DAELIM ROADWIN VJ125 - SERVICE, Service Manual

Page 1: ...01E HEAD OFFICE FACTORY 58 SUNG SAN DONG CHANGWON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7524 OVERSEAS SALES OFFICE 13 5 SUNG SOO 1DONG 1GA SUNG DONG GU SEOUL KOREA TEL 82 2 498 6465 FAX 82 2...

Page 2: ...ause 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 this publication...

Page 3: ......

Page 4: ...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 electri...

Page 5: ...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 6: ...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 7: ...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 8: ...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 9: ...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 10: ...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 11: ...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 12: ...NFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The engine serial number is stamped on left crankcase FRAME SERIAL NUMBER LOCATION The frame serial number is stamped on the left side of...

Page 13: ...aulic Disk REAR BRAKE Hydraulic Disk FUEL CAPACITY 16 FUEL RESERVE CAPACITY 1 1 CASTER ANGLE 25 2 TRAIL 93 5mm FRONT FORK OIL CAPACITY 265 2 5cc TYPE Air Cooled 4 stroke SOHC CYLINDER NUMBER ARRANGEME...

Page 14: ...1 T GEAR RATIO 5th 0 923 24 26 T GEARSHIFT PATTERN Left foot operated return system 1 N 2 3 4 5 IGNITION TYPE DC CDI Ignition IGNITION TIMING F MARK 8 BTDC 1 600 rpm FULL ADVANCE 28 BTDC 4 000 rpm AC...

Page 15: ...R PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW TAPPET VALVE ADJUST HOLE CAP TAPPET ADJUST NUT PRIMARY DRIVE GEAR NUT CLUTCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET...

Page 16: ...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 NUT U NUT SOCKETBOLT 3 0 30 1 2 12 5 9 59 4 2 42 3 4 34 3 0 30 1...

Page 17: ...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 18: ...IPTION REFERENCE SECTION REMARK CLUTCH CENTER HOLDER 7 ACG ROTOR PULLER 8 VALVE GUIDE DRIVER 9 VALVE GUIDE REAMER 9 UNIVERSAL BEARING PULLER 11 BEARING REMOVER SET 11 THREAD ADAPTER 11 ASSEMBLY SHAFT...

Page 19: ...Y CABLE BATTERY EARTH CABLE HARNESS COVER WIRE CLIP ST MAG BATTERY CABLE BATTERY EARTH CABLE ST MAG SW WIRE C CLUTCH CABLE WINKER SW CORD CHOKE CABLE CABLE GUIDE LH FR WINKER HEAD LIGHT CABLE GUIDE SP...

Page 20: ...OSE THROTTLE JUNCTION CABLE GUIDE IGN COIL CORD CHOKE CABLE THROTTLE CABLE TO ACCELERATION PUMP THROTTLE CABLE TO CARB ST MAG SW WIRE FUSE CODE ST MAG BATTERY CABLE FUSE BOX BATTERY EARTH CABLE BATTER...

Page 21: ...MAG SW ASS Y ST MOTOR CABLE BATTERY EARTH CABLE SIDE STAND SW CORD RR STOP SW CORD RESERVE TANK RR BRAKE HOSE RR BRAKE HOSE GUIDE RR BRAKE RESERVE TUBE RR BRAKE HOSE RR CALIPER RR BRAKE HOSE RESERVE T...

Page 22: ...RH CABLE GUIDE COMBI METER CORD WINKER SW CORD RH WINKER CORD LH WINKER CORD WIRE CLIP COMB SW CORD COMB SW WIRE HAZARD SW CORD DETAIL OF HEAD LIGHT CASE PART WINKER SW WIRE WINKER WIRE WIRE CLIP WIRE...

Page 23: ...MEMO...

Page 24: ...HT AIM 2 12 CLUTCH SYSTEM 2 12 SIDE STAND 2 13 SUSPENSION 2 14 BOLTS NUTS FASTENERS 2 14 WHEELS TIRES 2 15 STEERING HEAD BEARINGS 2 15 THROTTLE GRIP PLAY 2 6mm SPARK PLUG CR8EH 9 SPARK PLUG GAP 0 8 0...

Page 25: ...1 kgf m 11N m AC GENERATOR CAP 0 6 kgf m 6N m CRANKSHAFT HOLE CAP 0 8 kgf m 8N m AIR CLEANER CASE COVER SCREW 0 43kgf m 4 3N m REAR AXLE NUT 8 8kgf m 88N m DRIVE SPROCKET BOLT 1 2kgf m 12N m DRIVEN S...

Page 26: ...r 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 years or...

Page 27: ...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 28: ...OKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER CHOKE LEVER SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREW...

Page 29: ...ole before inserting the spark plug To prevent damage to the cylinder head handtighten the spark plug before using a wrench to tighten to the specified torque Do not overtighten the spark plug Inspect...

Page 30: ...USTING WRENCH B SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPAR...

Page 31: ...USTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTI...

Page 32: ...drive and driven sprockets If any are loose torque them 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 When installing the d...

Page 33: ...KE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to page 15 6 for brake pad replacement Do not mix a dust or different types...

Page 34: ...bleeding procedures REAR BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to page 15 6 for brake pad replacement FRONT BR...

Page 35: ...specified by local laws and regulations An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance BRAKE STOP SWITCH BRAKE STOP SWITCH BRAKE STOP...

Page 36: ...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 raise the side stand Start the engine wit...

Page 37: ...secured Support 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 th...

Page 38: ...e If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings section 13 STEERING HEAD BEARINGS Check that the cables do not interfere with handlebar rotation STA...

Page 39: ...MEMO...

Page 40: ...5 f m 15N m OIL FILTER SOCKET BOLT 1 2 f m 12N m OIL FILTER COVER BOLT 1 1 f m 11N m OIL PUMP MOUNTING BOLT 1 1 f m 11N m 3 SERVICE INFORMATION 3 1 TROUBLESHOOTING 3 2 ENGINE OIL LEVEL INSPECTION 3 3...

Page 41: ...ption External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed often enough Faulty head gasket Worn piston rings L...

Page 42: ...AUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL...

Page 43: ...FT PUMP SHAFT PUMP SHAFT PUMP SHAFT OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OI...

Page 44: ...PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP BODY PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHAFT PUMP SHA...

Page 45: ...the oil pump to operate smoothly SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RING SETTING RIN...

Page 46: ...H LEVER PIVOTS THROTTLE CABLE CHOKE CABLE SPEEDOMETER CABLE CLUTCH CABLE BRAKE LEVER PIVOTS SIDE SAND PIVOT FRONT FORK DUST SEAL LUBRICATION POINTS Use general grease unless specified here Apply oil o...

Page 47: ...4 0 FUEL SYSTEM...

Page 48: ...al gasoline and then put in a vessel If it is desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be...

Page 49: ...justment Excessively lean or rich mixture Clogged fuel system Intake air leak Clogged fuel system Lean mixture Clogged carburetor jets Clogged fuel tank breather Clogged fuel strainer screen Twisted p...

Page 50: ...T BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOL...

Page 51: ...COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER SIDE COVER AIR CLEANER CONNECTING TUBE BAND AIR CLEANER CONNECTING TUBE B...

Page 52: ...HROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTT...

Page 53: ...rottle valve with the throttle stop screw on the carburetor and install the valve on the carburetor Inspect the following items Throttle grip free play 2 6mm Idling speed 1 600 100 rpm Gasoline is ext...

Page 54: ...RAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRING SPRIN...

Page 55: ...EWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALV...

Page 56: ...LOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE...

Page 57: ...W JET SLOW JET FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT LEVEL GAUGE FLOAT...

Page 58: ...THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW...

Page 59: ...ed with the throttle stop screw PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW...

Page 60: ...MEMO...

Page 61: ...5 0 COOLING SYSTEM...

Page 62: ...5 COOLING SYSTEM SERVICE INFORMATION GENERAL SAFETY TORQUE VALUE OIL THROUGH BOLT 3 2kgf m 32N m 5 SERVICE INFORMATION 5 1 RADIATOR 5 2 Wait until the engine is cool before servicing the cooling syst...

Page 63: ...diator from the frame Remove the oil through bolts from the cylinder and RH LH radiator hose Replace the radiator when the choked area of radiator core is over 20 of radiant heat area SCREWS SCREWS SC...

Page 64: ...MEMO...

Page 65: ...6 0 ENGINE REMOVAL INSTALLATION...

Page 66: ...ection 7 Geashift section 7 A C Generator section 8 Starter clutch section 8 The following works require engine removal for service Cylinder head valve section 9 Cylinder piston section 10 Transmissio...

Page 67: ...R BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS REAR ENGINE HANGER BOLTS CLUTCH CABLE CLUT...

Page 68: ...BLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE CLUTCH CABLE FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS F...

Page 69: ...7 0 CLUTCH GEARSHIFT...

Page 70: ...FREE LENGTH 35 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...

Page 71: ...plate warpage Clutch lock nut loose High fluid level or high fluid weight Clutch disengages Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play Difficult to thrust...

Page 72: ...ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER ROD CLUTCH LIFTER RO...

Page 73: ...R CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER CLUTCH LEVER HOLE HOLE HOLE HOLE HOLE HOLE...

Page 74: ...H OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE CLUTCH OUTER GUIDE...

Page 75: ...TE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CLUTCH PLATE CL...

Page 76: ...R SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM GEAR SHIFT CAM BOLT BOL...

Page 77: ...torque GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM GEAR CHANGE ARM...

Page 78: ...T WASHER THRUST WASHER THRUST WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WASHER SPLINE WA...

Page 79: ...NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm Remove the lo...

Page 80: ...OCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT WRENCH 20X24mm LOCK NUT...

Page 81: ...stall the right crankcase cover bolts Tighten the bolts crisscross pattern in 2 3 steps securely TORQUE 1 1kgf m 11N m Connect the clutch cable end to the clutch lever then install the clutch wire hol...

Page 82: ...MEMO...

Page 83: ...8 0 A C GENERATOR STARTER CLUTCH...

Page 84: ...gine 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 10 013 10 045 10 100 STARTER ID...

Page 85: ...R WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATOR WIRE CLAMP A C GENERATO...

Page 86: ...R 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 COVER L CLANK...

Page 87: ...AR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER...

Page 88: ...diameter SERVICE LIMIT 9 970mm STARTER IDLE GEAR GEAR SHAFT REDUCTION GEAR GEAR SHAFT STARTER CLUTCH INSPECTION Check the operation of the one way clutch by turning the driven gear You should be able...

Page 89: ...nt to the starter clutch outer mounting bolt threads Hold the flywheel with a flywheel holder and tighten the starter clutch mounting socket bolts TORQUE 3 2kgf m 32N m Install the starter driven gear...

Page 90: ...GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLAR STARTER DRIVEN GEAR COLLA...

Page 91: ...CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWITCH COUPLER GEAR CHANGE SWI...

Page 92: ...OVER L REAR COVER L REAR COVER L REAR COVER L REAR COVER L REAR COVER PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MARK PUNCH MAR...

Page 93: ...9 0 CYLINDER HEAD VALVES...

Page 94: ...T 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 CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m 4N m CYLINDER HEAD CO...

Page 95: ...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 9 Exce...

Page 96: ...MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER MOUNTING BOLTS TENSIONER...

Page 97: ...HAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM SPRINGS ROCKER ARM...

Page 98: ...t for wear or damage Measure the height of the cam lobe SERVICE LIMIT IN 37 110 mm EX 36 870 mm Be sure to check the valve clearance CAMSHAFT BEARINGS Remove the gasket dowel pins and cam chain guide...

Page 99: ...spark plug cover from the cylinder head PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT BOLT PIVOT...

Page 100: ...er of the new valve guide If the clearance is not within the service limit replace the valve VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE DRIVER VALVE GUIDE...

Page 101: ...eat contact and results in the valve seat refacing not able to be performed Use cutting oil on the reamer during this operation Rotate the reamer clockwise never counterclockwise when inserting and re...

Page 102: ...s 60 35 4 45 5 IN 22mm Ex 22mm IN 23mm EX 20mm IN 24 5mm Ex 24 5mm 37 VALVE SEAT Valve faces and stem tips cannot be ground If a valve face or stem tip is rough worn unevenly or contacts the seat impr...

Page 103: ...5 degree finish cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter Refinish the seat to specifications using a 45 degree finish cutter Using a 60...

Page 104: ...STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL STEM SEAL SPRING SEAT SPRING SEAT SPRING SEAT SPRING SEAT S...

Page 105: ...cylindermatingsurface Install the cam chain guide to the cylinder Install the dowel pins and new gasket Install the cam chain tensioner and assemble pivot bolts TORQUE 1 0 kgf m 10N m Install the spar...

Page 106: ...AFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT SHAFT BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLES BOLT HOLE...

Page 107: ...nstall the camshaft holder Apply engine oil to the threaded part install the camshaft holder nut and bolts and tighten them driving with 2 3 times TORQUE 2 0 kgf m 20N m Tighten the cylinder head bolt...

Page 108: ...TING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS Fill clean engine oil into the operating parts of the cylinder head Adjust the valve...

Page 109: ...10 0 CYLINDER PISTON...

Page 110: ...installation of piston ring Damaged piston ring Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston 10 SERVICE INFORMATION 10 1 TROUBLESHOOTING 10 1 CYLINDER REMOVAL...

Page 111: ...n an X and Y axis Take the maximum reading to determine the out of round Calculate the cylinder for taper at three levels in an X and Y axis Take the maximum reading to determine the taper If any of t...

Page 112: ...of the piston Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the clip fall into the crankcase PISTON DISASSEMBLY Clean carbon deposits from the piston Ins...

Page 113: ...reading to determine the inner diameter Replace the piston if the inner diameter is over the service limit SERVICE LIMIT 15 040 mm Measure the piston pin outer diameter at three points Replace the pi...

Page 114: ...the ring end gaps 120 degrees apart Space the side rail gaps 40mm or more apart as shown Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase The mark that...

Page 115: ...ge 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 part of the crankcase and install the cam chain guide by aligning the p...

Page 116: ...MEMO...

Page 117: ...11 0 CRANKCASE TRANSMISSION CRANKSHAFT...

Page 118: ...RTER MOTOR SECTION 18 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 98...

Page 119: ...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 120: ...GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH CAM CHAIN CAM CHAIN CAM CHAI...

Page 121: ...R SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT COUNTER SHAFT SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIF...

Page 122: ...meter and outside diameter SERVICE LIMIT M5 OUTSIDE DIAMETER 22 930mm M3 M2 OUTSIDE DIAMETER 22 950mm C1 OUTSIDE DIAMETER 19 930mm M3 C2 INSIDE DIAMETER 20 050mm C1 INSIDE DIAMETER 16 550mm Measure ou...

Page 123: ...a bearing puller to remove it TOOL UNIVERSAL BEARING PULLER RIGHT LEFT FEELER GAUGE CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKSHAFT CRANKS...

Page 124: ...SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING COUNTER SHAFT BEARING ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMENT ATTACHMEN...

Page 125: ...NKSHAFT INSTALLATION Coat a new left crankshaft bearing with clean engine oil and install new bearings into the right crankcase TOOLS DRIVER ATTACHMENT 72 78mm PILOT 35mm Install the crankshaft into t...

Page 126: ...EARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING MAIN SHAFT BEARING REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER 15mm REMOVER...

Page 127: ...SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT DRUM SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SHIFT FORK SH...

Page 128: ...IFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HOLE GEAR SHIFT DRUM HO...

Page 129: ...CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH...

Page 130: ...MEMO...

Page 131: ...12 0 EXTERNAL PARTS...

Page 132: ...for leaks after installation TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 12 SERVICE INFORMA...

Page 133: ...LT BOLT CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTING GROMMET CENTER COVER SETTI...

Page 134: ...BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT RELAY LIGHT...

Page 135: ...BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKET GASKE...

Page 136: ...RONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT FENDER FRONT...

Page 137: ...13 0 FRONT WHEEL FRONT FORK STEERING...

Page 138: ...t 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 2 6kgf m 26N m FORK...

Page 139: ...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 140: ...BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSIN...

Page 141: ...NDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HANDLE WEIGHT CAP HAND...

Page 142: ...OP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE FORK TOP BRIDGE HOLE HANDLE PIPE HANDL...

Page 143: ...PIPE THROTTLE PIPE THROTTLE PIPE SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SWITCH HOUSING SW...

Page 144: ...OLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BRAKE CALIP...

Page 145: ...PEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX...

Page 146: ...D BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING R...

Page 147: ...T 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 FR BRAKE DISK FR TIRE FR DISTANCE COLLAR RADIAL...

Page 148: ...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 BOX SPEEDOM...

Page 149: ...LT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE PINCH BOLT HANDLE PIPE P...

Page 150: ...SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DESASSEMBLY Remove the fork pipe bolt from the fork Remove the fork spring and expand and release the fork pipe several times to drain...

Page 151: ...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 152: ...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 153: ...RK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK PIPE BUSHING FORK...

Page 154: ...T PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE SEAT PIPE Install the oil seal stopper ring into the...

Page 155: ...SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING FORK SPRING O RING O RING O RING O RING O RING O RING O RING O RING O RI...

Page 156: ...IDGE FORK TOP BRIDGE FORK TOP BRIDGE SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS BOTTOM PINCH BOLT BOTTOM PINCH BOLT BOTTOM PINCH BO...

Page 157: ...BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY BRAKE HOSE STAY FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANG...

Page 158: ...E RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE BOTTOM CONE RACE DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SE...

Page 159: ...ding INSTALLATION STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL BALL STEEL...

Page 160: ...interference 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...

Page 161: ...14 0 REAR WHEEL REAR SUSPENSION...

Page 162: ...d 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 34...

Page 163: ...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 164: ...LOCK NUT LOCK NUT LOCK NUT LOCK NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE SHAFT AXLE SHA...

Page 165: ...n and driven sprocket at the same time GOOD REPLACE DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEA...

Page 166: ...OVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT REMOVER SHAFT DAMPER...

Page 167: ...P RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUS...

Page 168: ...SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT AXLE SHAFT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER...

Page 169: ...the bag around the drill motor and briefly run the drill motor inside the bag this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start DUST...

Page 170: ...ARD MOUNTING BOLTS LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT L...

Page 171: ...AL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP Remove the U nut and swin...

Page 172: ...CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP DUST SEAL CAP...

Page 173: ...ove of the swingarm Install the rear wheel mudguard Install the rear wheel 14 7 Install the removed parts in the reverse order of removal LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FLANGE BOLT LOWER FL...

Page 174: ...MEMO...

Page 175: ...15 0 HYDRAULIC BRAKE FRONT REAR...

Page 176: ...isconnecting the hose Bleed the air in case of removing the brake hose 15 SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 2 BRAKE FLUID REPLACEMENT AIR BLEEDING 15 3 BRAKE PAD DISK 15 6 FRONT MASTER CYLIN...

Page 177: ...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 178: ...SERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR CAP RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR PLATE RESERVOIR...

Page 179: ...E BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER HOSE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER VALVE BLEEDER...

Page 180: ...ze the brke lever or push the brake pedal open the bleeder valve 1 2 turn and then close the valve 2 Release the brake lever or pedal until the bleeder valve has been closed 3 Repeat steps 1 and 2 unt...

Page 181: ...E CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CALIPER BRAKE CA...

Page 182: ...R PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS HANGER PINS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS B...

Page 183: ...ADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS BRAKE PADS HANGER PINS HANGER PINS HANGER PINS HANGER...

Page 184: ...limit Replace the brake disk if the wheel bearings are normal Remove the bolts from the master cylinder holder and remove the master cylinder assembly FRONT MASTER CYLINDER REMOVAL Drain the front hyd...

Page 185: ...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 186: ...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 187: ...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 188: ...OLT 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 WASHERS WASHERS WASHERS WASHERS WASH...

Page 189: ...LTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS C...

Page 190: ...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 191: ...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 192: ...MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER C...

Page 193: ...EDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP SPEEDOMETER CABLE CLAMP PISTON SEAL...

Page 194: ...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 195: ...LIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON CALIPER PISTON DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DU...

Page 196: ...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 197: ...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 198: ...KET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS COTTER PIN COTTER PIN...

Page 199: ...AIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY MAIN STEP BAR ASSEMBLY COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER PIN COTTER P...

Page 200: ...MEMO...

Page 201: ...Br W Br W Br W CDI UNIT Br W B CABLE HEADLIGHT RELAY HEADLIGHT 12V 35 35W SPEEDOMETER ILLUM 12V 2W X 2EA 12V 3W TAIL LIGHT 12V 5W BATTERY 12V 10AH Y Y A C GENERATOR REG RECTI MAIN SWITCH FUSE 15A Y B...

Page 202: ...atedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to...

Page 203: ...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 204: ...RMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL TERMINAL BATTERY HOLDER BATTERY HOLDER BATTERY HOLDER BATTERY HOLDE...

Page 205: ...MINALS MAIN FUSE When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in...

Page 206: ...es touch your fingers Use the following recommended tester Using another manufacturer s equipment may not allow you to obtain the specified values REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR REC...

Page 207: ...Remove the LH side cover 12 2 Disconnect the A C generator cord coupler Measure the resistance between the yellow leads RESISTANCE VALUE 0 5 1 5 20 If the resistance values are much larger than the s...

Page 208: ...MEMO...

Page 209: ...RY 12V 10AH G G W L B Y R G B P B W G W G L Y A C GENERATOR PULSE GENERATOR HEADLIGHT RELAY L Y W L B Y CDI UNIT B W MAIN SWITCH B Black Y Yellow L Blue G Green R Red W White P Pink 17 0 IGNITION SYST...

Page 210: ...ring Connect the same color couplers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to...

Page 211: ...nnected CDI unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty ignition system control circuit such as side stand switch 6 Faulty peak voltage adaptor 7 Faulty CD...

Page 212: ...agonosis above and if there is no spark at plug check the CDI unit and ignition coil by using a CDI tester TOOL DIGITAL TESTER Inspection Items ITEM GROUNDWIRE IGNITIONCOIL PRIMARYCOIL PULSEGENERATOR...

Page 213: ...D CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD CORD BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BLUE YELLOW TERMINAL BL...

Page 214: ...ition timing is incorrect Read the instruction for timing light operation SIDE STAND SWITCH IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL IGNITION C...

Page 215: ...HERE IS CONTINUITY NORMAL IF THERE IS NO CONTINUITY TERMINALS STANDARD ITEM ON Side stand retracted OFF Side stand lowered REPLACEMENT Remove the RH side cover 12 2 Disconnect the side stand coupler f...

Page 216: ...MEMO...

Page 217: ...ITION CONTROL UNIT SIDE STAND SWITCH STARTER MAGNETIC SWITCH STARTER SWITCH MAIN SWITCH NEUTRAL LAMP Y R FUSE 15A BATTERY 12A 10AH B CABLE B CABLE B G R GEAR POSITION G Y G W B W Lg R Lg R B W B W BAT...

Page 218: ...ehicle A weak 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...

Page 219: ...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 220: ...CABLE CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUTCH WIRE HOLDER CLUT...

Page 221: ...ER REAR COVER REAR COVER WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE AR...

Page 222: ...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 223: ...R CASE ASSEMBLY BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BRUSH HOLDER BR...

Page 224: ...MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE MOTOR CASE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATURE ARMATU...

Page 225: ...BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS CASE BOLTS O RING O RING O RING O RING O RING O RING O RING O...

Page 226: ...ton The coil is normal if the starter magnetic switch clicks If you don t hear the switch CLICK inspect the magnetic switch using the procedure below BATTERY WIRE CABLE BATTERY WIRE CABLE BATTERY WIRE...

Page 227: ...INSTALLATION Install in the reverse order of removal STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH ST...

Page 228: ...MEMO...

Page 229: ...LIGHTS METER SWITCHES 19 0 STARTER RELAY NEUTRAL SWITCH RIGHT HANDLEBAR SWITCH IGNITION SWITCH LEFT HANDLEBAR SWITCH HORN FUEL UNIT FR STOP SWITCH WINKER RELAY...

Page 230: ...n 2 terminals If there is coil resistance within circuits or to check the large resistance resulting form the connector corrosion an ohmmeter is required to check the circuit resistance value The foll...

Page 231: ...adlight Battery discharged Wiring and switch resistance high Headlight Hi Low bean cannot be charged Faulty light bulb Faulty dimmer switch Fuel meter indicator malfunctioning Coupler separated Harnes...

Page 232: ...n 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 prevent early bulb failure...

Page 233: ...or rear brake pedal applied When ever any one does not turn on replace the stop tail light bulb WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER LENS WINKER...

Page 234: ...ATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER COMBINATION METER SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SOCKET BOLTS SO...

Page 235: ...PPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER UPPER COVER COMBINATI...

Page 236: ...TOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH CONNECTOR MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MA...

Page 237: ...SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER SWITCH STARTER...

Page 238: ...CH 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 SWITCH FRONT STOP SWITCH FRONT STOP SWITCH...

Page 239: ...connector Broken wire harness Be careful not to damage the wire Be careful not to damage the float arm Check the base packing for damage JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUMPER WIRE JUM...

Page 240: ...om the standard value replace the fuel unit WIRE TERMINAL GREEN AND YELLOW WHITE GREEN AND BLUE WHITE BLUE WHITE AND BLUE WHITE FLOATUPPERLINE 30 36 400 700 450 750 FLOATLOWERLINE 400 750 140 160 450...

Page 241: ...MEMO...

Page 242: ...WINKER RELAY B Gr G 2 BAT COMB SW 1 BAT W W G Y L MINI 3P L W G W Y B B R 2P R FUEL UNIT FR STOP SW BAT 3 ST HL TL B G Y MINI 6P Y R V G Y G Y Br L Br V Y R LIGHT START SW Y Y Y Y Y Y B L A C G G B Y...

Page 243: ...er 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 normal Engi...

Page 244: ...gine 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 Faul...

Page 245: ...lity fuel being used Lean fuel mixture Clutch slipping 12 Check for engine overheating Correct Incorrect Incorrect valve clearance Faulty C D I unit Faulty pulse generator 1 Check ignition timing and...

Page 246: ...EED 1 Check the ignition timing and Incorrect Faulty valve clearance adjustment valve clearance Faulty CDI unit Faulty pulse generator 2 Disconnect fuel tube at Fuel flows No fuel to fuel tank carbure...

Page 247: ...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 248: ...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 249: ...MEMO...

Page 250: ...MEMO...

Page 251: ...SERVICEMANUAL 2004 1 PRINTED 2004 1 PUBLICATION NO C COPY...