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13. Check the smooth rotation of inner or outer race of the 

ball bearing by rotating  it manually.

Replace the ball bearing having excessive axial/
longitudinal hanging.

Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball bear-
ing)

Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.

14. Pay attention to installation direction 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 axle.

15. When  blowing the ball bearing with compressed air

after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.

16. Install the snap ring so that chamfered side directs to

the load-applied side. After installation, check the
proper installation by rotating the snap ring.

17. Check each part for proper tightening and operation

after installation.

18. The brake fluid and coolant can damage the painted

plastic or rubber parts. Keep these parts from contact-
ing with them and wash these parts with water in case
of contact.

SINGLE-SEALED TYPE

DOUBLE-SEALED TYPE

OPEN TYPE

SNAP RING

CHAMFERED EDGE

MANUFACTURER

S NAME, BEARING No.

19. Install 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 until the tube fully inserted in the

joint. Install the clip if it is supplied. Replace the tube
having slacked end.

MANUFACTURER

S NAME

C A V I -

CLIP

FITTING

SERVICE INFORMATION

Summary of Contents for S3

Page 1: ...SM63 1010 01E...

Page 2: ...ETRANSMISSION AC GENERATOR FLYWHEEL CYLINDERHEAD VALVE CYLINDER PISTON CRANKCASE TRANSMISSION CRANKSHAFT FRONTWHEEL FRONTFORK STEERING REAR WHEEL REAR CUSHION BRAKES CHARGINGSYSTEM IGNITION SYSTEM STA...

Page 3: ...ALNUMBERLOCATION 1 1 SPECIFICATION 1 2 TWIST TORQUE 1 4 SPECIALTOOL 1 6 PARTSCOMPOSITIONMAP 1 8 SYMBOLS ABBREVIATIONS 1 12 CAUTIONSATWORK 1 13 CAUTIONSATASSEMBLY DISASSEMBLY 1 13 CAUTIONSAT WIRING 1 1...

Page 4: ...k HydraulicDisk 11 5L 1 9L 27 94 5mm Underbone Telescopic 85mm UnitSwingArm 80mm 120 70 14 tubeless 140 60 13 tubeless 2 00kgf cm2 200kpa 2 40kgf cm2 200kpa 2 00kgf cm2 200kpa 2 50kgf cm2 200kpa Hydra...

Page 5: ...RYCAPACITY SPARKPLUG SPARKPLUGGAP FUSECAPACITY STARTINGSYSTEM HEADLIGHT HIGH LOW POSITIONLAMP WINKERS TAIL STOPLAMP COMBIMETERLAMP SPEEDOMETER TACHOMETER NEUTRALINDICATORLAMP HIGHBEAMINDICATORLAMP TUR...

Page 6: ...5 3 5 4 5 3 0 4 0 5 0 5 5 4 0 5 0 3 5 4 5 1 0 2 0 4 0 5 0 STEERINGSTEMNUT STEERINGTOPTHREAD BOTTOMBRIDGE FORKPIPE BOLT HANDLEPOSTNUT FRONTWHEELAXLENUT REARWHEELAXLENUT BRAKEOILBOLT FRONT REAR CALIPERB...

Page 7: ...IONERLIFTBOLT TENSIONERLIFTSCREW ACGFLYWHEELNUT STARTERCLUTCHOUTERSOCKET OILPUMPASS BOLT OILSEPERATOR ACGSTATORCOMPSCREW TAPPETADJUSTHOLECAP WATERPUMPIMPELLER DRIVEFACENUT DRIVEPLATENUT CLUTCHOUTERNUT...

Page 8: ...datthetimeofassemblingcrankshafttocrankcase Usedatthetimeofdisassemblingtopblaceandbottomballrace Usedatthetimeofpressingbottomconeracetosteeringstem Usedatthetimeofinputtingtheoilsealoffrontfork Used...

Page 9: ...ing Molybdenumsolutionismadebymixingengineoilandmolybdenum greaseas1 1mixingratio Indicatestoapplygrease NLG1 2 Indicatestoapplymolybdenumgrease Containingmorethan30 molydenumdisulfide NLG1 2orequival...

Page 10: ...TOTAL AREA DETAIL COMPOSITON MAP PARTSCOMPOSITIONMAP LH FRONT SIDE RH FRONT SIDE LH CENTERSIDE RH CENTERSIDE LH REARSIDE RH REARSIDE TOP STRAIGHT SERVICE INFORMATION...

Page 11: ...SWITCH FUELLIDLOCKCABLE SEATLOCKCABLE FUELBREATHERTUBE CHARGINGSOCKETCOUPLER FUELSPLYTUBE VINYLTUBE RADIATORHOSE HORNCONNECTOR FR BRAKEHOSE HAZARD STARTSWITCHCODE WATERPATHTUBE COMBINATIONSWITCHTUBE D...

Page 12: ...ODE STARTMAGNETICSWITCHASS Y STARTERMOTORCABLE STARTMAGNETIC CABLE BATTERY CODE OXYGENSENSORCOUPLER BATTERY 12V10AH FUELBREATHERTUBE SEATLOCKCABLE EMIASS Y EMICODE FUELHOSE INJECTOR INJECTORCODE HIGHT...

Page 13: ...EBREATHERTUBE BREATHERTUBEGUIDE REGULATORRECTIFIER REGULATORRECTIFIERCODE REARBRAKECODE SEATLOCKCABLE WIREHARNESS ECUCOMP ECUGROUNDCONNECTIONCODE ENGINEBREATHETUBE WIRECLIP ACGCODECOMP FUELHOSE INJECT...

Page 14: ...SIONCODECOMP DESSRECEIVER FUELBREATHERTUBE FUELSPLYTUBE SPEEDOMETERCABLE CABLEGUIDE HORNCOMP WATERPATHTUBE FRONTBRAKEHOSE HIGHTENSIONCODE THERMOSENSOR WIREHARNESS SEATOPENSOLENOIDCODE REARBRAKEHOSEPIP...

Page 15: ...ys pay attention to other worker s action and alway have safety in mind 6 The skin exposed to used engine oil can be a major reason of the skin cancer Pay attention not to exposed and wash carefully w...

Page 16: ...tightened from the 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...

Page 17: ...ng Prior to installation apply oil or grease to the bearing 16 Install the snap ring so that chamfered side directs to the load applied side After installation check the proper installation by rotatin...

Page 18: ...ase of the engine while removing gasket materi al completely Remove damaged contact surface by wiping with the oil stone equally 23 Pay attention not to bend the cable excessively Transformed or damag...

Page 19: ...ing and conti nuity of each part after maintenance When connecting the battery the plus terminal must be connected first After connecting the terminal apply the grease to the terminal When disconnecti...

Page 20: ...necting 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 the coupler slightly an...

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