DAELIM Roadwin R, Service Manual

Page 1: ...ICE FACTORY 58 SUNG SAN DONG CHANG WON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7520 OVERSEAS SALES OFFICE FACTORY 13 5 SEONGSU 1 GA 2DONG SEONGDONG GU SEOUL KOREA TEL 82 2 3408 2634 FAX 82 2 4...

Page 2: ...SERVICEMANUAL 2007 01 PRINTED 2007 01 PUBLICATION C CO OP PY Y P PR RO OH HIIB BIIT T...

Page 3: ...cannot find the cause of trouble refer to Section 21 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of...

Page 4: ......

Page 5: ...t on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must be performed in the place free of the open fire or electr...

Page 6: ...e bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test and remove the cleaning oil with compresse...

Page 7: ...rection in case of the single sided sealed ball bearing Install the open direction or double sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer...

Page 8: ...ll the oil seal so that the manufacturer marked surface directs outer surface direction not covered with oil Pay attention not to bend or damage the lip Apply the grease to the lip 20 Connect the tube...

Page 9: ...er in case of water proof coupler Recheck the condition of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After co...

Page 10: ...following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting t...

Page 11: ...ng T start broaden the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start fro...

Page 12: ...ess not to be pulled or expanded when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please read...

Page 13: ...NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL...

Page 14: ...isk REAR BRAKE Hydraulic Disk FUEL CAPACITY 14 85 FUEL RESERVE CAPACITY 4 0 CASTER ANGLE 25 2 TRAIL 93 5mm FRONT FORK OIL CAPACITY 265 2 5cc TYPE Liquid 4 stroke DOHC 4 Valve CYLINDER NUMBER ARRANGEME...

Page 15: ...IGNITION TYPE Full Transisterized IGNITION TIMING F MARK 18 BTDC 1 600 rpm FULL ADVANCE 30 BTDC 8 500 rpm AC GENERATOR 12V 17A 5 000 rpm BATTERY CAPACITY 12V 10AH SPARK PLUG CR9EH 9 SPARK PLUG GAP 0 8...

Page 16: ...DER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARI...

Page 17: ...f m N m FRAME 2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5 M8 1 25 M6 1 0 M14 1 5 M8 1 25 M10 1 25 M8 1 25 M6 1 0 M22 1 0 M22 1 0 M8 1 25 M8 1 25 M8 1 25 M14 1 25 M10 1 25 6mmTapping M8 1 25 M8 1 25 M8 1 25 U...

Page 18: ...ates reference page Example Refer to page 3 1 Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease with the ratio 1 1 Use m...

Page 19: ...ve Seat DESCRIPTION REFERENCE SECTION REMARK CLUTCH CENTER HOLDER 8 ACG ROTOR PULLER 9 VALVE GUIDE DRIVER 10 VALVE GUIDE REAMER 10 UNIVERSAL BEARING PULLER 12 BEARING REMOVER SET 12 THREAD ADAPTER 12...

Page 20: ...HARNESS COVER ST HAZ SW ST HAZ SW CORD CLUTCH CABLE WATER PASS TUBE ASS Y C RADIATOR HOSE A CLUTCH CABLE DRAIN TUBE FUEL DRAIN TUBE WATER PASS TUBE ASS Y D RADIATOR RESERVE TANK ST MOTOR CABLE ST MAG...

Page 21: ...CLIP CLUTCH CABLE THROTTLE CABLE IG COIL EARTH WINKER SW ST HAZ SW COMB LOCK SW WIRE HARNESS O2 SENSOR COUPLER NOISE SUPPRESSORCAP HIGH TENSION CORD FR BRAKE HOSE ST HAZ SW CORD ST HAZ SW THROTTLE CA...

Page 22: ...LE HARNESS COVER WIRE CLIP ST MAG SW WIRE ST MAG BATTERY CABLE BATTERY EARTH CABLE RESERVE TANK RR BRAKE HOSE RR BRAKE HOSE GUIDE RR BRAKE HOSE RR BRAKE RESERVE TUBE RR BRAKE HOSE CLAMP RR BRAKE HOSE...

Page 23: ...DETAIL OF FUSE BOX PART DETAIL OF BATTER PART DETAIL OF THROTTLE BODY PART DETAIL OF REGRECTIFIER PART REG RECTIFIER REG EARTH WIRE O2 SENSOR WIRE ST MAG SW WIRE ST MAG BATTERY CABLE REG RECTIFIER CO...

Page 24: ...MEMO...

Page 25: ...STAND 2 13 SUSPENSION 2 14 BOLTS NUTS FASTENERS 2 14 WHEEL TIRE 2 15 STEERING STEM 2 15 COOLANT LEVEL INSPECTION 2 16 COOLANT REPLACEMENT 2 16 THROTTLE GRIP PLAY 2 6mm SPARK PLUG CR9EH 9 SPARK PLUG GA...

Page 26: ...10N m AC GENERATOR CAP 0 6 kgf m 6N m CRANKSHAFT HOLE CAP 0 8 kgf m 8N m AIR CLEANER CASE COVER SCREW 0 43kgf m 4 3N m REAR AXLE NUT 8 8kgf m 88N m DRIVE SPROCKET BOLT 1 2kgf m 12N m DRIVEN SPROCKET N...

Page 27: ...dealers or repair centers NOTES 1 At higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in unusually wet or dusty areas 3 Replace every 2...

Page 28: ...2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm 2 6mm ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER...

Page 29: ...ANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLEANER ELEMENT AIR CLE...

Page 30: ...with a micrometer Inspect and adjust valve clearance while the engine is cold below 35 C 95 F If the valve lifter is to be removed use the special tool Be careful not to drop the shim into the cylind...

Page 31: ...er cap and install the cap TORQUE 0 6kgf m CYLINDER COMPRESSION PRESSURE Warm up the engine to normal operating temperature Stop the engine disconnect the spark plug caps and spark plug install the co...

Page 32: ...duations on both sides of the swing arm ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUST...

Page 33: ...re loose tighten them to the specified torque TORQUE DRIVE SPROCKET BOLT 1 2kgf m 12N m DRIVE SPROCKET NUT 5 9kgf m 59N m Always replace the chain and sprocket as a set Because using the stretched cha...

Page 34: ...LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE L...

Page 35: ...imit groove Refer to page 16 7 for brake pad replacement FRONT BRAKE LEVER FREE PLAY Check the free play after pulling the lever BRAKE LEVER FREE PLAY 10 20mm REAR BRAKE PEDAL FREE PLAY Adjust the bra...

Page 36: ...ure the clutch lever free play at the end of the clutch lever FREE PLAY 10 20mm Adjust the headlight beam as specified by local laws and regulations An improperly adjusted headlight may blind oncoming...

Page 37: ...ly apply grease to the pivot area If the side stand moves too freely check the side stand spring Check the axial movement of the side stand Check the side stand switch Sit astride the motorcycle and r...

Page 38: ...secured Erect the motorcycle with the main stand Check a wear of the rear fork bush by moving the rear wheel aside If there is a free play replace the rear fork bush Tighten all nuts and bolts of the...

Page 39: ...side to side If the handlebar moves unevenly binds or has vertical movement inspect the steering stem STEERING STEM Check that the cables do not interfere with handlebar rotation STANDARD PRESSURE WHE...

Page 40: ...ER level lines Fill the coolant to the reserve tank up to the F upper level Remove the drain bolt and drain the coolant Tilt the vehicle to the right in order to assure complete and rapid draining Rem...

Page 41: ...ame ENGINE OIL TORQUE VALUES TAPPET ADJUST HOLE CAP 1 5 f m 15N m OIL FILTER COVER BOLT 1 1 f m 11N m SERVICE INFORMATION 3 1 TROUBLESHOOTING 3 2 ENGINE OIL LEVEL INSPECTION 3 3 ENGINE OIL CHANGE 3 3...

Page 42: ...on naturally External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed regularly Faulty head gasket Worn piston rin...

Page 43: ...heck to see if the oil is leak 3 3 LUBRICATION Make the engine warm and erect the motorcycle with side stand in order to assure complete and rapid draining OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GA...

Page 44: ...UE 1 1 kgf m 11 N m OIL PUMP REMOVAL Drain the engine oil 3 3 Remove the oil filter 3 4 DISASSEMBLY Clean the oil pump body inner and outer rotors with fresh cleaning oil OIL FILTER COVER OIL FILTER C...

Page 45: ...IMIT 0 25mm ASSEMBLY Clean all parts with fresh cleaning oil Install the lnner and outer rotor to the pump body INSTALLATION Install the oil filter cover to the RH crank case Fill the recommended oil...

Page 46: ...LUBRICATION POINTS 3 6 LUBRICATION Use general grease...

Page 47: ...MEMO...

Page 48: ...4 0 FUEL SYSTEM...

Page 49: ...ventilated area STANDARD OF MAINTENANCE Fuel tank capacity 14 85 Reserve fuel capacity 4 0 Fuel pump specification KGF38 Flow quantity Mimnim 20 Flow pressure 380kpa Injector specification Injector an...

Page 50: ...een by loosening the fuel cock Do not smoke or allow flames or sparks in the work area because gasoline is extremely flammable Immediately wipe off a leaked gasoline SOCKET BOLTS SOCKET BOLTS SOCKET B...

Page 51: ...EANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER CONNECTING TUBE BAND AIR CLEANER CONNECTING TUBE BAND AIR CLEANER CONNECTI...

Page 52: ...MEMO...

Page 53: ...27 12 CHECKING OF ESS CIRCUIT 5 30 13 CHECKING OF MIL CIRCUIT 5 32 14 ECU Electronic control unit 5 33 15 CRANK POSITION SENSOR 5 34 16 FUEL PUMP 5 35 17 THROTTLE BODY 5 38 18 HOW TO USE SCAN 5 42 SE...

Page 54: ...se these parts may be damaged by the impact of the drop Do not touch the ECU terminal because it may be damaged by the static The ignition key off before assembly and disassembly of the ECU coupler ot...

Page 55: ...ipe and injector The fuel in tank being high pressed by fuel pump moves to the division pipe through fuel filter Next the fuel is supplied to injector being highly maintained as regulated pressure abo...

Page 56: ...EMS Engine Management System 5 4 3 TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO 5 6 7 8 11 14 15 16 36 38 were not connected Terminal arrangement is based on the ECU 4 WIRING DIAGRAM OF THE ECU...

Page 57: ...econds when the main key is turned on Remarks 1 If the EMS has some problem and the MIL on and off engine starting and driving are temporary by the EMS s fail safe function But the EMS is not normal c...

Page 58: ...ver a minimum driving of vehicle MILon off INTAKE MIL INTAKE MILon on INTAKE INTAKE The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order Th...

Page 59: ...r to check the malfunction of vehicle is placed in the rh side cover Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool The...

Page 60: ...ct information to driver If the MIL on when engine is working engine is able to be operated by fail safe However in the event that Injector Fuel pump Ignition coil has something wrong vehicle may not...

Page 61: ...uel pump failure EFP Intake Manifold absolute pressure signal failure IMP Throttle position signal failure TPS O2 sensor heater output failure LSH Lambda signal failure VLS Engine temperature signal f...

Page 62: ...e ignition key on off If many problems happened in the EMS parts at the same time only one defect code will is displayed by the priority order Even thought repair a fault and remove the memorized faul...

Page 63: ...ECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONNECTOR INJECTOR CONN...

Page 64: ...5 12 CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit Coupler terminal is based on wire harness INJECTOR FUELPUMPRELAY ECU 40 INJECT...

Page 65: ...ey If the fuel pump operated for 3 seconds the power supply relay of injector is normal 6 Measure between the voltage of coupler Measuring terminal BLACK RED electric wire ground Measuring voltage bat...

Page 66: ...is Located on the left side of the throttle body MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT CONNECTOR MAPAT C...

Page 67: ...y 4 Measure the input voltage of MAPAT intake pressure sensor intake temperature sensor s coupler Input voltage 4 5 5 5 V Measuring terminal MAPAT 3 terminal MAPAT 1 terminal Remarks Measuring unit of...

Page 68: ...electricwire P G electricwire P L electricwireto see if they have been broken orhave short circuited if there is a bad contact badnessofterminalNo 3 No 26 No 27ofECUcoupler If the electric wire is no...

Page 69: ...o problem ECU is broken Replace the ECU with the new one it rechecks 4 Turn on the ignition key Start the engine and idling 5 Measure the voltage of intake pressure sensor for ECU check Measuring the...

Page 70: ...NSENSOR Remove LH side cowl TPS coupler Remove TPS screw 2EA Replace the TPS It is Located on the right side of throttle body The key is off before disassembly CAUTION ETS ETS ETS ETS ETS ETS ETS ETS...

Page 71: ...ge of TPS 3 Disassemble the TPS coupler 4 Turn on the ignition key Input voltage 4 5 5 5 V Measuring terminal ECU NO 18 Gr B GRAY BLACK ECU NO 4 W R WHITE RED Measure the terminal voltage of TPS s cou...

Page 72: ...9 If resistance and continuty are normal connect the coupler of TPS 10 Turn on the ignition key 11 Measure the TPS voltage of the wire harness to check the ECU Rotate the throttle lever measure the vo...

Page 73: ...eft hand side of cylinder head The key is off before disassembly ETS torque 3 0 3 kgf m CAUTION CAUTION ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTOR ETS CONNECTO...

Page 74: ...Measure the terminal voltage of ETS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit for voltage voltage V If the voltage value is not normal Check to see if the ECU coupler is loose or...

Page 75: ...the ETS Engine Temperature Sensor Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil Read the temperature of thermometer depending upon oil temper...

Page 76: ...ECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR ISA CONNECTOR AIR CLEANER AIR CLEANER AI...

Page 77: ...tage of ISA 3 Disassemble the coupler of ISA measure the resistance between ISA terminals ISA resistance 31 5 38 5 20 remarks Measuring unit of resistance Resistance R 4 If there is no problem check a...

Page 78: ...asuring unit Voltage V If the measured voltage is normal Checkthe B R electricwire L G electricwire W R electricwireto see if they have been broken or have short circuited if there is a bad contact of...

Page 79: ...SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2 SENSOR O2...

Page 80: ...urn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 Disassemble the coupler of oxygen O2 sensor and turn on ignition k...

Page 81: ...FAULT CODE BY OXYGEN O2 SENSOR LAMBDA SIGNAL 1 Turn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 The wire harness...

Page 82: ...coupler 6 Turn on the ignition key 7 Measure the voltage or tachometer of wire harness for ECU check Measuring terminal B electric wire G electric wire Output Voltage battery voltage Measuring termin...

Page 83: ...oltage Measuring terminal ECU No 24 L B BLUE BLACK EARTH Output voltage battery voltage Remarks Measuring unit of voltage Voltage V If the measured voltage is normal Checkthe L B electricwire B electr...

Page 84: ...E ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GROUND WIRE ECU GR...

Page 85: ...COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR SWITCH COUPLER 2P GEAR...

Page 86: ...oved CAUTION NOTICE FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP...

Page 87: ...EMS Engine Management System 5 35 The terminal arrangement of the fuel pump The following color chart is the internal color of the fuel pump 16 FUEL PUMP...

Page 88: ...er assemble Measure the resistance between Y W YELLOW WHITE wire and G GROUND wire of fuel unit terminal Remark Measuring unit of resistance Resistance If the measured resistance value is out of stand...

Page 89: ...NSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR THROTTLE BODY INSULATOR...

Page 90: ...the insulator Replace the o ring with new one ASSEMBLY OF THE THROTTLE BODY Install in the reverse order of removal Assemble the o ring into the throttle body Replace the o ring with new one CAUTION C...

Page 91: ...tor gasket ADJUSTMENT OF THROTTLE CABLE INSPECTION OF SENSOR AND ACTUATOR Assemble the throttle cable Adjust the free play of the throttle grip 2 4 Connecteachsensorandtheactuator scoupler ChecktheISA...

Page 92: ...E COUPLER TO CHECK THE MALFUNCTION OF VEHICLE THE COUPLER TO CHECK THE MALFUNCTION OF VEHICLE THE COUPLER TO CHECK THE MALFUNCTION OF VEHICLE THE COUPLER TO CHECK THE MALFUNCTION OF VEHICLE THE COUPLE...

Page 93: ...rn onthelgnitionkey Pressthepowerbuttonofthediagnostictool Presstheenterbuttonintheinitialscreen Presstheenterinthevehiclediagnosisscreen PresstheenterbuttonontheresettingECUvalues Presstherestbuttono...

Page 94: ...EMS Engine Management System 5 42 Presstheenterbuttonwhenitisready WhentheECUwasinitialized turnoffthelgnition keyandthenturnontheignitionkey...

Page 95: ...Turnthelgnitionkeyon Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Pressthebuttonatthevehiclediagnosticscreen Presstheenterbuttononthecurrentdata By looking the displaye...

Page 96: ...onnectedtothecouplerofdiagnostictool Turnthelgnitionkeyon Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbutton...

Page 97: ...tedtothecouplerofdiagnostictool Starttheengine Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Press the enter button on the vehicle diagnosis screen Presstheenterbuttonont...

Page 98: ...6 0 COOLING SYSTEM...

Page 99: ...the radiator cap if the coolant temperature is over 100 C It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding When the temperat...

Page 100: ...in radiator hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck Thermostat stuck o...

Page 101: ...them with water and consults a doctor immediately If any coolant is swallowed induce vomiting gargle and consult a physician immediately Especially pay attention to reserve the coolant Keep out of re...

Page 102: ...A Apply water to the cap sealing surface before the test SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS RADIATOR CAP BOLT BOLT BOLT BOLT BOLT...

Page 103: ...er hose from the radiator Disconnect the thermostatic switch wire coupler Disconnect thefan motor wire coupler RADIATOR DISASSEMBLY Remove 3 bolts and than remove the fan shround from the radiator Che...

Page 104: ...nt temperature over 88 92 the thermostatic switch ON RADIATOR INSTALLATION Intall the radiaator on the radiator bracket with the 2 bolts and 1 nut Connet the upper and lower hoses and secure them with...

Page 105: ...installation check for coolant leaks WATERPUMP MECHANICAL SEAL WATER SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage If the mechanical seal is leaking remove th...

Page 106: ...ver Inspect the mechanical water seal and seal washer for wear or damage WATER PUMP BODY REMOVAL REMOVE Water pump body Water pump shaft Remove the water pump impeller The impeller has left hand threa...

Page 107: ...e Drive in a newmechanical seal using a mechanical seal driver WATER PUMP SHAFT WATER PUMP IMPELLER INSTALLATION When the mechanical seal in replaced a new seal washer must be in stalled to the impell...

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Page 115: ...5 5 34 2 CLUTCH DISK THICKNESS 2 9 3 0 2 6 CLUTCH PLATE WARPAGE 0 2 CLUTCH OUTER I D 28 000 28 013 28 030 CLUTCH OUTER GUIDE O D 27 967 27 980 27 950 TORQUE VALUES CLUTCH LOCK NUT 6 5kgf m 65N m Apply...

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Page 126: ...he coolant If any difficulty is encountered in joining the crank shaft spline to the oil pump shaft spline remove the crankshaft hole cap then install the right crank case cover while turning the cran...

Page 127: ...MEMO...

Page 128: ...9 0 A C GENERATOR STARTER CLUTCH...

Page 129: ...service can be done with the engine installed in the frame SPECIFICATIONS ITEM STANDARD VALUE SERVICE LIMIT O D 39 622 39 635 39 607 STARTER DRIVEN GEAR I D 22 010 22 022 22 100 STARTER IDLE GEAR I D...

Page 130: ...M GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE...

Page 131: ...CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVER L CLANK CASE COVE...

Page 132: ...UFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY WOODRUFF KEY STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR START...

Page 133: ...tarter driven gear collar Clean the taper part of crank shaft and remove the dust If installing the rotor with dust in taper part the key will be damaged Because the contacted area of taper will be sm...

Page 134: ...ft Install the new gasket and dowel pins Install the L crankcase cove and tighten the bolts to the specified torque TORQUE 1 1kgf m 11N m Install the starter gear and shaft Replace with new O ring and...

Page 135: ...e driven gear You should be able to turn the driven gear counterclockwise smoothly but the gear should not turn clockwise as like photo DISASSEMBLY Remove the three socket bolts and remove the one way...

Page 136: ...or damage Install the one way clutch flange into the clutch outer Apply the screw locking bond to the socket bolt and install it TORQUE 3 2kgf m Check the starter driven gear for damage or wear Measu...

Page 137: ...MEMO...

Page 138: ...10 0 CYLINDER HEAD VALVES...

Page 139: ...HAFT ASSEMBLY 10 13 TORQUE VALUES CAM CHAIN TENSIONER PIVOT BOLT 1 0 kgf m 10N m SPARK PLUG 1 1 kgf m 11N m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m 20N m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m 12N m CA...

Page 140: ...n 3 Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 10 Exc...

Page 141: ...e LH crankcase cover Verify that the piston is located at the top dead center Make all camshaft lobes face downward If all camshaft lobes face upward rotate the crankshaft to the left for 1 turn 180 a...

Page 142: ...k if it turns smoothly Check the bearing for wear or damage CYLINDER HEAD REMOVAL Remove the cylinder head cover Remove the camshaft Remove the cylinder head special socket nut M8 Remove the cylinder...

Page 143: ...move the carbon deposits from the combustion chamber To prevent the loss of tension do not compress the valve springs more than necessary to remove the cotters Mark all parts during disassembly so the...

Page 144: ...clearance with a dial indicator while rocking the stem in the direction of normal thrust SERVICE LIMIT IN 0 080 mm EX 0 100 mm Measure the inner diameter of the new valve guide If the clearance is not...

Page 145: ...ing the valve guide out Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat co...

Page 146: ...more than necessary Reface the valve seat whenever the valve guide has been replace VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE...

Page 147: ...the seat using cutter as like IN 20 degree EX 30 degree flat cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too low on the valve grind the seat usin...

Page 148: ...YLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYL...

Page 149: ...the cylinder head Install in the remove order of removal CYLINDER HEAD INSTALLATION Cleananygasketmaterialfromthecylindermatingsurface Install the cam chain guide to the cylinder Install the dowel pi...

Page 150: ...iming gear while turning the camshaft If the cam chain tensioner lifter is dropped the shaft will advance by the spring force CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SHAFT HOLDER CAM SH...

Page 151: ...emove oil from the cylinder head cover grooves and accurately assemble the gasket to the cylinder head cover ORIGINAL NUMBER ORIGINAL NUMBER ORIGINAL NUMBER ORIGINAL NUMBER ORIGINAL NUMBER ORIGINAL NU...

Page 152: ...11 0 CYLINDER PISTON...

Page 153: ...Improper installation of piston ring Damaged piston ring Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston SERVICE INFORMATION 11 1 TROUBLESHOOTING 11 1 CYLINDER R...

Page 154: ...gasket and dowel pin Carefully remove any adhering gasket material from the cylinder head mating surface Do not scratch the surface INSPECTION Inspect the cylinder wall for scratches and wear Measure...

Page 155: ...ER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GAUGE FILTER GA...

Page 156: ...earance by subtracting the piston pin outer diameter from the pin bore inner diameter SERVICE LIMIT 0 020 mm SMALL END BEARING SURFACE INSPECTION Measure the inner dismeter of the connecting rod small...

Page 157: ...sembly Do not confuse the top and second rings Space the ring end gaps 120 degrees apart Install the ring forward to the marking facing up Do not accord the side rail of oil ring Place a clean shop to...

Page 158: ...cate the piston rings and install the cylinder Be careful not to damage the piston rings Be careful not to drop the cam chain into the crankcase Install the lower part of the cam chain guide to the pa...

Page 159: ...MEMO...

Page 160: ...12 0 CRANKCASE TRANSMISSION CRANKSHAFT...

Page 161: ...TARTER MOTOR SECTION 19 ITEM STANDARD VALUE SERVICE LIMIT FORK I D 12 000 12 018 12 050 SHIFT FORK SHAFT POLE THICKNESS 4 930 5 000 4 500 SHAFT O D 11 976 11 994 11 960 MAIN SHAFT O D M3 M5 19 967 19...

Page 162: ...bent Shift fork shaft bent Gear shift spindle claw bent Shift drum guide grooves damaged Shift drum guide pin damaged Transmission jumps out of gear Gear dogs worn Shift fork shaft bent Shift drum sto...

Page 163: ...rate the right crankcase from the left crankcase by tapping the crankcase with a soft hammer Remove the cam chain Remove the crankcase breather tube Loosen the ten 6mm crankcase bolts in a crisscross...

Page 164: ...s an assembly SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT SHIFT FORK SHAFT...

Page 165: ...Measure the gear inside diameter SERVICE LIMIT M5 23 050mm M3 C2 23 070mm C4 20 070mm C1 20 050mm Measure the gear bush inside diameter and outside diameter SERVICE LIMIT M5 OUTSIDE DIAMETER 22 930mm...

Page 166: ...e crankshaft use a bearing puller to remove it TOOL UNIVERSAL BEARING PULLER CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CR...

Page 167: ...COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING DR...

Page 168: ...at the socket bolt screw part with oil and install the main shaft bearing set plate TORQUE 1 2kgf m 12N m CRANKSHAFT INSTALLATION Coat a new left crankshaft bearing with clean engine oil and install n...

Page 169: ...ain shaft and counter shaft into the left crankcase together MAIN SHAFT COUNTER SHAFT Note the installation direction of each snap ring Do not use the worn snap ring again Check the snap rings are sea...

Page 170: ...FORK LEFT FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTER FORK CENTE...

Page 171: ...e switch pin into the groove of the shift drum Tighten the right crankcase bolt to the specified torque TORQUE 1 1kgf m 11N m GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITC...

Page 172: ...12 12 CRANKCASE TRANSMISSION CRANKSHAFT Install the cam chain Install the disassembled parts Install in the reverse order of removal Install the engine on the frame Section 7 MEMO...

Page 173: ...MEMO...

Page 174: ...13 0 EXTERNAL PARTS...

Page 175: ...allation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler SERVICE INFORMATION 13 1 TROUBLESHOOTI...

Page 176: ...oval SIDE COVER REMOVAL Remove the seat see above Remove the R L side cover mounting bolts then remove the R L side covers Installation is in the reverse order of removal Remove the seat mounting bolt...

Page 177: ...reverse order of removal Remove the R L special screws Remove the rear fender mounting bolts then remove the rear fender Installation is in the reverse order of removal REAR FENDER Remove the rear co...

Page 178: ...the exhaust pipe joint cap nuts Remove the exhaust pipe flange gasket Remove the following Exhaust pipe mounting bolt Exhaust pipe joint Exhaust pipe joint collar Exhaust pipe Exhaust pipe gasket Muff...

Page 179: ...mmat from the front fender Remove the front fender mounting special screws Remove the front fender forward Install in the reverse order of removal Check the protrusion of the exhaust pipe stud bolt In...

Page 180: ...14 0 FRONT WHEEL FRONT FORK STEERING...

Page 181: ...the engine to support the motorcycle SPECIFICATIONS TORQUE VALUES STEERING HANDLE PIPE BOLT 2 6kgf m 26N m FRONT BRAKE DISK BOLT 4 2kgf m 42N m FRONT AXLE NUT 5 9kgf m 59N m FORK TOP BRIDGE PINCH BOLT...

Page 182: ...ficient tire pressure Worn tire Steers to one side Damaged incorrectly tightened steering head bearing Unbalance of left right cushion Bent front fork Bent front axle shaft and inclind tire Worn tire...

Page 183: ...CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOCKET BOLT SOC...

Page 184: ...Loosen the handle pipe pinch bolt Remove the handlebars from the front forks HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE...

Page 185: ...pin with the hole in the handlebar Tighten the forward screw first then the rear screw Apply DAELIM Bond A to the inside of the grip and to the clean surfaces of the left handlebar and throttle grip...

Page 186: ...E THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE THROTTLE PIPE SWITCH HOUSING S...

Page 187: ...en the axle nut U nut Loosen the oval screw and pull the speedometer cable out of the speedometer gear box Remove the axle nut front axle the front wheel and R side collar INSPECTION Axle Place the ax...

Page 188: ...OMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR...

Page 189: ...EARING REMOVER SHAFT BEARING REMOVER SHAFT BEARING REMOVER SHAFT BEARING REMOVER SHAFT BEARING REMOVER SHAFT BEARING REMOVER SHAFT BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARIN...

Page 190: ...SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL FR WHEEL SIDE COLLAR FR CASTING WHEEL RADIAL BALL BEARING GEAR BOX RETAINER SPEEDOMETER GEAR LH...

Page 191: ...orrectly with the screw SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOME...

Page 192: ...nch bolt and remove the fork pipe from the handle pipe fork top bridge and steering stem FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE...

Page 193: ...L DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DESASSEMBLY Remove the fork pipe bolt from the fork REBOUND SPRING REBOUND SPRING REBOUND SPRING REBOUND SPRING REBOUN...

Page 194: ...NG SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SLIDER BUSHING SL...

Page 195: ...OTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE OIL LOCK PIECE OIL LOCK PIECE OIL LOCK PIECE...

Page 196: ...l lock piece onto the end of the seat pipe Install the seat pipe into the fork pipe Install the fork pipe into the bottom case Install the guide bush and slider bush Install the fork pipe into the bot...

Page 197: ...mble the oil seal to the bottom case Install the oil seal with special tools until the attachment groove of thebottom case set ring is exposed TOOLS OIL SEAL DRIVER OIL SEAL DRIVER BODY ATF automatic...

Page 198: ...ing to the fork cap bolt Install the fork cap bolt to the fork pipe Install the spring with the smaller pitch side facing downward FORK OIL FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING...

Page 199: ...t to the specified torque TORQUE 2 3 kgf m 23 N m Tighten the fork top bridge pinch bolt to the specified torque TORQUE 2 6 kgf m 26 N m Tighten the handle pipe pinch bolt to the specified torque TORQ...

Page 200: ...BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE H...

Page 201: ...STEERING STEM DRIVER Replace the cone reces and ball races in pairs DRIVER ATTACHMENT STEERING STEM DRIVER STEERING STEM DRIVER STEERING STEM DRIVER STEERING STEM DRIVER STEERING STEM DRIVER STEERING...

Page 202: ...SOCKET Move the steering stem right and left five times to seat the steel balls Make sure that the steering stem moves smoothly without play or binding then loosen the steering head top thread Retigh...

Page 203: ...L front forks then tighten the steering stem nut to the specified torque TORQUE 7 4 kgf m 74N m Install the following Front fork 14 12 Handlebar 14 3 Install the front brake hose stay and tighten the...

Page 204: ...10 0 CYLINDER HEAD VALVES...

Page 205: ...15 0 REAR WHEEL REAR SUSPENSION...

Page 206: ...rd caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR BRAKE DISK BLOT 4 2 f m 42N m REAR AXLE NUT 8 8 f m 88N m REAR CUSHION UPPER NUT 3 4 f m 34N m REAR CUSHION LOWER BOLT 3 4 f m 3...

Page 207: ...not tightened properly Insufficient air in tire Worn rear fork bush Soft suspension Weak spring Improper rear cushion adjust Incorrect rear damper Hard suspension Improper rear cushion adjust Bent dam...

Page 208: ...Remove the drive chain from the driven sprocket Remove the axle from the left side and remove the rear wheel Remove the side collars DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE D...

Page 209: ...ged DISASSEMBLY Remove the bolts and brake disk Remove the dust seal Remove the snap ring Remove the nuts and final driven sprocket Check the drive chain and driven sprocket at the same time Do not di...

Page 210: ...deterioration or damage Replace it if necessary Remove the oil seal Wheel Bearing Removal Install the bearing remover into the bearing install the bearing remover shaft at the opposite position and re...

Page 211: ...l the nut after aligning the flange part of fixing bolt with the sprocket inside groove and install the nuts TORQUE 5 9 kgf m 59 N m Install the brake disk with literal mark facing out Install and tig...

Page 212: ...H side cover Loosen the rear cushion upper flange bolt and remove the rear cushion The damper unit is filled with high pressure nitrogen gas Do not disassemble gas damper unit Heating a gas filled dam...

Page 213: ...his will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUS...

Page 214: ...mudguard Remove the brake hose from the swingarm Remove the rear cushion lower flange bolt LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT L...

Page 215: ...move the two screws and chain slider Check the chain slider for wear or damage Remove the dust seal caps Remove the bushes pivot bearings and pivot distance center collar Check the dust seal cap bushe...

Page 216: ...swingarm Install the drive chain slider on the swingarm then tighten the screws TORQUE 0 6 kgf m 6 N m SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS...

Page 217: ...ue TORQUE 4 0 kgf m Install the brake hose clamp correctly Install the rear caliper bracket into the groove of the swingarm Install the rear wheel mudguard Install the rear wheel 15 3 Install the remo...

Page 218: ...MEMO...

Page 219: ...16 0 HYDRAULIC BRAKE FRONT REAR...

Page 220: ...disconnecting the hose Bleed the air in case of removing the brake hose SERVICE INFORMATION 16 1 TROUBLESHOOTING 16 2 BRAKE FLUID REPLACEMENT AIR BLEEDING 16 3 BRAKE PAD DISK 16 6 FRONT MASTER CYLINED...

Page 221: ...restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pad disk Misaligned wheel Clogged restricted brake hose jo...

Page 222: ...IR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK RESERVOIR TANK...

Page 223: ...bleeder valve adding fluid when the fluid level in the master cylinder reservoir is low Repeat the previous step procedures until air bubbles do not appear in the plastic hose Tighten the bleeder valv...

Page 224: ...s been closed 3 Repeat steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleeder valve Front brake Install the master cylinder cap and tighten the screws Rear brake Install th...

Page 225: ...aliper bracket bolts and brake capliper 16 6 HYDRAULIC BRAKE HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER...

Page 226: ...voir as this operation causes the level to rise Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads Remove the dust plugs using the L wre...

Page 227: ...caliper bracket bolts TORQUE 3 0 kgf m 30 N m Tighten the hanger pins and pin plugs TORQUE 1 8 kgf m 18 N m Install the rear brake hose clamp Install the rear wheel mudguard BRAKE PADS BRAKE PADS BRAK...

Page 228: ...cylinder assembly FRONT MASTER CYLINDER REMOVAL Drain the brake fluid 16 3 Disconnect the brake light switch wire connectors Remove the brake hose oil bolt and washers Brake fluid causes damage to th...

Page 229: ...T STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW BOOT BOOT BOOT BOO...

Page 230: ...damage Measure the master cylinder piston O D SERVICE LIMIT 12 645mm ASSEMBLY Check the master cylinder for abnormal scratches Measure the master cylinder I D SERVICE LIMIT 12 755mm MASTER CYLINDER C...

Page 231: ...TON PISTON PISTON PISTON PISTON PISTON PISTON FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP SWITCH FRONT STOP...

Page 232: ...minated gently wipe off the fluid with a piece of cloth or wash in water Close hose joints properly to prevent leakage of brake fluid BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT B...

Page 233: ...IN JOINT PIN JOINT PIN JOINT PIN JOINT PIN JOINT PIN JOINT PIN JOINT PIN TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE...

Page 234: ...TER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER SPRING SPRI...

Page 235: ...ndary cup Install the spring secondary cup and master piston assembly MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MA...

Page 236: ...ING O RING O RING O RING O RING O RING O RING TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT PIPE TUBE JOINT...

Page 237: ...rake fluid Do not use high pressure air or bring the nozzle too close to the inlet Avoid spilling fluid on painted plastic or rubber parts Be careful not to damage the piston sliding surface PISTON SE...

Page 238: ...liper cylinder I D SERVICE LIMIT 25 42mm ASSEMBLY Check the caliper pistons for scratches scoring or other damage Measure the caliper piston O D SERVICE LIMIT 25 27mm CALIPER BRACKET PISTONS PISTON SE...

Page 239: ...se eyelet joint Avoid spilling fluid on painted plastic or rubber parts PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEAL PISTION SEA...

Page 240: ...BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS BRACKET BOLTS CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPER BRACKET CALIPE...

Page 241: ...the pad ASSEMBLY CALIPER BRACKET PIN BOLT A PISTONS PISTON SEALS PIN BOLT DUST PLUGS HANGER PINS PAD SPRING INNER PAD OUTER PAD RR CALIPER BRACKET PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PIST...

Page 242: ...IL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHE...

Page 243: ...der socket bolts to the specified torque SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOC...

Page 244: ...MEMO...

Page 245: ...17 0 BATTERY CHARGING SYSTEM 30A 15A fi ECU B Black Y Yellow G Green R Red W White Lg Light green MAIN SWITCH BATTERY...

Page 246: ...lowed to repeatedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is...

Page 247: ...ire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator Charging System faulty Check the battery current leakage 16 4 Check the regulator rectifier 16 5 Battery is f...

Page 248: ...L TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL...

Page 249: ...ERY TERMINAL GROUND CABLE DIGITAL TESTER AMPERE METER MAIN FUSE TERMINALS MAIN FUSE When measuring current using a tester set it to a high range and then bring the range down to an appropriate level C...

Page 250: ...e harness side are normal and there are no loose connections at the regulator rectifier coupler inspect the regulator rectifier unit by measuring the resistance between the terminals Resistance value...

Page 251: ...CHARGING COIL INSPECTION Remove the seat 13 2 Remove the LH side cover 13 2 Disconnect the A C generator cord coupler Measure the resistance between the yellow leads RESISTANCE VALUE 0 5 1 5 20 If th...

Page 252: ...MEMO...

Page 253: ...18 0 IGNITION SYSTEM BATTERY ECU FUSE BOX AC GENERATOR REGULATOR RECTIFIER IGNITION COIL...

Page 254: ...ften related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive peak voltage As inspections for coil resistance values ar...

Page 255: ...onnector 4 Open circuit or poor connection in ground cord of the ECU unit 5 Faulty peak voltage adaptor 6 Faulty ECUunit in case when above No 1 6 are normal 1 Faulty spark plug or leaking ignition co...

Page 256: ...Check the resistance of coil between black yellow and green is within the specified range 0 1 0 3 20 Check continuity between ground and frame INSPECTION A C GENERATOR COUPLER A C GENERATOR COUPLER A...

Page 257: ...Iftheresistancevalueiswithinthespecifiedrangethe coilisgood Ifresistanceis infinite replacethecoilwithanewone STANDARD VALUE 0 73 0 08 Withthesparkplugcapon measuretheresistancebetween theprimarycoil...

Page 258: ...in wire harness Remove the side stand switch mounting screws and remove the cord clamp and side stand switch TERMINALS COLOR STANDARD ITEM SIDESTANDSWITCH ON Side stand erected PUSU THE SHAFT HELASE T...

Page 259: ...R G W G Y Y G B W B B B W B W W B Black Y Yellow G Green R Red W White Lg Light green Y R MAIN SWITCH FUSE FUSE NEUTRAL LAMP BATTERY 12A 10AH GEAR POSITION SIDE STAND SWITCH SWITCH STARTER MAGNETIC SW...

Page 260: ...ak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while the engine is not cranki...

Page 261: ...netic switch coil ground wire 18 9 Connect the starter magnetic switch coupler Measure the starter magnetic voltage at the starter magnetic switch coupler 18 9 Check the starter magnetic switch operat...

Page 262: ...der Remove the starter motor mounting bolts and ground cable Pull the starter motor out of the crankcase 19 3 ELECTRIC STARTER DISASSEMBLY Remove the following O ring Starter motor case bolts spring w...

Page 263: ...Washers Armature Check the oil seal and bushing in the front cover for wear or damage Check the commutator bars of the armature for discoloration Discoloration of the commutator bars Replace with a n...

Page 264: ...ld be no continuity Check for continuity between the insulated brush and cable terminal There should be continuity Check for continuity between each commtator bar and armature shaft There should be no...

Page 265: ...the brush length SERVICE LIMIT 5 mm Remove the following Washer nut Washer O ring Terminal setting bush Brush holder REAR COVER ARMATURE BRUSH BRUSH HOLDER SEAL RING SEAL RING FRONT COVER SHIM O RING...

Page 266: ...stall the two washers Install a new seal ring onto the motor case Apply thin coat of grease to the armature shaft end Install the rear cover aligning its mark with the motor case mark Install the brus...

Page 267: ...ver aligning its mark with the motor case mark Install the ground cable and mounting bolts and tighten the bolts securely Install the clutch wire holder Install the starter motor cable then tighten th...

Page 268: ...ic switch connector Shift the transmission into neutral Measure the voltage between the Yellow Red wire terminal and ground If the battery voltage appears only when the starter switch is pushed with t...

Page 269: ...isconnect the wire connector of the magnetic switch Connect the positive wire to the yellow red wire terminal and the negative wire to the green yellow wire terminal There should be continuity INSTALL...

Page 270: ...MEMO...

Page 271: ...LIGHTS METER SWITCHES 20 0...

Page 272: ...the connector corrosion an ohmmeter is required to check the circuit resistance value The following color codes are used throughout this section B Black Y Yellow L Blue G Green R Red W White Br Brown...

Page 273: ...re turned OFF Be sure to turn the ignition switch OFF and let the bulb cool down before replacement If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to...

Page 274: ...not turn on replace the stop tail light bulb BULB REPLACEMENT Remove the screws and tail light lens Slightly press down on the bulb and turn it counterclockwise Replace with a new bulb Install in the...

Page 275: ...METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION M...

Page 276: ...e socket bolts and remove the main switch Install in the reverse order of removal MAIN SWITCH INSPECTION Remove the key cover Remove the main seat Remove the fuel tank Remove the main switcs coupler C...

Page 277: ...GHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH...

Page 278: ...uity with the brake lever applied and there should be no continuity with the brake lever is released REAR Remove the seat 13 2 Remove the RH side cover 13 2 Disconnect the rear stop switch connector a...

Page 279: ...ome on Faulty winker relay Poor connection of the connector Broken wire harness GEAR CHANGE SWITCH Remove the seat 13 2 Remove the LH side cover 13 2 Disconnect the neutral switch connector from the s...

Page 280: ...P FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNIT FUEL UNI...

Page 281: ...MEMO...

Page 282: ...t cylinder compression Low compression Low speed of starter crank Incorrect valve clearance Faulty valve seat Worn cylinder and piston rings Seized valve Improper valve timing 4 Start by following nor...

Page 283: ...ly Engine speed increased Engine speed doesn t increase Closed carburetor choke Clogged fuel aisle Clogged air cleaner Clogged fuel tank breather Clogged muffler 4 Accelerate lightly Correct Incorrect...

Page 284: ...cation Not overheated Overheated Excessive carbon build up in combustion chamber Poor quality fuel being used Lean fuel mixture Clutch slipping 12 Check for engine overheating Correct Incorrect Incorr...

Page 285: ...EED 1 Check the ignition timing and Incorrect Faulty valve clearance adjustment valve clearance Faulty ECU unit Faulty pulse generator 2 Disconnect fuel tube at Fuel flows No fuel to fuel tank carbure...

Page 286: ...amaged Faulty float Balance coil damaged or shorted Terminal loose Faulty terminal connection Balance coil lead shorted or damaged GAUGE READING INACCURATE IGNITION SWTICH ON 1 Operate the turn signal...

Page 287: ...Balance coil lead shorted or damaged GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit 2 Remove the tank and operate the float 3 Move...

Page 288: ...MEMO...

Page 289: ...MEMO...

Page 290: ...MEMO...

Page 291: ...MEMO...

Page 292: ...22 WIRING DIAGRAM...

Page 293: ...22 1 WIRING DIAGRAM...

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