COOLANT CHECK Check the engi
57. ventilated and away from fire or sparks 4 1 FUEL SYSTEM FUEL TANK REMOVAL WARNING Gasoline is highly flammable and explosive Keep heat sparks and flames away from gasoline Remove the seat side covers Refer to page 7 3 4 Remove the fuel tank mounting bolts Disconnect the fuel 5 2 Remove the fuel tank Drain fuel completely 9 REMOUNTING Remount the fuel tank in the reverse order of removal FUEL COCK 9 REMOVAL Remove the fuel tank Drain fuel completely Remove the fuel cock 9 INSPECTION If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss of engine power may result Clean the fuel filter with compressed air Also check the fuel cock for cracks REMOUNTING Remount the fuel cock in the reverse order of removal FUEL SYSTEM 4 2 CAUTION Tighten the fuel cock bolts evenly FUEL PUMP 9 REMOVAL Remove the seat and fuel tank Disconnect the fuel hoses and vacuum hose Remove the fuel pump mounting bolts 9 INSPECTION A WARNING Gasoline is very explosive Extreme care must be taken Disconnect the fuel hose 3 connect the suitable hose and insert the free end of the hose into a receptacle Check the fuel flow when starting the engine for a few seconds by pressing the starter switch
58. 0 8 1 2 kgf m Cooling fan motor mounting bolt 8N 0 8 kgf m Install the radiator Route the radiator hoses properly Pour engine coolant Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 Install the front fender Fan motor Battery Ammeter COOLING SYSTEM 5 6 COOLING FAN THERMO SWITCH The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo switch The thermo switch remains open when the temperature of the engine coolant is low but closes when the tempera ture reaches approximately 88 C 1907 setting the cooling fan in motion 9 REMOVAL Remove the front fender Refer to page 7 3 Drain engine coolant Refer to page 2 12 Disconnect the cooling fan thermo switch lead wire coupler Remove the cooling fan thermo switch 9 INSPECTION Check the thermo switch closing or opening tem peratures by testing it at the bench as shown in the figure Connect the thermo switch to a circuit tester and place it in the OIL contained in a pan which is placed on a stove Heat the oil to raise its temperature slowly and read the column thermometer 2 when the switch closes of opens Cooling fan thermo switch Standard operating temperature Approx 95 C 203 F Approx 88 C 190 F Multi circuit tester set 09900 25008 OFF
59. 008 in 2 0 Exhaust valve Aa mm 0 008 0 012 in Intake valve Inspect the tappet for wear and scratch If modification or scratch is present replace the tappet When you checked the valve clearance if the valve clearance is wide please replace the present shim into thick one if the valve clearance is nar row please replace the present shim into thin shim Refer to page 8 33 34 f SHIM KIND There are 49 kinds of shim which thickness is increased by each 0 025 mm from 2 30 mm to 3 50 mm ENGINE 3 24 3 25 ENGINE VALVE HEAD RADIAL RUNOUT Support the valve using a v block and measure the valve head radial runout using the dial gauge as shown If the runout exceeds the service limit replace the valve with a new one Valve head radial runout 0 35 mm 0 014 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 ui VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two direc tions X and Y perpendicular to each other Position the dial gauge as shown If the deflection exceeds the service limit determine whether the valve or the guide should be replaced with a new one Valve stem deflection Service limit 0 35 mm 0 014 in 0 35 mm EX 0 014 in Dial gauge 09900 20606 Magnetic stand 09900 20701 VALVE
60. 2 24 OIL PRESSURE Du E 2 1 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the vehicle operating at peak performance and economy CAUTION More frequent servicing should be performed on vehicles that are used under severe conditions PERIODIC MAINTENANCE CHART ENGINE Interval Initial 1month Every 3 months Every 6 months page Air cleaner element ES Clean 2 3 Exhaust pipe nuts and muffler bolts Tighten Tighten 2 4 Valve clearance Inspect m Inspect 2 5 Spark plug inspect 2 8 Replace every 18months Fuel hose inspec 2 9 Replace every 4 years Engine oil and oil filter Replace Replace 2 10 Engine oil hoses Inspect Inspect 2 11 Throttle cable Inspect Inspect 2 9 Idle speed Inspect Inspect 2 9 Clutch Inspect Inspect 2 13 Engine coolant Replace every 2 years 2 12 Radiator hoses lispegt 2 13 Replace every 4 years Spark arrester Clean 2 13 m CHASSIS Interval Initial 1 month Every 3 months Every 6 months page Drive chain Inspect every time before riding 2 20 Brakes Inspect Inspect 2 14 Brake hoses neper 2 18 Replace every 4 years Brake fluid nopee 2 16 Replace every 2 years Tires Inspect
61. 3 7748 Cylinder or cylinder head distortion a 0 05 0 002 1st Approx 11 0 0 433 Piston ring free end gap 2nd Approx 10 0 0 394 7 1st 0 25 0 40 0 010 0 016 0 5 0 020 Piston ring end gap Assembly condition 2nd 0 40 0 55 0 016 0 022 0 7 0 028 1st 0 150 0 006 Piston ring to groove clearance 2nd 0 150 0 006 1st 1 21 1 23 0 0476 0 0484 Piston ring groove width 2nd 1 01 1 03 0 040 0 041 Oil 2 01 2 03 0 079 0 080 1st 1 170 1 190 0 0461 0 0469 Piston ring thickness 2nd 0 970 0 990 0 0382 0 0390 Piston pin hole bore 19 002 19 008 0 7481 0 7484 19 030 0 7492 Piston pin O D 18 992 18 995 0 7477 0 7478 18 980 0 7472 9 OIL PUMP SERVICING INFORMATION 8 16 ANDARD Oil pressure 1 0 3 0 kgf cm at 60 3 000 rpm Oil pump reduction ratio 9 CLUTCH STANDARD 1 3 45 34 Unit mm in Clutch cable play 10 15 0 4 0 6 1 2 92 3 08 0 115 0 121 2 62 0 103 Drive plate thickness 2 342 3 58 0 135 0 141 3 12 0 123 NO 1 15 9 16 0 0 626 0 630 15 1 0 595 Drive plate claw width 2 15 9 16 0 0 626 0 630 15 1 0 595 Driven plate distortion 0 1 0 004 Clutch spring free length 54 2 2 134 51 6 2 032 8 17 SERVICING INFORMATION 9 CAMSHAF
62. 5002 ELECTRICAL SYSTEM 6 10 Segment S J 6 11 ELECTRICAL SYSTEM STARTER MOTOR REASSEMBLY Reassemble the starter motor Pay attention to the following points Reassembly the starter motor as shown in the illustration amp Align the match mark on the housing with the line on the housing end Apply SUPER GREASE to the O ring and remount the starter motor AG SUPER GREASE ELECTRICAL SYSTEM 6 12 SWITCHES Measure each switch for continuity using a tester If any abnormality is found replace the respective switch assemblies with new ones Pocket tester 09900 25002 HAZARD WARNING SWITCH OFF 6 13 ELECTRICAL SYSTEM LAMPS 9 HEAD LAMP CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure HEAD LAMP BULB REPLACE MENT Remove the front fender bolts Move the front fender upward to get enough space to remove the head lamp bulb Remove the dust cover 1 and socket spring After removing the bulb at socket replace the new bulb To install the head lamp reverse the abo
63. D Place the vehicle on the level ground and support the vehicle with a jack or wooden block Remove the cushion lever cover Remove the cushion rod Remove the cushion lever REAR SWINGARM Remove the cushion rod and cushion lever Refer to above Remove the rear shock absorber Refer to page 7 54 Remove the rear wheels Refer to page 7 8 Remove the rear axle and axle housing Refer to page 7 67 CHASSIS 7 60 7 61 CHASSIS Remove the brake hose Loosen the swingarm pivot nut and remove the swingarm pivot shaft Remove the swingarm assembly Remove the chain buffer CHASSIS 7 62 INSPECTION AND DISASSEMBLY i SPACER Remove the seals D and spacers 2 from the swingarm Remove the spacers from the cushion lever and cushion rod Inspect the spacers for any flaws or other dam age If any defects are found replace the spacers with new ones ui DUST SEAL Inspect the dust seals for wear or damage If any defect are found replace them with new ones 7 63 CHASSIS m SWINGARM BEARING AND BUSHING Insert the spacer D into the bearing bushing and then check the play when moving the spacer up and down If excessive play is noted replace the bearing and bushing with a new one m CUSHION LEVER BEARING AND CUSHION ROD BEARING Insert the spacer into th
64. FOREWORD GROUP INDEX This manual contains an introductory description on HYOSUNG Rapier450 and procedures for its inspection service and overhaul of its main compo nents Other information considered as generally known is PERIODIC MAINTENANCE not included Read GENERAL INFORMATION section to familiar ize yourself with outline of the vehicle and MAINTE NANCE and other sections to use as a guide for ENGINE proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum FUEL SYSTEM and quick service GENERAL INFORMATION This manual has been prepared on the basis of the latest specification at the time of publication COOLING SYSTEM If modification has been made since then difference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the ELECTRICAL SYSTEM basic principles of operation and work proce dures They may not represent the actual vehicle exact CHASSIS ly in detail A WARNING SERVICING INFORMATION This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer CF HYOSUNG COPYRIGHT HYOSUNG MOTORS amp MACH
65. HASSIS REMOVAL m HANDLEBAR Remove the front fender Refer to page 7 3 Remove the master cylinder assembly from the handlebar Refer to page 7 19 Remove the throttle lever Disconnect the parking brake cable and the clutch cable 4 Remove the clutch switch 5 Remove the handlebar switch box 6 Remove the speedometer Remove the harness clamps Remove the steering head cover bracket and the handlebar CHASSIS 7 32 STEERING SHAFT AND TIE ROD Drain engine oil and coolant Refer to page 2 10 and 2 12 Remove the radiator assembly Refer to page 5 2 Disconnect the oil hoses and overflow hose f Remove the oil tank Refer to page 5 17 18 Remove the cotter pins and tie rod end nuts CAUTION Replace the removed cotter pins with new ones Remove the tie rods 7 33 CHASSIS Remove the cotter pin and steering shaft nut 2 and washer CAUTION Replace the removed cotter pins with new ones Remove the O ring Remove the steering shaft holder cotter pin Remove the steering shaft holder bolts Remove the cable hose guide and the steering shaft holder Remove the steering shaft Remove the bushing and the dust seal from the steering s
66. INERY INC 2007 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections is listed on the previous page as GROUP INDEX select the section where you are looking for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively SYMBOL DEFINITION SYMBOL DEFINITION Q 2 1 torque DE PAPPI THREAD LOCK RER oil unless otherwise specified APPI OUSE Brake AGH Apply SUPER GREASE i ra Measure in voltage range ACH Apply SUPER GREASE C Measure in resistance range AH Apply SILICONE GREASE Measure in current range An Apply MOLY PASTE s Use special tool Apply BOND 1215 LLC Use engine coolant FORK Use fork oil NOTE Difference between photographs and actual vehicles depends on the markets GENERAL INFORMATION CONTENTS INFORMATION LABELS HR GENERAL PRECAUTIONS SERIAL NUMBER LOCATION
67. If the fuel flow is not found check the fuel cock Refer to page 4 1 If the fuel cock and hoses are not fault replace the fuel pump 9 REASSEMBLY Carry out the assembly procedure in the reverse order of disassembly Tighten the fuel pump mounting bolts Connect the fuel hoses 3 and vacuum hose 5 securely FUEL HOSE ROUTING Fuel hose To carburetor Fuel hose To fuel cock Vacuum hose To intake pipe 4 3 FUEL SYSTEM CARBURETOR 9 CONSTRUCTION FUEL SYSTEM 4 4 9 LOCATION OF CARBURETOR I D NO The carburetor is stamped on the location on the carburetor as shown in the right photo REMOVAL Remove the left side cover Refer to page 7 4 Disconnect the fuel hosed Loosen the carburetor clamp screw Remove the carburetor side cap 4 5 FUEL SYSTEM Disconnect the throttle cable Remove the O ring 9 DISASSEMBLY Remove the fuel hose 3 and air vent hoses A Remove the throttle stop screw 5 Remove the choke lever Remove the carburetor top CAUTION Do not use compressed air on the carburetor body removing the diaphragm this may damage the diaphragm Remove the spring D along with the diaphragm assembly Remove the je
68. Install the cotter pins CAUTION Replace the removed cotter pins with new ones CAUTION The lock nuts D with a narrow width have left hand threads i OIL TANK AND RADIATOR Install the oil tank Refer to page 5 18 Reinstall the radiator assembly Refer to page 5 4 Pour engine oil Refer to page 2 11 Pour engine coolant and bleed air from the cooling circuit Refer to page 2 12 f HANDLEBAR Assemble the handlebar 2 handlebar clamp 3 and steering head cover bracket NOTE The higher portion of handlebar clamp must face forward so that the clearance of holder is in back of the handlebar Align the punch mark on the handlebar with the mating surface of handlebar clamp e First tighten the bolt to the specified torque and then tighten the bolt to the specified torque V Handlebar clamp bolt 18 28 N m 1 8 2 8 kgf m CHASSIS 7 38 lt Forward 7 39 CHASSIS Install the speedometer Install the handle switch box with the lug on the switch half inserted into the hole on the handle bar NOTE When installing the handlebar make sure that the cable wiring harness and brake hose routing are proper Refer to page 8 26 to 31 Install the clutch lever assembly to the handlebar with the mating surface of clutch
69. N Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will dam age them severly 9 BRAKE PAD REPLACEMENT Flatten the lock washer and then slightly loosen the pad mounting pins 2 Loosen the lock nut and turn out the parking brake adjuster several turns Remove the caliper by removing the caliper mounting bolts 5 Remove the brake pads by removing the pad mounting pins CAUTION Do not operate the brake pedal while dis mounting the pads Replace the brake pads as a set otherwise braking performance will be adversely affected Install the new brake pad NOTE Before installing the new pads inspect the pad mounting pins for wear If excessive wear is found replace them with new ones Be sure to loosen the parking brake adjuster before installing the pads Tighten the pad mounting pins to the specified torque and then bend the lock washer V Rear brake pad mounting pin 18 28 N m 1 8 2 8 kgf m NOTE After replacing the brake pads pump the brake pedal several times to check for proper brake operation and then check the brake fluid level CHASSIS 7 42 7 43 CHASSIS Tighten the caliper mounting bolts to the specified torque V Brake caliper mounting bolt 18 28 N m 1 8 2 8 kgf m Adjust the parking brake Refer t
70. N TROUBLESHOOTING 9 ENGINE Complaint Engine will not start or is hard to start Symptom and possible causes Compression too low Valve clearance out of adjustment Worn valve guides or poor seating of valves Valves mistiming Piston rings excessively worn Worn down cylinder bore Poor seating of spark plug Starter motor cranks but too slowly NOOR WD Plug not sparking 1 Fouled spark plug 2 Wet spark plug 3 Defective ignition coil 4 Open or short circuit in high tension cord 5 Defective magneto 6 Defective igniter No fuel reaching the carburetor 1 Clogged hole in the fuel tank cap Clogged or defective fuel cock Defective carburetor float valve Clogged fuel pipe Adjust Repair or replace Adjust Replace Replace or rebore Retighten Consult electrical complaints Clean or replace Clean and dry Replace Replace Replace Replace Clean Clean or replace Replace Clean or replace Engine stalls easily Noisy engine Fouled spark plug Clogged fuel hose Clogged jets in carburetor Valve clearance out of adjustment Defective CDI unit ak ND Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down camshaft Noise appears to come from piston 1 Piston or cylinder worn down
71. NGINE 3 12 NOTE If the cylinder does not come off easily lightly tap it using a plastic hammer Remove the cylinder gasket and dowel pins 3 13 ENGINE Place a clean rag over the cylinder base to pre vent the piston pin circlip from dropping into the crankcase Remove the piston pin circlip Draw out the piston pin and remove the piston Remove the magneto Remove the dowel pins and gasket 2 Remove the clutch cover ENGINE 3 14 NOTE When remove or inspect the clutch drive and driv en plate remove only the clutch pressure cover Remove the dowel pins and gasket Loosen the clutch spring mounting bolts working in diagonal stages Remove the bolts and springs Remove the clutch pressure disk Remove the clutch drive plates No 1 and driven plates Remove the spring washer and spring washer seat Remove the clutch drive plate No 2 3 15 ENGINE Remove the clutch push piece push rod 2 Flatten the clutch sleeve hub washer Hold the clutch sleeve hub using the special tool and then remove the clutch sleeve hub Clutch sleeve hub holder 09920 53710 Remove the clutch sleeve hub 5 Remove the primary driven gear asse
72. PERIODIC MAINTENANCE A CAUTION To avoid damaging the cylinder head threads first finger tighten the spark plug and then tight en it to the specified torque using the spark plug wrench Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque 9 Spark plug 11 N m 1 1 kgf m FUEL HOSE Inspect Interval Inspect Every 3 months Replace Every 4 years Inspect the fuel hose for damage and fuel leakage If any damages are found replace the fuel hoses with a new one THROTTLE CABLE PLAY Inspect Interval Inspect Initially at 1 month and Every 3 months thereafter Adjust the throttle cable play as follows Loosen the lock nut N of the throttle cable Turn the adjuster in or out to obtain the correct play LOUER TER JEANS 3 5 mm 0 12 0 20 in e After adjusting the throttle cable play tighten the lock nut ENGINE IDLE SPEED Inspect Interval Inspect Initially at 1 month and Every 3 months thereafter NOTE Make this adjustment when the engine is hot Connect the engine tachometer to the high ten sion cord e Start the engine and set the engine idle speed between 1 300 and 1 500 rpm by turning the throt tle stop screw PERIODIC MAINTENANCE 2 10 Engine idle speed 1 300 1 500 rpm Engine tachometer 09900 26006 ENGINE OIL AND OIL FILTER Inspec
73. Remove the O rings 5 13 COOLING SYSTEM Remove the E ring from the impeller shaft Remove the impeller from the other side Remove the bearing NOTE If there is no abnormal noise bearing removal is not necessary INSPECTION m BEARING Inspect the play of the bearing by hand while it is in the water pump case Rotate the inner race by hand to inspect abnormal noise and smooth rotation Replace the bearing if there is anything unusual BEARING CASE Visually inspect the bearing case for damage Replace the water pump body if necessary IMPELLER Visually inspect the impeller and its shaft for damage 9 REASSEMBLY AND INSTAL LATION Install the water pump in the reverse order of removal Pay attention to the following points e Install the bearing Apply SUPER GREASE to the impeller shaft a SUPER GREASE Install the impeller to the water pump body COOLING SYSTEM 5 14 5 15 COOLING SYSTEM Fix the impeller shaft with the E ring 1 e Fill the bearing with engine oil until engine oil comes out from the hole of the bearing housing Apply engine coolant to the O ring 2 Install a new O ring CAUTION Use a new O ring to prevent engine coolant leakge Install the rear brake master cylinder mo
74. ST PROCEDURE Check the oil pressure in the following manner Remove the oil check plug D and install the adapter of oil pressure gauge at the removed position Connect an engine tachometer Warm up the engine as follows Summer 10 min at 2 000 rpm Winter 20 min at 2 000 rpm After warming up the engine increase the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Engine tachometer 09900 26006 Oil pressure gauge 09915 74511 pressure gauge adaptor 09915 74532 V Engine oil check plug 18N m 1 8 kgf m ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL o reae lr apa sees a eei ee ENGINE REMOUNTING Ea E HERE ENGINE DISASSEMBLY ENGINE COMPONENT INSPECTION AND SERVICE CYLINDER HEAD 6053 re Rex P ERR RU awe PEE RIDE CAM CHAIN TENSION ADJUSTER AND TENSIONER PISTON AND PISTON RING HMM HR CRANK BALANCER AND BALANCER DRIVE GEAR TRANSMISSION er ru eese Due Reo CLUTCH COVER Muni pU Os ENGINE REASSEMBLY CAUTION Mark an identification of assembly location on each removed part so that each will be restored to the original position during rea
75. STEM DIAMETER Measure the valve stem outside diameter using the micrometer If the diameter measured exceeds the standard replace the valve Valve stem diameter Standard 4 975 4 990 mm 0 1959 0 1965 in 4 955 4 970 mm 0 1951 0 1957 in Micrometer 0 25 mm 09900 20201 ui VALVE SPRING The force of the coil spring keeps the valve seat tight A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by mea suring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the valve spring is not within specification replace both the inner and outer springs as a set Valve spring free length Service limit 36 9 mm 1 45 in 39 9 mm 1 57 in Vernier calipers 09900 20101 Valve spring tension Standard 6 5 7 1 kgf Inner 14 3 15 7 Ibs at length 32 0 mm 1 26 in 12 0 14 0 kgf 26 5 30 9 Ibs at length 35 5 mm 1 40 in m CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out put power Any of these abnormality could be caused by a worn camshaft m CAMSHAFT WEAR Worn down cams
76. T CYLINDER HEAD Unit mm in STANDARD IN 39 98 40 02 1 574 1 576 39 88 1 570 Cam height EX 39 98 40 02 1 574 1 576 39 88 1 570 Camshaft O D IN amp EX 21 959 21 980 0 8645 0 8654 Camshaft housing ID 7 22 012 22 025 0 8666 0 8671 Camshaft journal oil clearance 0 15 0 006 0 10 0 004 Camshaft runout mn Cylinder head cover distortion 0 05 0 002 Cam chain pin Arrow 3 15th pin CONROD CRANKSHAFT Unit mm in ANDARD Conrod small end 1 19 006 19 014 0 7483 0 7486 19 040 0 7496 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 65 0 004 0 026 1 0 0 040 Conrod big end width 24 95 25 00 0 982 0 984 ET Crank web to web width 71 0 1 2 795 0 004 Crankshaft runout 0 05 0 002 TRANSMISSION DRIVE BELT Primary reduction ratio STANDARD SERVICING INFORMATION 8 18 Unit mm in 2 500 75 30 Secondary reduction ratio 3 143 44 14 Gear ratio 2 538 33 13 2nd 1 684 32 19 3rd 1 261 29 23 ey 4th 1 040 26 25 ERES 5th 0 885 23 26 Reverse 2 231 29 13 Shift fork to groove clearance Shift fork groove width NO 1 amp NO 2 0 10 0 30 0 004 0 012 4 85 5 00 0 191 0 197 NO 3 4 85 5 00 0 191 0 197 Shift fo
77. adjuster D fully for S or H direction counter clockwise or clockwise Count the number of turns from the fully turned in position Fully turned in H direction or clockwise provides stiffest compression damping force and turning S direction or counter clockwise the adjuster will soft en compression damping force Rear shock absorber Standard remem 12 turn from end of S force adjuster direction counter clockwise 2 Tension damping force To adjust the tension damping force turn in the adjuster fully for S or direction counter clockwise or clockwise Count the number of turns from the fully turned in position Fully turned in H direction or clockwise provides stiffest tension damping force and turning 5 direc tion or counter clockwise the adjuster will soften tension damping force Rear shock absorber Standard tension damping force 14 tum from end of S adjuster direction counter clockwise STANDARD REAR SHOCK ABSORBER DAMPING FORCE PS Turn to 5 direction counter clockwise Turn to 5 direction counter clockwise Standard 14 turn from end of S direction counter clockwise 14 turn from end of S direction counter clockwise Turn to H direction clockwise Turn to H direction clockwise 7 59 CHASSIS REAR SUSPENSION CONSTRUCTION 9 REMOVAL CUSHION LEVER AND CUSHION RO
78. aft 09900 20701 Magnetic stand With using dial gauge 09910 32812 Crankshaft installer Used to install the crankshaft in the crankcase Special tools Part Number Part Name Description 09910 36000 Cap plug wrench Used to install or remove the magneto cover cap SERVICING INFORMATION 8 10 Special tools Part Number Part Name Description 09916 14510 Valve spring compressor Used to remove and remounting valve stem 09913 50121 Oil seal remover Used to remove the oil seal 09916 14520 Valve spring compressor attachment Used with valve spring compressor 09913 70122 Bearing installer Used to drive bearing in 09920 13120 Crankcase separator Separate to crankcase 09913 75820 Bearing installer Used to drive bearing in 09920 53710 Clutch sleeve hub holder Used to install or remove clutch sleeve hub nut 09913 76010 Bearing installer Used to drive bearing in 09921 20200 Bearing remover 10mm Used to remove bearing with the rotor remove sliding shaft 09913 80112 Bearing installer Used to drive bearing in 09921 20210 Bearing remover 12mm Used to remove bearing with the rotor remove sliding shaft 09915 64511 Compression gauge Measure cylinder compression 09923 73210 Bearing remover 17mm Used to remove bearing with the rotor remove sliding shaft
79. age If any damages are found replace the steering shaft holders with new ones CHASSIS 7 36 REASSEMBLY AND REMOUNTING Reassemble and remount the steering shaft in the reverse order of removal and disassembly Pay attention to the following points STEERING SHAFT Apply SUPER GREASE A to the O ring dust seals and steering shaft before remounting the steering shaft SUPER GREASE Install the dust seal D and bushing to the steering shaft e Install the new O ring and washer to the steering shaft Tighten the steering shaft nut to the specified torque V Steering shaft nut 49 N 4 9 kgf m Install the cotter pin CAUTION Replace the removed cotter pin with a new one Apply SUPER GREASE to the dust seals and sliding surface of the steering shaft holders before remounting the steering shaft holders AG SUPER GREASE 7 37 CHASSIS Tighten the steering shaft holder bolts to the spec ified torque V Steering shaft holder bolt 18 28 N m 1 8 2 8 kgf m NOTE Make sure that the wiring harness cables and brake hose routing are properly Refer to page 8 26 to 8 31 Install the steering shaft holder cotter pin TIE ROD Tighten the tie rod end nuts to the specified torque V Tie rod end nut 22 35 N m 2 2 3 5 kgf m
80. ame manner above In case of valve adjustment which is not the tappet shim selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 270 2 70 select 295 2 95 mm of the shim which 270 2 70 mm of the shim add up the excess clearance 0 25 mm when adjust with the standard 0 15 as the intake standard clear ance 0 1 0 2 mm A CAUTION If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning of valve clearance SPARK PLUG Inspect Every 6 months Replace Every 18 months Disconnect the spark plug cap and remove the spark plug CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug If carbon is deposited remove it using a wire or pin with a pointed end SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If the spark plug gap is out of specification adjust the gap Spark plug gap 0 7 0 8 mm 0 028 0 032 Thickness gauge 09900 20806 m ELECTRODE Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the spark plug with a new one And also replace the spark plug if it has a broken insulator damaged thread etc PERIODIC MAINTENANCE 2 8 0 7 0 8 mm 0 028 0 032 in 2 9
81. and or cup 8 9 SERVICING INFORMATION SPECIAL TOOLS Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09900 20101 Vernier Calipers Used to conveniently measure various dimensions 09900 20806 Thickness gauge Measure clearance of piston ring 09900 20201 Micrometer 0 25mm 09900 21109 Torque wrench Used for precise measurement 00 25mm measure ranges Measure torque of tightening 09900 20202 Micrometer 25 50mm 09900 21304 V block Used for precise measurement 25 50mm measure ranges With using magnetic stand 09900 20203 Micrometer 50 75mm Used for precise measurement 50 75mm measure ranges 09900 22401 Small bore gauge Measure inside diameter of conrod small end 09900 20204 Micrometer 75 100mm 09900 25002 Pocket tester Used for precise measurement 75 100mm measure ranges Measure voltage electric current resistance 09900 20508 Cylinder gauge set 09900 25008 Multi circuit tester set Measure inside diameter of cylinder Inspect thermo switch or temperature switch 09900 20605 Dial calipers 09900 26006 Engine tachometer Meassure width of conrod big end Measure rotational frequency of engine 09900 20606 Dial gauge 09910 20115 Conrod holder Meassure oscillation of wheel with using magnetic stand Used to lock the cranksh
82. ar axle CHASSIS 7 48 NOTE Make sure that the disk is free of any greasey matter Apply THREAD LOCK 1324 to the brake disk bolts and tighten them to the specified torque THREAD LOCK 1324 V Brake disk bolt 18 28 N m 1 8 2 8 kgf m Install the rear axle Refer to page 7 70 Install the rear wheel Refer to page 7 12 BRAKE DISK INSPECTION amp Refer to page 7 18 7 49 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY Drain the brake fluid Refer to page 7 43 Place a rag underneath the brake hose union bolt on the master cylinder to catch any split brake fluid Remove the brake hose union bolt 1 and discon nect the brake hose A CAUTION Immediately wipe off any brake fluid contacting any part of the vehicle The brake fluid reacts chemically with paint plastics rubber materials etc and will damage them severely Remove the rear master cylinder Loosen the master cylinder rod lock nut Turn the adjuster 5 Remove the master cylinder mounting bolt Remove the master cylinder by turning the master cylinder rod 2 Disconnect the reservoir tank hose 8 9 MASTER CYLINDER INSPECTION i Refer to page 7 20 PRESSURE CONTROL VALVE REMOVAL Drain the brake fluid Place a rag underneath the brake hose union bolt on the pressure control valve to catch any split
83. ar wheel Tighten the wheel set nuts to the specified torque V Wheel set nut 39 2 58 8 N m 3 92 5 88 kgf m ON ROAD type NOTE When installing the rear wheel make sure that the arrow on the tire points in the direction of rotation m TIRE i Refer to page 2 18 7 13 CHASSIS FRONT BRAKE CONSTRUCTION WARNING This brake system is filled with an ethylene glycol based DOT4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based brake fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long periods When storing brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disk or brake pad reduces braking performanec Discard contaminated pads and clean the brake disk with high quality brake cleaner or a neutral detergent A CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will dam age them severly 9 BRAKE PAD REPLACEMENT Remove the front wheel Refer to page 7 8 Remove the brake caliper mounting bolts and brak
84. are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts if found it worn down to the limit Cam height Service limit Intake cam 39 88 mm 1 570 in ENGINE 3 26 Intake open B T D C 270 Intake close A B D C BDC 180 Exhaust close A T D C 90 Exhaust open B B D C Micrometer 25 50 mm 09900 20202 3 27 ENGINE m CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place Use the plastigauge to read the clearance at the widest portion which is specified as follows Camshaft journal oil clearance IN amp EX 0 15 mm 0 006 in If the camshaft journal oil clearance exceeds the ser vice limit measure the inside diameter of the camshaft housing and outside diameter of the camshaft journal Replace the camshaft or the cylin der head and camshaft housing depending upon which one exceeds the specification Camshaft housing I D Standard 22 012 22 025 mm Small bore gauge 09900 22401 Camshaft O D Standard 21 959 21 980 mm Micrometer 0 25 mm 09900 20201 m CAMSHAFT RUNOUT Support the valve using a V blocks and
85. ates driven and drive Adjust Replace Replace Replace Dragging clutch Transmission will not shift Transmission will not shift back Clutch control out of adjustment or too much play Weakened clutch springs Distorted clutch plates driven and drive Broken gearshift cam Distorted gearshift forks Worn gearshift pawl Broken return spring on shift shaft Shift shafts are rubbing or sticky Distorted or worn gearshift forks Adjust Replace Replace Replace Replace Replace Replace Repair Replace Transmission jumps out of gear Worn shifting gears on driveshaft or countershaft Distorted or worn gearshift forks Weakened stopper pawl spring on gearshift cam Worn gearshift pawl Replace Replace Replace Replace Engine idles poorly Valve clearance out of adjustment Poor seating of valves Defective valve guides Defective pick up coil Spark plug gap too wide Defective ignition coil resulting in weak sparking Float chamber fuel level out of adjustment in carburetor Clogged jets Adjust Replace Replace Replace Adjust or replace Replace Adjust Clean Engine runs poorly in high speed range Valve springs weakened Valve timing out of adjustment Worn cams Spark plug gap too narrow Defective ignition coil Float chamber fuel level too low Clogged air
86. battery plate Disconnect the battery lead wires Remove the battery 2 l i 2 i KRG EN Fall ur Remove the rear fender mounting bolts Remove the rear fender _ S t mm ee I IVA 31 REMOUNTING Remount the exterior parts in the reverse order of removal Pay attention to the following points FOOTREST Apply THREAD LOCK 1324 to the bolts and tighten bolts to the specified torque THREAD LOCK 1324 7 Footrest mounting bolt 40 60 m 4 0 6 0 kgf m MUDGUARD BRACE Apply THREAD LOCK 1324 to the mudguard brace bolts 2 THREAD LOCK 1324 CHASSIS 7 6 7 7 CHASSIS FRONT AND REAR WHEELS 9 CONSTRUCTION REMOVAL FRONT AND REAR WHEELS Place the vehicle on level ground Support the vehicle with a jack or wooden block Remove the wheel E FRONT WHEEL HUB Remove the front wheel Refer to above Remove the front hub plate Remove the cotter pin then loosen the wheel hub nut Remove the wheel hub nut and washer Remove the front brake caliper Refer to page 7 15 Remove the front wheel hub CHASSIS 7 8 CAUTION Do not operate the brake lever while removing the caliper Remove the disk Refer to page 7 18
87. brake fluid Remove the brake hose union bolts and discon nect the brake hoses PRESSURE CONTROL VALVE REASSEMBLY Reassemble the pressure control valve in the reverse order of removal MASTER CYLINDER REASSEM BLY AND REMOUNTING Refer to page 7 20 Reassemble and remount the master cylinder in the reverse order of removal and disassembly Pay attention to the following point Apply MOLY PASTE to the master cylinder push rod ACH MOLY PASTE Install the master cylinder rod lock nut adjuster and rear master cylinder Tighten the master cylinder rod lock nut mas ter cylinder mounting bolts and brake hose union bolt to the specified torque V Rear brake master cylinder rod lock nut 10 20 N m 1 0 2 0 kgf m Rear brake master cylinder mounting bolt 8 12 N m 0 8 1 2 kgf m Brake hose union bolt 40 60 N m 4 0 6 0 kgf m CHASSIS 7 50 CAUTION The removed brake hose washers should be replaced with new ones Bleed air from the system after reassembling the brake master cylinder Refer to page 2 17 7 51 CHASSIS 9 REVERSE CABLE REMOVAL Remove the reverse lever assembly 1 from the bracket Remove the reverse cable mounting screw Remove the 2 Remove the screw Remove the reverse 1 Disconnect the cable by removing the spool
88. brake fluid circuit Pads worn down Too much play on brake lever or pedal Oil adhesion on friction surface of pads Worn disk SERVICING INFORMATION 8 8 Refill to level mark Bleed air out Replace Adjust Clean disk and pads Replace Insufficient brake power Worn pads Oil adhesion of engaging surface of pads Worn disk Air in hydraulic system Leakage of brake fluid from hydraulic system Repair or replace Replace Clean disk and pads Replace Bleed air Brake squeaking Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Loosen front wheel axle or rear wheel axle Worn pads Foreign material in brake fluid Clogged return port of master cylinder NOOR WN Repair surface with sandpaper Modify pad fitting Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Excessive brake lever stroke 1 Air in hydraulic system 2 Insufficient brake fluid Improper quality of brake fluid Bleed air Replenish fluid to specified level bleed air Replace with correct fluid Leakage of brake fluid Insufficient tightening of connection joints 2 Cracked hose Worn piston and or cup Tighten to specified torque Replace Replace piston
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90. ck nut 18 1 8 Rear brake caliper holder pin 18 1 8 Rear brake caliper pin bolt 23 2 3 SERVICING INFORMATION 8 14 SERVICE DATA 9 VALVE GUIDE Unit mm in STANDARD 36 0 1 42 29 0 1 14 0 1 0 2 0 004 0 008 0 2 0 3 0 008 0 012 0 010 0 037 0 0004 0 0015 0 030 0 057 0 0012 0 0022 Valve stem deflection Valve guide 5 000 5 012 0 1969 0 1973 4 975 4 990 0 1959 0 1965 4 955 4 970 0 1951 0 1957 Valve stem runout 0 05 0 002 Valve head thickness 0 50 0 02 Valve seat width 1 25 1 65 0 049 0 065 Valve diam Valve clearance When cold Valve guide to valve stem clearance Valve stem O D Valve seat angle i 45 Valve head radial runout 0 35 0 014 36 9 1 45 39 9 1 57 Valve spring free length 6 5 7 1 kgf 14 3 15 7 1 5 at length 32 0 mm 1 26 in 12 0 14 0 kgf 26 5 30 9 Ibs at length 35 5 mm 1 40 in Valve spring tension 8 15 SERVICING INFORMATION 9 CYLINDER PISTON PISTON RING Unit mm in ANDARD Compression pressure 16 kg cm at 500 rpm 14 kg cm Piston to cylinder clearance 0 050 0 060 0 0020 0 0024 0 120 0 0048 Cylinder bore 96 000 96 015 3 7795 3 7801 96 075 3 7825 Piston diam 95 945 95 960 3 7774 3 7780 Measure at 18 mm 0 71 in from the skirt end 95 880
91. cleaner element Clogged fuel hose resulting in inadequate fuel supply to carburetor Replace Adjust Replace Repair Replace Adjust Clean Clean or replace 8 3 SERVICING INFORMATION Complaint Dirty or heavy exhaust smoke Symptom and possible causes 1 Too much engine oil in the engine 2 Worn piston rings or cylinder 3 Worn valve guides 4 Cylinder wall scored or scuffed 5 Worn valves stems 6 Defective stem seals 7 Worn side rails Check with inspection win dow drain out excess oil Replace Replace Replace Replace Replace Replace Engine lacks power 1 Loosen of valve clearance 2 Weakened valve springs 3 Valve timing out of adjustment 4 Worn piston ring or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Worn camshaft 8 Spark plug gap incorrect 9 Clogged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe Adjust Replace Adjust Replace Repair or replace Clean or replace Replace Adjust or replace Clean Adjust Clean Drain out excess oil Retighten or replace Engine overheats 1 Heavy carbon deposit on piston head 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 Fuel level too low in float chamber 5 Air leak from intake pipe 6 Use
92. cylinder head gasket to prevent gas leakage CYLINDER HEAD e With the head snugly seated on the cylinder secure it by tightening the bolts in diagonal stages Tighten the cylinder head bolts diagonally to the specified torque 9 Cylinder head bolt 47 N m 4 7 kgf m NOTE Apply engine oil to the threaded parts of the cylinder head bolts and its washers Be sure to install the washer with rounded side facing up After tightening the cylinder head bolts to specifi cation tighten the cylinder head base bolts and cylinder base nuts to the specified torque 9 Cylinder head base bolt 10 N m 1 0 kgf m Cylinder base nut 10 N m 1 0 kgf m CAMSHAFT ASSEMBLY Turn the magneto rotor until the line on the magneto rotor is aligned with the triangle mark on the crankcase CAUTION If the crankshaft is turned without drawing the cam chain upward the cam chain will catch between crankcase and cam chain sprocket ENGINE 3 56 NOTE Just before installing the camshaft into the cylin der head apply MOLY PASTE to the camshaft journals and cam faces Also apply engine oil to the camshaft housing MOLY PASTE Place each camshaft into the correct position e With the T line on the magneto rotor is aligned with the triangle mark on the crankcase hold the camshaft steady
93. d on this vehicle is a 21 X7 10 for the front and a 20 X11 9 for the rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires 2 19 PERIODIC MAINTENANCE STEERING Inspect Interval Inspect Initially at 1 month and Every 3 months thereafter Steering system should be adjusted properly for smooth manipulation of the handlebar and safe run ning TOE IN Place the vehicle on level ground Make sure the tire pressure for right and left tires is the same and set to the proper specification Set the front wheels in the straight position Place a load of 75 kg 165 Ibs on the seat Measure the distance 4 of the front wheels with a toe in gauge as shown and calcu late the difference between 4 and 8 Standard 0 5mm 0 0 2 in When apply to a load 75 kg 165 Ibs Toe in If the toe in is out of specification bring it into the specified range Refer to page 7 40 DRIVE CHAIN Inspect Interval Inspect drive chain each time the vehicle is ridden Visually check the drive chain for the possible defects listed below Support the vehicle by a jack and a wooden block turn the rear wheel slowly by hand with the transmis sion shifted to Neutral Loose pins Excessive wear Damaged rollers Improper chain adjust Dry or rusted links ment Kinked or binding
94. e brake caliper pistons all way into the caliper e Fill the system with brake fluid and bleed air Refer to page 2 17 Inspection after reassembly Refer to page 2 16 BRAKE DISK REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 7 8 Remove the front wheel hub Refer to page 7 8 Remove the brake disk BRAKE DISK INSPECTION Remove the front wheel Refer to page 7 8 Remove the caliper Refer to page 7 15 Check the brake disk for damage or cracks Measure the thickness using the micrometer Replace the brake disk if the thickness is less than the service limit or if damage is found Brake disk thickness 3 0 mm 0 12 in CHASSIS 7 18 Micrometer 0 25 mm 09900 20201 Measure the runout using the dial gauge Replace the brake disk if the runout exceeds the ser vice limit Service limit 0 3 mm 0 012 in Dial gauge 09900 20606 Magnetic stand 09900 20701 Brake disk runout f either measurement exceeds the service limit replace the brake disk Refer to above BRAKE DISK REASSEMBLY AND REMOUNTING Reassemble and remount the brake disk in the reverse order of removal and disassembly Pay attention to the following points Install the disk to the wheel hub NOTE Make sure that the disk is clean and free of any greasy matter Apply THREAD LOCK 1324
95. e 7 42 Remove the pad spring CHASSIS 7 44 7 45 CHASSIS Loosen the caliper pin bolt D and then remove the caliper holder Remove the caliper pin bolt Place a rag over the brake caliper piston 3 to pre vent the piston from popping out Force out the piston by pushing the piston hanger pin Remove the dust seal and piston seal 5 CAUTION Do not reuse the dust seal and piston seal to pre vent leakage of brake fluid BRAKE CALIPER INSPECTION amp Refer to page 7 16 ui PARKING BRAKE Inspect the parking brake for any damages and smooth rotation by turning the axle If there is any thing unusual replace the parking brake with a new one BRAKE CALIPER REASSEM BLY AND REMOUNTING i Refer to page 7 17 Reassemble and remount the brake caliper in the reverse order of removal and disassembly Pay attention to the following points PISTON SEALS Install the piston seal and dust seal BRAKE CALIPER HOLDER e Tighten the holder pin 3 to the caliper holder to the specified torque 9 Rear brake caliper holder pin 18 N 1 8 kgf Apply SILICONE GREASE to the brake caliper holder and caliper pin bolt AGH SILICONE GREASE e Tighten the brake caliper pin bolt 5 to the speci fied torque V Rear brake caliper pin bolt 23 N m 2 3 kgf m Install the
96. e bearing and then check the play when moving the spacer up and down If excessive play is neted replace the bearing with a new one m SWINGARM PIVOT SHAFT Using a dial gauge check the pivot shaft runout If the runout exceeds service limit replace the pivot shaft with a new one Swingarm pivot shaft runout 0 6 mm 0 024 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 CHASSIS 7 64 CUSHION LEVER AND ROD BOLT Inspect the cushion lever and rod bolts for damage or bend If any defect are noted replace them with new ones CHAIN BUFFER Inspect the chain buffer for wear and damage If any defects are found replace the chain buffer with a new one 7 65 CHASSIS REMOUNTING Remount the cushion lever cushion rod and swingarm in reverse order of removal Pay attention to the following points Install the swingarm and pivot shaft Tighten the swingarm pivot nut to the specified torque 7 Swingarm pivot nut 50 80 N m 5 0 8 0 kgf m Install the rear shock absorber and cushion lever Tighten the rear shock absorber mounting nuts to the specified torque V Rear shock absorber nut Upper D 40 60 N m 4 0 6 0 kgf m Rear shock absorber nut Lower 2 40 60 N m 4 0 6 0 kgf m Tighten the cushion rod nut and cushion lever nut to the specified torque V Cus
97. e pad mounting pins 2 Remove the brake pads CHASSIS 7 14 CAUTION Do not operate the brake lever during or after brake pad removal Replace the brake pads as a set otherwise braking performance will be adversely affected e Install the new brake pads NOTE Before installing the new pads inspect the pad mounting pins for wear If excessive wear is found replace them with new ones The E ring must be installed to the caliper e Tighten the brake pad mounting pins and brake caliper mounting bolts to the specified torque V Front brake pad mounting 18 28 m 1 8 2 8 kgf m Brake caliper mounting bolt 18 28 1 8 2 8 kgf m NOTE After replacing the brake pads pump the brake lever several times to check for proper brake operation and then check the brake fluid level 7 15 CHASSIS BRAKE FLUID REPLACEMENT Place the vehicle on a level surface and keep the handlebar straight Remove the master cylinder reservoir and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and classification DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely o
98. e resistance between the lead wires in the following table If the resistance is not within the specified value replace the stator coil with a new one Stator coil resistance Standard Pick up coil G L 90 1100 Charging coil Pocket Tester 09900 25002 ELECTRICAL SYSTEM 6 4 A CAUTION When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws THREAD LOCK 1324 WIRE COLOR L Blue G Green Y Yellow Br Brown BY Black with Yellow tracer OB Orange with Black tracer BW Black with White tracer WL White with Blue tracer Yellow with Green tracer 6 5 ELECTRICAL SYSTEM i IGNITION COIL Remove the front fender side cover fuel tank Refer to page 7 3 and 4 1 Pull out the spark plug Place it on the cylinder head after installing it at the plug cap to obtain ground Push the electric starter switch to rotate the starter motor to have the test of sparking performance If spark doesn t emit or the spark bring out the orange color replace the ignition coil IGNITION COIL Checking with Pocket Tester Remove the front fender side cover fuel tank Refer to page 7 3 and 4 1 Disconnect the ignition coil lead wires and spark plug cap and remove the ignition coil Measure the ignition coil resistance in both the pri mary and secondary windings using a pock
99. ench 09910 36000 NOTE lt The piston must be at top dead center TDC on the compression stroke in order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold Rotate the magneto rotor counter clockwise with socket wrench to set the piston at TDC on the compression stroke Rotate the rotor until the T line on the magneto rotor is aligned with the triangle mark on the crankcase To inspect the valve clearance insert a thickness gauge between the tappet and the camshaft Standard When cold 0 10 0 20 mm 0 004 0 008 in 0 20 0 30 mm 0 008 0 012 in Thickness gauge 09900 20806 PERIODIC MAINTENANCE 2 6 2 7 PERIODIC MAINTENANCE the clearance is out of specification first remove the cam chain tension adjuster camshaft housing camshaft To install the tappet shim at original position record the shim NO and clearance to present by A B C D mark on the cylinder head Select the tappet that agree with tappet clearance vertical line and shim NO horizontal line as refer to the tappet shim selection chart Refer to page 8 33 34 Adjust valve timing install the camshaft housing and the tension adjuster After the crankshaft rotate about 10 times measure the valve clearance If the clearance be not correct adjust the standard clearance as the s
100. epair or replace Replace SERVICING INFORMATION 8 6 BATTERY Complaint Sulfation acidic white powdery substance or spots on surfaces of cell plates Symptom and possible causes 1 Not enough electrolyte 2 Battery case is cracked 3 Battery has been left in a run down condition for a long time 4 Contaminated electrolyte Foreign matter has enters the battery and become mixed with the electrolyte Add distilled water if the battery has not been damaged and sulfation has not advanced too far and recharge Replace the battery Replace the battery or recharge If sulfation has not advanced far try to restore the battery by replacing the electrolyte recharing it fully with the battery detached from the vehicle and then adjusting electrolyte specific gravity Battery runs down quickly 1 The charging method is not correct 2 Cell plates have lost much of their active material as a result of over charging 3 A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the high electrolyte specific gravity 4 Electrolyte specific gravity is too low 5 Contaminated electrolyte 6 Battery is too old Check the generator regulator rectifier and circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging
101. ers 4 bearings 1 dust seals and dust into the suspension arm CHASSIS 7 26 NOTE Stamped mark on the dust seal must face out side Degrease the tapered portion of knuckle and also knuckle end with nonflammable cleaning solvent Install the suspension arms to the steering knuck le and tighten the knuckle end nuts to the speci fied torque 9 Knuckle end nut 43 N m 4 3 kgf m Install the cotter pins A CAUTION Replace the removed cotter pins with new ones 7 27 CHASSIS Tighten the suspension arm pivot nuts to the specified torque V Suspension arm pivot nut 40 60 N m 4 0 6 0 kgf m Install the front grip and the front shock absorber Apply THREAD LOCK 1324 to the front shock absorber mounting bolts THREAD LOCK 1324 Tighten the shock absorber mounting nut to the specified torque 9 Shock absorber mounting nut Upper and Lower 40 60 m 4 0 6 0 kgf Apply THREAD LOCK 1324 to the disk cover mounting bolts and then tighten the bolts THREAD LOCK 1324 Tighten the tie rod end nut to the specified torque V Tie rod end nut 22 35 m 2 2 3 5 kgf m Install the cotter pin CAUTION Replace the removed cotter pin with a new one NOTE When installing the tie
102. et tester or an ohmmeter If the resistance in both the primary and secondary windings is close to the specified values the wind ings are in sound condition Unit KQ TESTER PROBE T 399530 064700 5 7 D6vt70KQ R E TES B SES 8 170 0 1064700 79 ocket tester 09900 25002 ELECTRICAL SYSTEM 6 6 i IGNITER Using the pocket tester 1 KO range measure the resistance between the terminal in the following table Pocket tester 09900 25002 CAUTION Numberical value may differ a little according to the tester Notice that there may be a defect which can not be identified even though the measure ment by using the tester indicates a low volt age lt The range of measurement adjust a X 1 1 unit Unit KQ TESTER PROBE D Feu oo IE S 3 E E E Buc 7196510775 7959 10764 161167721804 n oo 44636037 443756003 9894513396 o 2636 3120 4220 co 26986 3M54255 E OO ES 6 7 ELECTRICAL SYSTEM CHARGING SYSTEM Regulator Rectifier
103. f the service procedures do not require use of battery power diconnect theQ battery lead wire at the battery Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and cer tain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any material left over from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Do not use self locking nuts a few times over Use a torque wrench to tighten fasteners to the torque values when specified Wipe off grease or oil if a thread is smeared with them After reassembly check parts for tightness and operation AS WARNING To protect environment do not unlawfully dispose of used motor oil and other fluids batteries and tires To protect Earth s natural resouces properly dispose of used vehicles and parts 1 3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number is stamped on the right side of the frame pipe
104. force and turning 5 direction or counter clockwise the adjuster will soft en compression damping force Front shock absorber Standard 13 turn from end of S force adjuster direction counter clockwise 2 Tension damping force To adjust the tension damping force turn in the adjuster fully for S H direction counter clockwise or clockwise Count the number of turns from the fully turned in position Fully turned in direction or clockwise provides stiffest tension damping force and turning S direc tion or counter clockwise the adjuster will soften tension damping force Front shock absorber Standard tension damping End of 5 direction force adjuster counter clockwise STANDARD FRONT SHOCK ABSORBER DAMPING FORCE Compression Tension Turn to S direction counter clockwise Turn to S direction counter clockwise Standard 14 turn from end of S direction counter clockwise End of S direction counter clockwise Turn to H direction clockwise Turn to direction clockwise WARNING Unequal front suspension adjustment can cause poor handling and loss of stability Be sure to adjust the compression and tension damping force on the right and left front shock absorbers to the same setting CHASSIS 7 30 STEERING 9 CONSTRUCTION 7 31 C
105. ge If the clearance exceeds the service limit replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod big end bearing crankshaft crank pin etc with new ones Conrod big Standard end side 0 10 0 65 mm 1 0 mm 0 004 0 026 in 0 040 in Thickness gauge 09900 20806 CRANKSHAFT E CRANKSHAFT RUNOUT INSPECTION With the right and left crank journals supported using a V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit replace the crankshaft with a new one Crankshaft runout 0 05 mm 0 002 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 3 33 ENGINE CRANK BALANCER AND BALANCER DRIVE GEAR f DISASSEMBLY Disassemble the crank balancer and balancer drive gear as shown in the illustration REASSEMBLY Reassemble the crank balancer and balancer drive gear in the reverse order of disassembly STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand the gear turns in only one direction The starter driven gear should turn smoothly If excessive resistance is felt while turning the starter driven gear inspect the starter clutch Also inspect the surface of the starter dr
106. haft Remove the steering shaft holder half 9 INSPECTION Inspect the removed parts for the following abnormal ities Handlebar distortion Handlebar clamp wear DUST SEALS AND O RING Inspect the dust seal and O ring for wear or damage If any damages are found replace the dust seal or O ring with new ones m TIE ROD Inspect the tie rod for distortion or damage If any damages are found replace the tie rod with a new one CHASSIS 7 34 7 35 CHASSIS D Tie rod end Lock nut D Lock nut a 4 4 Tie rod j 7 DE O CAUTION gt GA gt T The lock nuts 3 with a narrow width left S 2 prd hand threads Uwe pt e LL Q 0 M S Y 4 u TIE ROD END Inspect the tie rod ends for smooth movement If there are any abnormalities replace the tie rod end with a new one Inspect the tie rod end boot for wear or damage If any damages are found replace the tie rod end with a new one f STEERING SHAFT Inspect the steering shaft 5 for distortion or bends If any damages are found replace the steering shaft with a new one STEERING SHAFT BUSHING Inspect the steering shaft bushing 6 for wear and damage ER If any damages are found replace it with a new one SL KE STEERING SHAFT HOLDER Inspect the steering shaft holders for wear or dam
107. he direction of the circlip Fit it to the side where the thrust is as shown in figure When installing the third drive gear bushing align the its oil hole with the driveshaft oil hole When installing the reverse driven gear bushing align the its oil hole with the driveshaft oil hole Sharp edge ENGINE 3 40 TRANSMISSION GEARS AND RELATED PARTS CRANKCASE i OIL STRAINER CAP Remove the oil strainer cap 3 41 ENGINE Remove the oil strainer screw Clean the oil strainer using compressed air OIL PUMP DRIVE GEAR Remove the oil pump drive gear BEARING INSPECTION Wash the bearing with a cleaning solvent and lubri cate it with motor oil before inspection Rotate the inner race and check to see that it turns smoothly If it does not turn quietly and smoothly or if there are signs of any abnormalities the bearing is defective and must be replaced with a new one as follows play play ENGINE 3 42 OIL SEAL INSPECTION Damage to the lip of the oil seal may result in leak age of the engine oil Inspect the oil seal for wear or damage If any damages are found replace the oil seal with a new one Fi ae i rimangono OIL SEAL REMOVAL Remove the oil seal retainer Remove
108. hion lever nut 70 100 N m 7 0 10 0 kgf Cushion rod nut 70 100 N m 7 0 10 0 kgf m CHASSIS 7 66 REAR AXLE 9 CONSTRUCTION 7 67 CHASSIS REMOVAL Place the vehicle on the level ground and support the vehicle with a jack or wooden block m SPROCKET Remove the left rear wheel Refer to page 7 8 Remove the left rear wheel hub Refer to page 7 9 Remove the rear caliper Loosen the chain adjuster D rear axle housing nuts and wrench bolts 3 Loosen the sprocket mounting bolts and remove the 2 REAR AXLE SHAFT Remove the rear wheel Refer to page 7 8 Remove the rear wheel hub Refer to page 7 9 Loosen the axle nuts by applying the rear brake Remove the axle nuts Remove the sprocket flange Remove the caliper Draw out the rear axle shaft to the right CHASSIS 7 68 Remove the brake disk CAUTION Do not attempt to remove the brake disk flange from the rear axle shaft The rear axle shaft is available only as an assem bly m REAR AXLE HOUSING Remove the axle housing bolts nuts and wrench bolts Remove the chain 1 Remove the chain adjuster bolt Remove the axle shaft Peer da Remove the axle housing from the swingarm
109. inder bore Master cylinder piston diam ZS i a Brake caliper cylinder bore Front Rear 32 1 26 E Brake caliper piston diam Front Rear 32 1 26 DE Front DOT4 Brake fluid type Rear DOT4 EE Rear axle shaft nunout EM 6 0 24 E Front 21 7 10 Tire size Rear 20 x 11 9 13 Front 10x5 5 Wheel rim size Rear 9x8 Front 4 0 16 Tire tread depth Rear 4 0 16 Toe in When apply to a load 75 kg 165 Ibs 0 5 mm 0 0 2 in EM Caster 7 3 Camber 0 8 25 SERVICING INFORMATION TIRE PRESSURE COLD INFLATION TIRE PRESSURE ONE PERSON 0 3 kgf cm 30 kPa 4 4 psi TWO PERSONS 0 35 kgf cm 35 kPa 4 9 psi FUEL OIL 0 3 kgf cm 30 kPa 4 4 psi A LAN 0 35 kgf cm 35 kPa 4 9 psi Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommened Fuel tank capacity Engine oil type Necessary amount of engine oil Engine oil capacity Total 2 700 m 80 Over SL SAE 10W 40 Change 2 500 md Filter change 2 600 mQ Overhaul 2 700 md Oil tand side 1 900 mQ Filter side 100 mQ Engine side 550 m0 Cil hose side 150 mQ SERVICING INFORMATION 8 26 WIRE AND CABLE ROUTING R r SIG LAMP RH R r SIG LAMP LH olo X a gl 5 2 z SE x 3 5 5
110. ioner 2 Remove the starter idle shaft 3 and starter idle gear Remove the gear position switch 5 Remove the O ring switch contact spring 9 Remove the left crankcase securing bolts Remove the right crankcase securing bolts Separate the crankcase using the special tool Crankcase separator 09920 13120 ENGINE 3 20 NOTE Fit the crankcase separator so that the tool arms parallel the side of the crankcase Remove the dowel pins Remove the gearshift fork shafts 2 gearshift forks and gearshift Remove the countershaft assembly 5 and drive shaft assembly O Remove the reverse idle gear with its shaft Remove the crank balancer 8 3 21 ENGINE Remove the crankshaft from the crankcase using the special tool Crankcase separator 09920 13120 ENGINE COMPONENT INS PECTION AND SERVICE CAUTION Identify the position of each removed part Organize the parts in their respective group for example exhaust or intake so that they can be installed in their original positions CYLINDER HEAD DISASSEMBLY Remove the tappets and shims 2 by hand or by using a magnet Compress the valve springs and then remove the valve cotters from the valve stem using the special tools Valve spring c
111. ircuit Refer to page 2 12 Install the front fender 5 11 COOLING SYSTEM WATER PUMP REMOVAL AND DISASSEMBLY Drain engine coolant Refer to page 2 12 Drain engine oil Refer to page 2 10 s WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor The engine must be harmful if swallowed or if it comes in contact with the skin or eyes If engine coolant gets into the eyes or contacts the skin flush the eyes or wash the skin thor oughly with plenty of water If engine coolant is swallowed induce vomiting and call a physi cian immediately Disconnect the water hoses Disconnect the rear brake switch spring and rear brake pedal spring as to lower side Remove the rear brake master cylinder mounting bolts Remove the clutch cover with pushing down the rear brake pedal NOTE Before draining engine oil and engine coolant inspect engine oil and coolant leakage between the water pump and clutch cover If engine oil is leaking visually inspect the oil seal and O ring If engine coolant is leaking visually inspect the O ring COOLING SYSTEM 5 12 Remove the circlip and water pump driven gear Remove the pin and washer Remove the water pump case from the clutch cover
112. it replace the clutch plates as a set Clutch driven plate distortion 0 1 mm 0 004 in Thickness gauge 09900 20806 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using a vernier calipers If any spring is not within the service limit replace all of the spring with new ones Clutch spring free length 51 6 mm 2 032 in Vernier calipers 09900 20101 OIL PUMP Remove the outer rotor D inner rotor and pin 3 Inspect the outer 1 and inner rotor for any scratches or other damage If any damages are found replace them with new ones ENGINE 3 36 CAUTION The oil pump case securing screw is applied with THREAD LOCK 1324 If an attempt is made to overhaul the oil pump assembly the screw may be damaged Only the oil pump unit is avail able as a replacement THREAD LOCK 1324 Apply engine oil to the sliding surfaces of the oil pump inner rotor outer rotor and shaft When installing the inner rotor 2 align the pin with the groove When installing the outer rotor face the punched mark on the outer rotor to the outside 3 37 ENGINE TRANSMISSION DISASSEMBLY Disassemble the transmission gears as shown u INSPECTION GEAR SHIFTING FORK Using a thickness gauge check the clearance between the groove of its gear and shifti
113. iven gear which contacts the starter clutch for wear or damage If any wear or damage is found replace the defective parts DISASSEMBLY With the magneto rotor held immovable remove the starter clutch bolts REASSEMBLY Apply a small quantity of THREAD LOCK 1324 to the starter clutch bolts and tighten them to the specified torque with the magneto rotor held immovable THREAD LOCK 1324 V Starter clutch bolt 23 28 N m 2 3 2 8 kgf m ENGINE 3 34 3 35 ENGINE CLUTCH m CLUTCH DRIVE PLATES EN Measure the thickness and claw width of the clutch LKR 3 drive plates using vernier calipers If a clutch drive 4 77 ON plate is not within the service limit replace the clutch plates as a set Clutch drive Standard plate NO 1 2 92 3 08 mm 0 115 0 121 in CCC NO 2 3 42 3 58 mm 0 135 0 141 in Clutch drive Service limit plate NO 1 2 62 mm 0 103 in UN MEE NO2 3 12 mm 0 123 in Clutch drive Standard plate NO 1 15 9 16 0 mm 0 626 0 630 in NO 2 159 160 mm 0 626 0 630 in Clutch drive plate NO 1 15 1 mm 0 595 in NO2 15 1 mm 0 595 Vernier calipers 09900 20101 CLUTCH DRIVEN PLATES Measure each clutch driven plate for distortion using the thickness gauge If a clutch driven plate is not within the service lim
114. lt 6 5 N m 0 65 kgf m 9 CAM CHAIN Install the cam 4 onto the sprocket Tighten the cam chain tensioner mounting bolt to the specified torque V Cam chain tensioner mounting bolt 10 N m 1 0 kgf m Install the starter idle shaft 6 and starter idle gear 7 9 STARTER CLUTCH AND MAG NETO ROTOR Remove the grease from the tapered portion of the crankshaft and the magneto rotor Install the starter driven gear and key Tighten the magneto rotor nut to the specified torque using the special tool V Magneto rotor nut 120 N m 12 0 kgf m Conrod holder 09910 20115 PRIMARY DRIVE GEAR AND WATER PUMP DRIVE GEAR Install the primary drive gear to the crankshaft 1 Install the water pump drive gear Apply engine oil to the thread and inside surface of the nut With the crankshaft held immovable using the special tool and then tighten the primary drive gear nut to the specified torque 9 Primary drive gear nut 140 N m 14 0 kgf m Conrod holder 09910 20115 NOTE This nut has left hand thread CAUTION Apply engine oil to the primary drive gear nut 9 GEARSHIFT CAM STOPPER Apply small quantity THREAD LOCK 1324 to the gearshift cam plate bolt THREAD LOCK 1324 e Install the gearshift cam plate and gearshift cam plate bolt Ins
115. mbly 6 and washer ENGINE 3 16 Remove the coller Remove the oil 2 Remove the oil pump driven gear by removing the 2 Remove the oil pin and oil pump assembly 3 17 ENGINE Remove the gearshift shaft D by removing the circlip 2 Remove the gearshift cam stopper 3 Loosen the gearshift cam plate bolt Remove the gearshift cam plate With the crankshaft held immovable using the special tool remove the primary drive gear nut washer and water pump drive gear 6 Conrod holder 09910 20115 CAUTION The primary drive gear nut has left hand threads If turning it counter clockwise it may cause damage Pay attention at the primary drive gear nut with a washer and water pump drive gear with a washer Remove the primary drive 1 e With the magneto rotor held immovable using the special tool loosen the rotor nut Conrod holder 09910 20115 Remove the magneto rotor using the special tool Rotor remover 09930 30164 ENGINE 3 18 CAUTION Do not hit the magneto rotor with a hammer oth erwise the rotor may be damaged Remove the magneto rotor key 2 Remove the starter driven gear 3 19 ENGINE Remove the cam chain D and cam chain ten s
116. ming this procedure REMOUNTING Remounting the rear shock absorber in the reverse order of removal Pay attention to the following points Tighten each bolt nut to the specified torque V Rear shock absorber nut Upper 40 60 N 4 0 6 0 kgf Rear shock absorber nut Lower 2 40 60 m 4 0 6 0 kgf m Rear cushion rod nut 70 100 m 7 0 10 0 kgf m CHASSIS 7 56 7 57 CHASSIS 9 REAR SUSPENSION SETTING m SPRING PRE LOAD ADJUSTMENT The rear suspension spring pre load is adjustable This adjustment is performed by changing spring set length REAR SUSPENSION SPRING SET LENGTH MINIMUM SOFTEST STIFFEST STANDARD 228 mm 235 mm 8 98 in 9 25 in A CAUTION Do not set the spring length out of the specified range Remove the rear shock absorber Refer to page 7 54 Loosen the lock nut Adjust the spring set length by turning the adjuster Tighten the lock nut Remount the rear shock absorber Refer to page 7 56 CHASSIS 7 58 m DAMPING FORCE ADJUSTMENT The compression and tension damping force are adjustable for rider s preference rider s weight and field condition NOTE Do not turn the adjuster screws more than given position or the adjuster may be damaged 1 Compression damping force To adjust the compression damping force turn in the
117. mly so that the top of the caps do not protrude above the upper surface of the battery s top cover 9 SERVICING Visually inspect the surface of the battery container If any signs of cracking or electrolyte leakage from the sides of the battery have occurred replace the battery with a new one If the battery terminals are found to be coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper 9 RECHARGING OPERATION Using the pocket tester check the battery voltage If the voltage reading is less than the 12 0 V DC recharge the battery with a battery charger How to charge Standard 0 8 A 5 10 hours 4A X 30 minutes A CAUTION When recharging the battery remove the battery from the vehicle NOTE Do not remove the caps on the battery top while recharging CAUTION Be careful not to permit the charging current to exceed 4A at any time After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester e If the battery voltage is less than the 12 5V recharge the battery again If battery voltage is still less than 12 5V after recharging replace the battery with a new one When the vehicle is not used for a long period check the battery every 1 month to prevent the battery discharge ELECTRICAL SYSTEM 6 18 Insert the caps firmly
118. n swingarm and suspension bearings Tighten Replace Replace Rear suspension too soft Weakened spring of shock absorber Leakage oil or gas of shock absorber Improperly set rear spring pre load adjuster Improperly set damping force adjuster Replace Replace Adjust Adjust Rear suspension too stift Bend shock absorber rod Bent swingarm Worn swingarm and rear suspension bearings Improperly set rear spring pre load adjuster Improperly set damping force adjuster Improper chain adjustment Replace Replace Replace Adjust Adjust Adjust Rear wheels wobble Distorted rear wheel rims Damage or worn rear axle housing bearings Defective or incorrect rear tires Loose rear wheel hub nuts Distorted rear axle Loosen rear axle housing mounting bolts Improper rear brake adjustment Damaged or worn rear swingarm and related bearings 1 2 3 4 5 1 2 3 4 5 6 T 8 1 2 3 4 5 1 2 3 de 2 1 2 3 1 Weakened spring 2 1 2 1 2 3 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 T 8 9 Rear shock absorber leaks oil 10 Loose rear swingarm nut Replace Replace Replace Tighten Replace Tighten Adjust Replace Replace Tighten 9 BRAKES Complaint Poor braking FRONT and REAR Symptom and possible causes Not enough brake fluid in the reservoir Air trapped in
119. ne coolant level by observing the upper and lower amp lines on the engine coolant reservoir tank the level is below the lower line add engine coolant until the level reaches the upper line m ENGINE COOLANT REPLACEMENT Remove the radiator cap and engine coolant reservoir tank Place pan below the water pump and then drain the engine coolant by removing the drain bolt 3 s WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor Engine coolant may be harmful if swallowed or if it comes in contact with the skin or eyes If engine coolant gets into the eyes or contacts the skin flush the eyes or wash the skin thor oughly with plenty of water If engine coolant is swallowed induce vomiting and call a physi cian immediately Flush the radiator with fresh water if necessary Tighten the drain plug securely Pour the specified engine coolant through the radiator cap inlet up to the inlet neck NOTE For engine coolant information refer to page 5 1 Bleed air from the system as follows 1 Shift the transmission into neutral Start the engine and let it idle for 2 3 minutes Snap the throttle 3 4 minutes to bleed air from the system Stop the engine and add the engine coolant up to the radiator cap inlet neck 4 Repeat the above procedure until no air bleed from the radiator cap inlet
120. ng fork The clearance for each of the three shifting forks plays an important role in the smoothness and posi tiveness of shifting action If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both Shift fork to Standard Service limit 0 50 mm 0 020 in groove 0 10 0 30 mm clearance 0 004 0 012 in Shift fork groove width Standard 4 85 5 00 mm NO 1 amp NO 2 0 191 0 197 in 4 85 5 00 mm 0 191 0 197 in Shift fork thickness Standard 5 3 5 4 mm NO 1 amp NO2 0 209 0 213 in 5 3 5 4 mm ENGINE 3 38 0 209 0 213 in Vernier calipers 09900 20101 Thickness gauge 09900 20806 3 39 ENGINE m REASSEMBLY Reassemble the transmission in the reverse order of disassembly Pay attention to following points NOTE Before installing the gears coat lightly engine oil to the inner surface of each gear and bushing CAUTION Never reuse circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted When installing a new circlip pay attention to t
121. ng set Standard 270 10 6 length Minimum Stiffest 258 10 2 Maximum Softest 235 9 25 Rear suspension spring set Standard 228 8 98 length Minimum Stiffest 213 8 39 STANDARD FRONT SHOCK ABSORBER DAMPING FORCE compression Tension U O O O Softer Turn to S direction counter clockwise Turn to S direction counter clockwise Standard 1 tum from end of S direction counter clockwise End of S direction counter clockwise Stiffer Turn to H direction clockwise Turn to H direction clockwise STANDARD REAR SHOCK ABSORBER DAMPING FORCE Rs Compression Tension Softer Turn to 5 direction counter clockwise Turn to 5 direction counter clockwise Standard 1 turn from end of S direction counter clockwise 14 turn from end of S direction counter clockwise Stiffer Turn to H direction clockwise Turn to H direction clockwise SERVICING INFORMATION 8 24 BRAKE WHEEL Unit mm in ANDARD Rear brake pedal height 355 14 0 when one person riding from the ground gt Front 4 0 0 16 3 0 0 12 Brake disk thickness Rear 4 3 0 17 3 0 0 12 Brake disk runout Front Rear CERES 0 3 0 012 Front 15 870 15 913 0 6248 0 6265 Rear 12 700 12 743 0 5000 0 5017 Front 15 827 15 854 0 6227 0 6242 Rear 12 657 12 684 0 4983 0 4994 a Master cyl
122. ng the circlip make sure that the sharp edge of the circlip faces outside When remounting the master cylinder to the han dlebar first tighten the mounting bolts for upside as shown V Front brake master cylinder mounting bolt 5 8 N m 0 5 0 8 kgf m e Tighten the brake hose union bolt to the speci fied torque V Brake hose union bolt 40 60 m 4 0 6 0 kgf m As WARNING Bleed air from the brake fluid circuit after assembling master cylinder Refer to page 2 17 CHASSIS 7 20 Handlebar 1 e Clearance 7 21 CHASSIS FRONT SUSPENSION 9 CONSTRUCTION A REMOVAL Remove the front wheel Refer to page 7 8 Remove the front wheel hub Refer to page 7 8 Remove the brake caliper Refer to page 7 15 Remove the front disk cover Remove the cotter pin and tie rod end nut CHASSIS 7 22 A CAUTION Replace the removed cotter pin with a new one Remove the front grip 7 23 CHASSIS Remove the shock absorber lower mounting bolt Remove the suspension arm assembly Remove the shock absorber upper mounting bolt 9 Remove the shock absorber Remove the cotter pins and nuts Remove the steering knuckle 5 Remove the spacers dust seals
123. nt Refer to page 2 12 Bleed air from the cooling circuit Refer to page 2 12 RADIATOR RESERVOIR TANK REMOVAL REMOUNTING Remove the reservoir tank mounting bolts and dis connect the siphon hose from the reservoir tank and drain engine coolant e Install the reservoir tank in the reverse order of removal e Fill the reservoir tank to the upper level line COOLING SYSTEM 5 4 5 5 COOLING SYSTEM COOLING FAN 9 INSPECTION Remove the front fender Refer to page 7 3 Disconnect the cooling fan motor lead wire cou pler and its thermo switch lead wire coupler Test the cooling fan motor for load current with an ammeter connected as shown in the illustration The voltmeter is for making sure that the battery applies 12 volts to the motor With the motor with electric motor fan running at full speed the ammeter should be indicating not more than 5 amperes If the fan motor does not turn replace the motor assembly with a new one NOTE When making above test it is not necessary to remove the cooling fan REMOVAL Drain engine coolant Refer to page 2 12 Remove the front fender Refer to page 7 3 Remove the radiator Refer to page 5 2 Disconnect the cooling fan thermo switch Remove the cooling fan INSTALLATION Install the cooling fan to the radiator 9 Cooling fan mounting bolt 8 12 N m
124. o page 2 15 BRAKE FLUID REPLACEMENT Place the vehicle on a level surface Remove the master cylinder reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid Specification and classification DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake pedal until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper level V Brake air bleeder valve 9 14 m 0 9 1 4 kgf m A CAUTION Never reuse the brake fluid left over from previ ous servicing and stored for long periods Bleed air from the brake system Refer to page 2 17 BRAKE CALIPER REMOVAL AND DISASSEMBLY Disconnect the parking brake cable by removing the lock nut and lever Disconnect the brake hose 3 and allow the brake fluid to drain into a suitable receptacle Remove the parking brake housing A WARNING Brake fluid if it leaks will interfere with safe run ning and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Remove the brake caliper by removing the caliper mounting bolts 5 Remove the pad Refer to pag
125. of incorrect engine oil 7 Defective cooling system Clean Add oil Repair or clean Adjust Retighten or replace Change See Cooling system section SERVICING INFORMATION 8 4 CARBURETOR Complaint Trouble with starting Symptom and possible causes 1 Starter jet is clogged 2 Starter pipe is clogged 3 Air leaking from a joint between starter body and carburetor Starter plunger is not operating properly Clean Clean Check starter body and carburetor for tightness adjust and replace gasket Check and adjust Idling or low speed trouble Pilot jet pilot air jet are clogged or loose Pilot outlet or bypass is clogged Starter plunger is not fully closed Check and clean Check and clean Check and clean Medium or high speed trouble Main jet or main air jet is clogged Needle jet is clogged Throttle valve is not operating properly Filter is clogged Check and clean Check and clean Check throttle valve for operation Check and clean Overflow and fuel level fluctuations Needle valve is worn or damaged Spring in needle valve is borken Float is not working properly Foreign matter has adhered to needle valve Fuel level is too high or low O1 WN RADIATOR COOLING SYSTEM Complaint Engine overheats Symptom and possible cause
126. ompressor 09916 14510 Valve spring compressor attachment 09916 14520 ENGINE 3 22 Remove the valve spring retainer D inner valve spring and outer valve spring Remove the valve from the other side Remove the oil seal 5 with long nose pliers Remove the valve spring seat m REASSEMBLY Install each valve spring 6 MOLY PASTE to each oil seal and press fit Q them into position A MOLY PASTE CAUTION Do not reuse the oil seals Apply MOLY PASTE to the valve as shown and then insert them into the valve guides MOLY PASTE A CAUTION When inserting each valve into the valve guides make sure not to damage the lip of the oil seal Install the valve spring with the smaller pitch facing the cylinder head Head direction 3 MAURO 3 23 ENGINE Install the valve spring retainer by pressing down the spring using the valve spring compressor Fit the cotter halves to the stem end and release the lifter to allow the cotter to wedge between the retainer and the valve stem Make sure that the rounded lip of the cotter fits snugly into the groove in the stem end Valve spring compressor 09916 14510 Valve spring compressor attachment 09916 14520 CAUTION Be sure to install all of the parts in their original p
127. on to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced outdoors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all off the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil exhaust system or radiator during or for a while after engine operation After servicing fuel oil engine coolant exhaust or brake systems check all lines and fittings related to the system for leaks A WARNING If parts replacement is necessary replace the parts with HYOSUNG Genuine Parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean and also lubricated when specified When use of a certain type of lubricant bond or sealant is specified be sure to use the specified type When removing the battery disconnect the battery lead wire first and then the battery lead wire When reconnecting the battery connect theCD battery lead wire first and then the battery lead wire Finally cover the battery terminal with the terminal cover When performing service to electrical parts i
128. or refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never re use brake fluid left over from a previous servicing which has been stored for a long period 1 5 GENERAL INFORMATION 9 ENGINE COOLANT Use an anti freeze engine coolant compatible with an aluminum radiator mixed with distilled water only m WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the aluminum radiator f ANTI FREEZE ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point Hyosung recommends the use of HYOSUNG COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator m LIQUID AMOUNT OF WATER ENGINE COOLANT For engine coolant mixture information refer to cooling system section page 5 1 CAUTION Mixture of anti freeze engine coolant should be limited to 60 Mixing beyond it would reduce its efficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting performance is greatly reduced Be sure to mix it above 50 even though the atmospheric temperature does not go down to the freezing point GENERAL INFORMATION 1 6 BREAK
129. osition must be at TDC on the compres sion stroke CYLINDER HEAD COVER Thoroughly wipe off oil from the fitting surfaces of the cylinder head and cover Apply BOND 1215 to the end caps of the cylin der head cover gasket as shown BOND 1215 Apply engine oil to both sides of the washer e Lightly tighten the cylinder head cover bolts in diagonal stages and then tighten them to the specified torque 9 Cylinder head cover bolt 14 N m 1 4 kgf m CAUTION Use a new washers 3 59 ENGINE CAM CHAIN TENSION ADJUSTER Apply engine oil to the push rod Unlock the ratchet mechanism and push the push rod all the way Install the new gasket and cam chain tension adjuster to the cylinder Tighten the cam chain tension adjuster mounting bolts to the specified torque 9 Cam chain tension adjuster mounting bolt 10N m 1 0 kgf Tighten the cam chain tension adjuster bolt 2 to the specified torque V Cam chain tension adjuster bolt 20N m 2 0 kgf m Install the thermostat ENGINE 3 60 Install the thermostat 1 and 2nd pipe Install the spark plug Install the starter motor 3 FUEL SYSTEM CONTENTS EUEB TANK aem CAUTION Gasoline must be handled carefully in an area well
130. ositions CYLINDER HEAD DISTORTION Decarbonize in combustion chamber Check the gasket surface of the cylinder head for dis tortion using a straightedge and thickness gauge Take clearance reading at several places as indicat ed If any clearance reading exceeds the service limit replace the cylinder head with a new one Cylinder head distortion 0 05 mm 0 002 in Thickness gauge 09900 20806 m VALVE FACE WEAR Visually inspect each valve face for wear or damage If any abnormal wear is found replace the respective valve with a new one The thickness of the valve face decreases as the face wears Measure the valve head thickness D If the valve head thickness is not within the specified value replace the valve with a new one Valve head thickness 0 5 mm 0 02 in Vernier calipers 09900 20101 m VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend Support the valve using a V blocks and measure the valve stem runout using the dial gauge as shown If the service limit is exceeded or abnormal condition exists replace the valve with a new one Valve stem runout z 0 05 mm 0 002 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 ui TAPPET amp SHIM WEAR When measuring the valve clearance the clearance should be within the standard range 0 1 0 2 mm 0 004 0
131. otor 1 Remove the spark plug Remove the thermostat cover 2 and 2nd pipe Remove the thermostat ENGINE 3 10 Remove the cam chain tension adjuster bolt 1 Remove the cam chain tension adjuster 2 Remove the cylinder head cover bolts in diagonal stages and then remove the cylinder head cover Remove the valve timing inspection plug 3 Remove the magneto cover cap 4 using the spe cial tool Cap plug wrench 09910 36000 3 11 ENGINE Turn the magneto rotor until the T line on the magneto rotor is aligned with the triangle mark on the crankcase NOTE Before removing the camshaft housing the piston must be at TDC of the compression stroke Remove the cam chain guide and camshaft housing Remove the dowel pins intake camshaft and exhaust camshaft NOTE Do not drop the dowel pins and camshaft drive chain into the crankcase Remove the four cylinder head bolts in diagonal stages Remove the cylinder head base bolts and then remove the cylinder head NOTE If the cylinder head does not come off easily lightly tap it using a plastic hammer Remove the cylinder head gasket 0 dowel pins Remove the cam chain guide Q Remove the cylinder base nuts 4 and then remove the cylinder E
132. ove the cushion lever cover 7 55 CHASSIS Remove the cushion rod lower bolt nut Remove the rear shock absorber mounting bolts nuts Remove the rear shock absorber by lifting up the swingarm INSPECTION Inspect the shock absorber body bearing seals and spacers for damage and leakage of oil If any defects are found replace the shock absorber with a new one CAUTION Do not attempt to disassemble the rear shock absorber It is unserviceable REAR SHOCK ABSORBER DISPOSAL WARNING The rear shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pres sure caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Remove the valve cap Press the valve with a screwdriver to bleed out the nitrogen gas WARNING Releasing high pressure gas from the rear shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the rear shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screw driver to press the valve Do not use your fin ger to depress the gas valve and be sure to direct the valve away from your face and body Be sure to always wear eye protection when perfor
133. park plug electrodes overheat or burn Spark plug too hot The engine overheats Spark plug loose Mixture too lean BROWN Replace by cold type plug Tune up Retighten Adjust carburetor Generator charge but charging rate is below the specification Lead wires tend to get shorted or open circuited or loosely connected at terminals Grounded or open circuited stator coils of generator Defective regulator rectifier Not enough electrolyte in the battery Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between the level lines Replace the battery Generator overcharges Internal short circuit in the battery Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier poorly grounded Replace the battery Replace Clean and tighten ground connection Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent shorting Generator internally shorted 3 Defective regulator rectifier Repair or replace Replace Replace Starter switch is not effective Battery run down Defective switch contacts Brushes not seating properly on commutator in starter motor Defective starter relay RON Recharge or replace Replace R
134. pect the brake disk cover for damage If any dam ages are found replace the brake disk cover with a new one FRONT SHOCK ABSORBER DISPOSAL WARNING The front shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pres sure caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Remove the valve cap Press the valve with a screwdriver to bleed out the nitrogen gas A WARNING Releasing high pressure gas from the front shock absorber unit can be hazardous Never perform any servicing until the nitrogen gas pressure has been released from the front shock absorber unit When releasing the gas pressure place a rag over the gas valve and use the tip of a screw driver to press the valve Do not use your fin ger to depress the gas valve and be sure to direct the valve away from your face and body Be sure to always wear eye protection when performing this procedure REASSEMBLY AND REMOUNTING Reassemble and remount the front suspension in the reverse order of removal and disassembly Pay attention to the following points SUPER GREASE to the dust seals dust covers and bearing SUPER GREASE Install the bearings D dust seals and spacers into the suspension arm Install the spac
135. prescribed order Direction of inside amp NO 2 Drive plate B NO 1 Drive plate Tighten the clutch spring set bolts securely in diagonal stages ENGINE 3 52 Install the dowel pins and new gasket CAUTION Use a new gasket to prevent oil leakage Tighten the clutch cover bolts securely 9 MAGNETO ROTOR COVER Install the dowel pins and new gasket CAUTION Use a new gasket to prevent oil leakage Tighten the magneto rotor cover bolts securely 3 53 ENGINE 9 PISTON RING Install the oil ring first the 2nd ring second and the 1st ring last NOTE lt 1st and 2nd 2 piston rings differ in shape The 1st and 2nd piston rings should be installed with the mark facing up First install a spacer into the oil ring groove and then install the two side rails 4 The spacer and side rails do not have a designated top and bottom They can be installed in any position CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove INCORRECT CORRECT Position the piston ring gaps as shown Before inserting the piston into its cylinder check that the gaps are properly positioned 5 2nd ring and lower side rail Upper side rail 7 1string and spacer
136. r If any of the measurements is founds less than the service limit replace the pin with a new one Piston pin diameter 18 980 mm 0 7472 in Micrometer 0 25 mm 09900 20201 PISTON RING FREE END GAP INSPE CTION Before installing piston rings measure the free end gap of each ring using vernier calipers If the gap is less than the service limit replace the ring Piston ring free end Standard 1st Approx 11 mm 0 433 in m gt Vernier calipers 09900 20101 m PISTON RING END GAP INSPECTION Assembly condition Insert the piston ring squarely into the cylinder using the piston head Measure the end gap with a thickness gauge If the gap exceeds the service limit replace the pis ton ring with a new one Piston ring end gap Assembly condition Standard 0 25 0 40 mm 0 010 0 016 in 0 40 0 55 mm 0 016 0 022 in Piston ring end gap Assembly condition Service limit 0 5 mm 0 020 in ENGINE 3 30 0 7 mm 0 028 in Thickness gauge 0990 20806 3 31 ENGINE m PISTON RING TO GROOVE CLEAR ANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit the piston ring into the groove With the ring com pressed and lifted up measure the clearance on the bottom side of the ring using a thickness gauge If any clearance reading exceeds the service limt replace both the piston and
137. re make sure that the cylinder head nuts are tightened to the specified torque val ues and valves are properly adjusted Have the engine warmed up by idling before testing Make sure that the battery is fully charged con dition Remove the related parts and test the compression pressure in the following manner As WARNING The hot radiator and the hot engine can burn you Wait until the radiator and the engine are cool enough to touch Remove the spark plug Fit the compression gauge in the plug holes Make sure that the connection is tightened Keep the throttle lever in full open position Press the starter switch and crank the engine for a few seconds Record the maximum gauge reading as the com pression of cylinder Compression gauge 09915 64511 2 25 PERIODIC MAINTENANCE OIL PRESSURE Check the engine oil pressure periodically This will give a good indication of the condition of the moving parts Standard Oil pressure 1 0 3 0kg a at 60 3 000 rpm If the oil pressure is lower or higher than the specification the following causes may be considered m LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage Damaged O ring Defective oil pump Combination of above items m HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items E OIL PRESSURE TE
138. rk thickness NO 1 amp NO2 5 3 5 4 0 209 0 213 NO 3 5 3 5 4 0 209 0 213 Drive chain Type RK 520EXW Links 20 pitch length 102 317 5 12 50 319 4 12 58 Drive chain slack 30 40 1 2 1 6 Reverse cable play 1 2 0 04 0 08 8 19 SERVICING INFORMATION 9 CARBURETOR Carburetor type Unit mm in SPECIFICATION BDS42 TYPE Bore size 242 Float height 1 300 1 500 rpm 13 0 51 Main jet 162 5 Main air jet 50 Jet needle 6DFY08 54 3 Needle jet O 6M Pilot jet Throttle valve 45 By pass Valve seat Starter jet Pilot screw Pilot outlet 214 PV Stroke 29 6 Throttle cable play 3 5 0 12 0 20 SERVICING INFORMATION 8 20 9 THERMOSTAT COOLING FAN COOLANT ITEM STANDARD LIMIT m Valve opening 76 C 169 F ermostat valve operating temperature Vanesa 71C 160 Thermostat valve lift Over 8 mm 90 Over 0 32 in 194 F OFF ON Approx 120 C 248 F Approx 113 C 235 OFF ON Approx 95 C 203 ON OFF Approx 88 C 190 F Use an antifreeze coolant compatible with Water temperature switch operating temperature Cooling fan thermo switch operating temperature Engine coolant type aluminum radiator mixed with distilled water only at the ratio of 50 50
139. rod end install the washer D between the nut and steering knuckle 9 FRONT SUSPENSION SETTING SPRING PRE LOAD ADJUSTMENT The front suspension spring pre load is adjustable This adjustment is performed by changing spring set length FRONT SUSPENSION SPRING SET LENGTH CHASSIS 7 28 to STANDARD MAXIMUM SOFTEST MINIMUM STIFFEST 270 mm 10 6 in 280 mm 11 0 in 258 mm 10 2 in A CAUTION Do not set the spring length out of the specified range Remove the front shock absorber Refer to page 7 23 Loosen the lock Adjust the spring set length by turning the adjuster Tighten the lock nut Remount the front shock absorber Refer to page 7 27 f 7 ACTE Sy ANY T7 7 29 CHASSIS m DAMPING FORCE ADJUSTMENT The compression and tension damping force are adjustable for riders preference rider s weight and field condition NOTE Do not turn the adjuster screws more than given position or the adjuster may be damaged 1 Compression damping force To adjust the compression damping force turn in the adjuster D fully for S or direction counter clockwise or clockwise Count the number of turns from the fully turned in position Fully turned in direction or clockwise provides stiffest compression damping
140. ry drive gear nut Camshaft housing bolt Horn mounting bolt Gearshift cam stopper Gear position switch bolt 8 13 SERVICING INFORMATION 9 CHASSIS Front amp Rear shock absorber mounting nut Upper Front amp Rear shock absorber mounting bolt Lower Rear axle housing nut Rear axle housing wrench bolt Swingarm pivot nut Steering shaft nut Steering shaft holder bolt Front amp Rear brake disk bolt Front brake master cylinder mounting bolt Rear brake master cylinder mounting bolt Front amp Rear brake caliper air bleeder valve Front amp Rear brake caliper mounting bolt Front amp Rear brake hose union bolt Footrest mounting bolt Front wheel hub nut Rear wheel hub nut 100 10 0 Front amp Rear wheel set nut 39 2 58 8 3 92 5 88 Front amp Rear brake pad mounting pin 18 28 1 8 2 8 Knuckle end nut 43 4 3 Suspension arm pivot nut 40 60 4 0 6 0 Tie rod end nut 22 35 2 2 3 5 Tie rod lock nut 29 2 9 Throttle case bolt 5 0 5 Parking brake housing bolt 28 2 8 Rear brake master cylinder rod lock nut 10 20 1 0 2 0 Rear cushion rod nut 70 100 7 0 10 0 Rear cushion lever nut 70 100 7 0 10 0 Rear sprocket mounting bolt 18 28 1 8 2 8 Rear axle shaft nut inner amp outer 120 150 12 0 15 0 Handlebar clamp bolt 18 28 1 8 2 8 Parking brake adjuster lo
141. s Not enough engine coolant Radiator core clogged with dirt or scale Faulty cooling fan Defective cooling fan thermo switch Clogged water passage Air trapped in the cooling circuit Defective water pump Use of incorrect engine coolant Defective thermostat Replace Replace Check and adjust Clean Adjust float height Add coolant Clean Repair or replace Replace Clean Bleed out air Replace Replace Replace Engine overcools Defective cooling fan thermo switch Extremely cold weather Defective thermostat Replace Put on the radiator cover Replace 8 5 SERVICING INFORMATION 9 ELECTRICAL Complaint No sparking or poor sparking Symptom and possible causes 1 Defective ignition coil 2 Defective spark plug Defective igniter Replace Replace Replace Spark plug soon become fouled with carbon Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug too cold Adjust carburetor Adjust carburetor Change Clean or replace Replace by hot type plug Spark plug become fouled too soon Worn piston rings Pistons or cylinder worn Excessive clearance of valve stems in valve guides Worn stem oil seal RON Replace Replace Replace Replace S
142. ssed air After cleaning reassemble the carburetor with new seals and gaskets Check for stopped wear Foreign substance Needle valve CAUTION Do not use wire to clean the passageways valve seat and jets Used compressed air only 4 9 FUEL SYSTEM FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Measure the float height while the float arm is just contacting the needle valve using a vernier calipers Float height 13 mm 0 51 in Vernier calipers 09900 20101 Bend the float arm 1 as necessary to bring the height to the specified level After adjustment check the float height and the fuel level again 9 REASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly When reassembling carefully observe the following instructions After cleaning reinstall the pilot air jet to the origi nal setting by turning the screw in until it lightly seat and then backing it out the same number of turns counted during disassembly Install the pilot jet 9 jet holder and main jet Align the hole 1 of the diaphragm with passage way on the carburetor body FUEL SYSTEM 4 10 NOTE When installing the diaphram make sure the diaphram is seated at the concave section of the carburetor Apply SUPER GREASE
143. ssembly Wash clean and dry the removed parts before inspecting and measuring Oil the rotating or sliding parts before assembly Make sure to use the correct type of lubricant where specified Check that each rotating or sliding part moves or operates smoothly after assembly Make sure to follow the bolt tightening order where specified If the correct length of the bolt is confused when tightening the crankcase or cover insert all the bolts and check that the tightening margin is equal in each bolt 3 1 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before taking the engine out of the frame wash the engine using a suitable cleaner Engine removal is sequentially explained in the fol lowing steps Drain engine coolant Refer to page 2 12 Remove the engine under Drain engine oil Refer to page 2 10 Remove the gearshift lever Remove the engine oil outlet hose 2 and inlet 4 CAUTION Do not lose the spacer with O ring behind the out let oil hose Remove the seat Refer to page 7 3 Disconnect the battery O lead wire 1 b ENGINE 3 2 Remove the fuel tank Refer to page 4 1 Disconnect the spark plug cap D oil tank over flow hose and breather hose 3 Remove the engine coolant inlet hose and dis connect the outlet hose 5
144. t Interval Replace Initially at 1 month and Every 6 months thereafter The oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change m ENGINE OIL REPLACEMENT Place an oil pan under the drain plug on the crankcase and drain plug on the oil tank Then drain out the engine oil by removing the engine oil drain plug and engine oil level gauge and outer cover oil filler cap 5 Reinstall the drain plug and gasket Tighten the engine oil drain plug and 9 to the specified torque and then pour the new oil through the oil filler hole of oil tank and filler hole of outer cover When performing an oil change without oil filter replacement the engine will hold about 2 500m2 Lof oil Use an engine oil that meets the ser vice classifications of over SL and that has a vis cosity rating of SAE 10W 40 V Engine oil drain plug 24N m 2 1 kgf m 9 12N m 1 2 kgf m Install the oil lever gauge Install the outer cover oil filler cap Start the engine and allow it to run for a few min utes at idling speed Turn off the engine and wait about three minutes and then check the oil level on the dipstick Remove the oil level gauge 4 Wipe the oil from the oil level gauge using a clean rag Reinsert the oil level gauge until the threads touch filler neck but do not screw the oil level gauge in If
145. t needle holder spring E ring 5 ring and jet needle Remove the diaphragm cover 8 Remove the diaphragm 9 FUEL SYSTEM 4 6 4 7 FUEL SYSTEM Remove the float chamber Remove the O ring A CAUTION Replace the removed O ring with a new one to prevent leakage of fuel Remove the float float and needle valve Remove the valve seat Remove the main jet D jet holder 2 and pilot jet 9 Remove the pilot air jet counting and tightening the number of turn FUEL SYSTEM 4 8 NOTE Before removing the pilot air jet its setting must be determined Slowly turn the pilot screw clockwise and count the number of turns until it is lightly seated Make a note of how many turns were made When reassembling the pilot screw you will want to set it to its original position 9 INSPECTION Check the following parts for damage and clogging Pilot jet Piston valve Main jet Starter jet Main air jet Gaskets and O rings Pilot air jet Pilot outlet and bypass Needle jet holder Float Needle valve Jet needle Valve seat Diaphragm If any abnormal condition is found wash the part clean If damage or clogging is found replace the part with a new one 9 CLEANING Clean all jets by using compre
146. tall the front fender ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS IGNITION SYSTEM i et t ee det on ets CHARGING SYSTEM iirc es nef eiae ia p dde STARTER SYSTEM 6 1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Cooling fan motor relay Head lamp relay Ignition coil D Left handlebar switch Ou NE Igniter Magneto Horn 9 Regulator Rectifier Gear position switch Turn signal relay 1 Starter relay ELECTRICAL SYSTEM 6 2 85 2 SES o amp 5 Qo amp GE EE s oou Front brake lamp switch 0 Battery Starter motor Rear brake lamp switch Main fuse 6 3 ELECTRICAL SYSTEM IGNITION SYSTEM Lia FUSE O l Z az rax BATTERY 12V 8Ah 9 INSPECTION SPARK PLUG Clean the plug with a wire brush and pin Use the pin to remove carbon taking care not to damage the porcelain Check the gap with a thickness gauge S k pl 0 7 0 8 mm ar P nud 0 028 0 032 in Thickness gauge 09900 20806 0 7 0 8 mm 0 028 0 032 in t m MAGNETO Using the pocket tester measure th
147. tall the gearshift cam stopper to the speci fied torque V Gearshift cam stopper 32 N m 3 2 kgf m ENGINE 3 48 3 49 ENGINE Install the gearshift shaft e Install the circlip OIL PUMP Before mounting the oil pump apply engine oil to the sliding surfaces of the oil pump case outer rotor inner rotor and crankcase Apply a small quantity of THREAD LOCK 1324 to the oil pump mounting screws and then tighten them securely THREAD LOCK 1324 When installing the oil pump driven gear align the with the groove OIL PIPE Apply engine oil to the O rings Tighten the oil pipe bolt securely ENGINE 3 50 9 CLUTCH Install the clutch sleeve hub lock washer Hold the clutch sleeve hub using the special tool and then tighten the clutch sleeve hub nut to the specified torque V Clutch sleeve hub nut 90 N m 9 0 kgf m Clutch sleeve hub holder 09920 53710 3 51 ENGINE Bend the tongue of the washer securely Install the push rod 2 clutch push piece 3 Install the clutch drive plate NO 2 Install the spring washer seat and spring wash er onto the clutch sleeve hub correctly Install the clutch driven plates and drive plates NO 1 one by one into the clutch sleeve hub in the
148. the oil seal A CAUTION Replace the removed oil seals with new ones OIL SEAL INSTALLATION Install the oil seals into the crankcase Pay atten tion to the following points Apply SUPER GREASE to the lip of the oil seals AG SUPER GREASE Install the new oil seals 3 43 ENGINE CLUTCH RELEASE CAMSHAFT Remove the clutch release camshaft 1 Install the clutch release camshaft correctly CLUTCH COVER OIL FILTER Refer to page 2 11 WATER PUMP t Refer to page 5 11 ENGINE 3 44 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly Pay special attention to the following points NOTE Apply engine oil to each running and sliding part before reassembling the engine 9 CRANKSHAFT Determine the width between the webs referring to the figure when rebuilding the crankshaft Width between Standard webs 71 0 0 1 mm 2 795 0 004 in When mounting the crankshaft in the crankcase it is necessary to pull its left end into the crankcase by using the special tools Crankshaft installer 09910 32812 71 0 0 1 mm CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the accu racy of the crankshaft alignment will be affected
149. unting bolts V Rear brake master cylinder mounting bolt 8 12 N m 0 8 1 2 kgf m Connect the rear brake switch spring and rear brake pedal spring as to lower side Connect the water hoses Pour engine coolant Refer to page 2 12 Pour engine oil Refer to page 2 11 COOLING SYSTEM 5 16 OIL TANK AND HOSES 9 CONSTRUCTION 5 17 COOLING SYSTEM REMOVAL Remove the front fender Refer to page 7 3 Drain engine coolant Refer to page 2 12 Remove the radiator Refer to page 5 2 Drain engine oil Refer to page 2 10 Remove the engine under Remove the oil hoses COOLING SYSTEM 5 18 Remove the oil tank REMOUNTING Remount the oil tank and hoses in the reverse order of removal Pay attention to the following points Tighten the engine oil inlet hose union bolts to the specified torque 9 Engine oil inlet hose union bolt 23 N m 2 3 kgf 5 19 COOLING SYSTEM Install the new O ring to the hoses CAUTION Use the new O rings to prevent engine coolant leakage Install the gaskets Apply engine oil to the O ring and gaskets Pour engine oil Refer to page 2 11 Install the radiator Refer to page 5 4 Pour engine coolant Refer to page 2 12 Ins
150. ust seal s lip AG SUPER GREASE 7 11 CHASSIS Install the front disk to the front wheel hub Refer to page 7 18 Apply SUPER GREASE to the front axle SUPER GREASE Install the wheel hub Install the front brake caliper Refer to page 7 17 Tighten the front wheel hub nut to the specified torque V Front wheel hub nut 55 N m 5 5 kgf m Install the hub plate Install the cotter pin into the front axle Install the front wheel CAUTION Replace the removed cotter pin with a new one REAR WHEEL HUB Apply small amount of SUPER GREASE A to the wheel hub s spline SUPER GREASE Install the rear wheel hub washer and nut Tighten the rear wheel hub nut to the specified torque V Rear wheel hub nut 100 N m 10 0 kgf m Install the cotter pin into the rear axle Install the rear wheel CAUTION Replace the removed cotter pin with a new one FRONT WHEEL e Install the front wheel Tighten the wheel set nuts to the specified torque V Wheel set nut 39 2 58 8 m 3 92 5 88 kgf ON ROAD type NOTE When installing the front wheel make sure that the arrow on the tire points in the direction of rotation CHASSIS 7 12 REAR WHEEL Install the re
151. ut of the brake system Close the air bleeder valve and disconnect the clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window V Brake air bleeder valve 9 14 m 0 9 1 4 kgf m CAUTION Never reuse the brake fluid left over from previ ous servicing or stored for long periods Bleed air from the brake system Refer to page 2 17 BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 7 8 Disconnect the brake hose from the brake caliper by removing the brake hose union bolt D and allow the brake fluid to drain into a suitable recep tacle Remove the brake caliper by removing the brake caliper mounting bolts Remove the brake pads Refer to page 7 14 WARNING Brake fluid if it leaks will interfere with safe run ning and discolor painted surfaces Check the brake hose brake pipe and hose joints for cracks and leakage of brake fluid Remove the brake pad spring and brake caliper holder Using an air gun push out the brake caliper pis ton s WARNING Place a rag over the piston to prevent it from popping out and flying and keeping hand off the piston Be careful of brake fluid which can possibly splash Do not use high pressure air but increase the pressure gradually Remove the dust seal and piston seal
152. ve sequence BRAKE TAIL LAMP m BRAKE TAIL LAMP REPLACEMENT This ATV s brake tail lamp is LED Light Emitting Diode type If any abnormal condition are found replace the brake tail lamp assembly TURN SIGNAL LAMP ELECTRICAL SYSTEM 6 14 A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure uq TURN SIGNAL LAMP BULB REPLACEMENT Remove the lens by removing the screw 1 Push the bulb turn it to the counter clockwise and pull it out After stick in the new lamp assemble the lens CAUTION Overtightening the screws may cause the lens to crack 6 15 ELECTRICAL SYSTEM COMBINATION METER Remove the combination meter Disassemble the combination meter as shown in the illustration u INSPECTION Using the pocket tester check the continuity between lead wires Blue color coupler in the following illus tration If the continuity measured incorrect replace the respective part Pocket tester 09900 25002 A CAUTION When making this test it is not necessary to remove the combination meter LCD DISPLAY CLK TRP ODO a r DZ 2 S 9 z 2 oc ee OF a D gt E I gt a
153. will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air cleaner element in the fol lowing manner Remove the seat Refer to page 7 3 Remove the air cleaner case 1 Remove the air cleaner element Separate the polyurethane foam element 3 ele ment frame and element trap stopper 5 Fill a wash pan of a proper size with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Press the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will tear Immerse the element in HYOSUNG genuine oil B and then squeeze out the excess oil leaving the element slightly wet A CAUTION Inspect the air cleaner element for tears A torn element must be replaced If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or with torn ele ment Make sure that the air cleaner element is in good condition at all times Life of the engine depends largely on this component Remove the drain 1 of the air cleaner case to allow any water to drain out EXHAUST PIPE NUTS AND MUF FLER BOLTS Inspect Interval Tighten Initially at 1 month and Every 3 months thereafter
154. wingarm rear axle and bearing for scratches wear or damage If any damages are found replace them with a new one Refer to page 7 63 and 7 69 Inspect the front and rear shock absorbers for oil leakage or damage If any damages are found replace them with a new one Refer to page 7 24 and 7 55 CHASSIS BOLTS AND NUTS Inspect Interval Tighten Initially at 1 month and Every 3 months thereafter Check that all chassis nuts and bolts are tightened to their specified torque Refer to page 8 13 COMPRESSION PRESSURE The compression pressure reading of a cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic mainte nance records kept at your dealership should include compression pressure reading for each maintenance service Compression pressure Standard 16 kg cm at 500 rpm PERIODIC MAINTENANCE 2 24 Low compression pressure can indicate some of the following conditions Excessively worn cylinder wall Worn down piston or piston rings Piston rings stuck in grooves Poor seating of valves Ruptured or otherwise defective cylinder head gasket 14 kg cm at 500 rpm m COMPRESSION TEST PROCEDURE NOTE When the compression pressure goes below specification check the engine for conditions list ed above NOTE Before testing the engine for compression pressu
155. x 2 18 Steering Inspect Inspect 2 19 Suspensions Inspect 2 23 Front and Rear wheel set nuts Tighten every time before riding 7 12 Rear axle nut and lock nut Tighten Tighten 7 72 Chassis bolts and nuts Tighten Tighten 2 23 General lubrication Lubricate Lubricate 2 2 CAUTION Using poor quality replacement parts can cause your vehicle to wear more quickly and shorten its useful life Use only genuine Hyoung replacement parts or their equivalent PERIODIC MAINTENANCE 2 2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the vehicle Major lubrication points are indicated below D Clutch lever holder 4 Front brake lever holder 2 Steering shaft holder 5 Rear brake pedal and rod link 3 Throttle lever Drive shaft joint spline Motor 8 Grease NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with either motor oil or grease whenever the vehicle has been operated under wet or rainy condition 2 3 PERIODIC MAINTENANCE MAINTENANCE PROCE DURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart AIR CLEANER Inspect Interval Clean Every 3 months If the air cleaner is clogged with dust intake resis tance
156. y electrolyte FILLING ELECTROLYTE D Put the battery on even land and remove the alu minum tape sealing d Remove the cap at the electrolyte container A CAUTION Aluminum tape Do not remove the seal of the electrolyte contain Filler holes I L CR er not prick with sharp thing 6 17 ELECTRICAL SYSTEM Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any fluid to spill CAUTION The pouring of electrolyte may not be done if the electrolyte container is pushed slopely Confirmation of pour Make sure that air bubbles are coming up each elec trolyte container and keep this position for more than about 20 minutes A CAUTION If no air bubbles are coming up from a filler port tap the bottom two or three times Air bubble 5 Separation of electrolyte container After confirming that you entered the electrolyte into battery completely remove the electrolyte containers from the battery CAUTION Draw the empty receptacle out slowly because there may be a chance remaining electrolyte vaporize Insert the caps Insert the cap into the filler holes pressing it fir

caution - Hyosung

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