HYOSUNG RX 125 -, Service Manual

Page 1: ...SERVICE MANUAL 99000 97100 SERVICE MANUAL HYOSUNG MOTORS MACHINERY INC RX125 RX 125 ...

Page 2: ...for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer COPYRIGHT HYOSUNG MOTORS MACHINERY INC 1999 HYOSUNG MOTORS MACHINERY INC FOREWORD This manual contains an introductory description on HYOSUNG RX 125 and procedures for its inspection service and over...

Page 3: ...are listed on the previous page as GROUP INDEX select the section where what you are looking for belong 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS Example Rear wheel Rear brake ...

Page 4: ...LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Use special tool Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE A Apply SILICONE GREASE Apply MOLY PASTE Apply BOND 1215 DEFINITION SYMBOL DEFINITION SYMBOL Apply SUPER GREASE C ...

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Page 6: ...GENERAL INFORMATION INFORMATION LABELS 1 1 GENERAL PRECAUTIONS 1 1 SERIAL NUMBER LOCATION 1 3 FUEL AND OIL RECOMMENDATIONS 1 3 BREAK IN PROCEDURES 1 4 SPECIFICATIONS 1 5 CONTENTS 1 ...

Page 7: ...uctions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the messages highlighted by these signal words Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle When 2 or more persons work together pay attention to the safety of e...

Page 8: ...head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seals gaskets packing O rings locking washers cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over m...

Page 9: ...pare parts FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 85 95 octane Research Method or higher An unleaded gasoline type is recommended ENGINE OIL Make sure that the engine oil you use comes under API classification of SH SG or SF and that its viscocity rating is SAE 10W 40 If an SAE 10W 40 motor oil is not available select an alternate according to the right chart Difference be...

Page 10: ...but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manufacturer do not use or mix different typ...

Page 11: ...pe Starter system Kick self starter Lubrication system Wet sump TRANSMISSION Clutch Wet multi plate type Transmission 5 speed constant mesh Gearshift pattern 1 down 4 up Final reduction 3 357 Gear ratio Low 2 75 2nd 1 785 3rd 1 368 4th 1 045 Top 0 913 Drive chain 428H 132 links CHASSIS Front suspension Telescopic Rear suspension Swingarm type Steering angle 40 right left Caster 29 Trail 125 mm 4 9...

Page 12: ...ht 12V 35 35 W 2 Turn signal light 12V 1 7 W 2 Tail Brake light 12V 21 5 W 2 Speedometer light 14V 3 4 W High beam indicator light 12V 1 7 W Turn signal indicator light 12V 1 7 W License plate lens 12V 5 W CAPACITIES Fuel tank 9 0 ℓ Engine oil oil change 950 with filter change 1 050 overhaul 1 400 Front fork oil One side 443cc 2 5cc The specifications are subject to change without notice ...

Page 13: ...R CLEANER ELEMENT 2 4 VALVE CLEARANCE 2 5 COMPRESSION PRESSURE 2 6 SPARK PLUG 2 6 FUEL LINE 2 7 ENGINE OIL 2 7 ENGINE OIL FILTER 2 8 OIL PRESSURE 2 8 OIL SUMP FILTER 2 8 CARBURETOR 2 9 CLUTCH 2 9 DRIVE CHAIN 2 10 BRAKES 2 11 TIRES 2 13 STEERING 2 14 FRONT FORK OIL 2 14 CHASSIS AND ENGINE BOLTS AND NUTS 2 15 CONTENTS 2 PERIODIC MAINTENANCE ...

Page 14: ... 1 2 8 2 9 2 9 Clean every 3 000 km Adjust at initial and every 3 000 km Replace every 4 years Item Initial 1 000 km Every 4 000 km Every 8 000 km page Interval Drive chain Brakes Brakes fluid Disk Brake Tires Steering Front fork oil Chassis bolts and nuts Inspect Inspect Inspect Change Inspect Inspect Inspect Inspect Inspect Change 2 10 2 11 2 11 2 13 2 14 2 14 2 15 Inspect and clean every 1 000 ...

Page 15: ...arts which are subject to rust with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions Before lubricating each part clean off rusty sports and wipe off grease oil dirt or grime Item Interval and Every 4 000 km Every 8 000 km Interval Throttle cable Throttle grip Clutch cable Brake cable Speedometer cable Speedometer gear box Drive chain Brake pedal B...

Page 16: ...hould be kept as 12V CAUTION NOTE Inspect Initial 1 000 km and Every 4 000 km Voltage Less than 11 5V Between 11 5 12 8V More than 12 8V Charge 20Hour as 0 7A Charge 5 10Hour as 0 7A No charge How to charge MAINTENANCE PROCEDURE This section describes the service procedures for each section of the periodic maintenance BATTERY CYLINDER HEAD NUTS CYLINDER NUTS EXHAUSTPIPEBOLTSANDNUTS CYLINDER HEAD N...

Page 17: ...T Cylinder head nut 12mm 25 29 N m 2 5 2 9 kg m Cylinder base nut 10mm 6 8 N m 0 6 0 8 kg m Cylinder base nut 10mm 6 8 N m 0 6 0 8 kg m Exhaust pipe nuts 18 22 N m 1 8 2 2 kg m Muffler clamp bolt 9 16 N m 0 9 1 6 kg m When installing cylinder head cover the rubber packing is reached the mating surface of cylin der head cover CYLINDER NUTS Tighten the two 10 mm nuts to the specified torque EXHAUST ...

Page 18: ...nt Hyosung genuine oil Before and during the cleaning operation inspect the element for tears A torn element must be replaced Be sure to position the element snugly and correctly so that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted element CAUTION Excessive valve clearance results in valve noise and insufficien...

Page 19: ...p Refer to page 3 1 COMPRESSION PRESSURE SPARK PLUG Valve clearance specifications Thickness gauge 09900 20803 Tappet adjust driver 09917 13210 0 08 0 13 mm Valve clearance of IN and EX Valve clearance should be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke CAUTION NOTE Inspect Ini...

Page 20: ...de stand Drain the oil by removing the drain plug and filler cap Fit drain plug securely and add fresh oil through the filler The engine will be held about 950 of oil Use SAE 10W 40 viscosity of oil under API classification of SF or SG SH Start up the engine and allow it to run for several seconds at idling speed Shut down the engine and wait about one minute Then check the oil level in the oil le...

Page 21: ...he filter with a new one Before installing on the filter check to be sure that the O ring is properly installed Before putting on the filter cap check to be sure that the filter spring and the O ring are installed correctly Install the filter cap and tighten the screws securely Pour in engine oil and check the level Pour about 950 of engine oil into the engine only when changing oil and about 1 05...

Page 22: ...lay Tighten lock nut while holding the adjuster in position The clutch cable should be lubricated with a light weight oil whenever it is adjusted CLUTCH NOTE Make this adjustment when the engine is hot Start up the engine and set its speed at any where between 1 400 and 1 500 rpm by turning throttle stop screw IDLING ADJUSTMENT There should be 0 5 1 0 mm play on the throttle cable To adjust the th...

Page 23: ... oil SAE 90 Check the drive chain for wear and adjust the chain tension as follows Loosen axle nut after pulling out cotter pin and loosen the lock nut Adjust the drive chain carefully by tightening the adjuster CHAIN SAG Loosen the adjuster until the chain 50 60 mm of sag at the middle between engine and rear sprockets The mark on both chain adjusters must be the same position on the scale to ens...

Page 24: ... Brake light switch Adjust the brake light switch with new one when brake light dose not come on just before a pres sure is felt when the brake lever is squeezed DOT3 DOT4 or SAE J1703 Specification and Classification HYOSUNG Brake fluid 99000 07100 The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and pe...

Page 25: ...pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loosen the bleeder valve by turning quarter of it so that the brake fluid runs into the receptacle this will remove the tension of the brake lever causing it to touch the handlebar grip Then cl...

Page 26: ...ition of normal lining wear an extended line from the index mark on the brake camshaft should be within the range embossed on the brake panel with the brake on To check wear of the brake lining follow the steps below First check if the brake system is properly adjusted While operating the brake check to see that the range on the brake panel If the index mark is outside the range as shown in the il...

Page 27: ...e is no play in the front fork attachment If the play is found perform steering bearing adjustment as described in page 6 24 of this manual Tightening torque FRONT FORK OIL Fork top cap bolt 30 40 N m 3 4 4 0 kg m Steering stem head bolt 80 100 N m 8 0 10 0 kg m Fork top clamp bolt 22 30 N m 2 2 3 0 kg m Front fork lower clamp bolt 20 30 N m 2 0 3 0 kg m NOTE Change lnitial 1 000 km and 8 000 km R...

Page 28: ...orque with a torque wrench Front axle bolt 50 80 N m 5 0 8 0 kg m Caliper mounting bolt 18 28 N m 1 8 2 8 kg m Brake hose union bolt 20 25 N m 2 0 2 5 kg m Master cylinder bolt 5 8 N m 0 5 0 8 kg m Swing arm pivot nut 50 80 N m 5 0 8 0 kg m Rear shock absorber fitting nut 40 60 N m 4 0 6 0 kg m Rear axle nut 50 80 N m 5 0 8 0 kg m Rear brake cam lever bolt 8 12 N m 0 8 1 2 kg m Engine mounting bol...

Page 29: ...PERIODIC MAINTENANCE 2 16 ...

Page 30: ...ND SERVICING 3 10 UPPER END COMPONENTS REASSEMBLY 3 20 LEFT ENGINE DISASSEMBLY 3 26 RIGHT ENGINE DISASSEMBLY 3 28 LOWER END COMPONENTS DISASSEMBLY 3 30 LOWER END COMPONENTS INSPECTION AND SERVICING 3 33 LOWER END COMPONENTS REASSEMBLY 3 38 GEAR SHIFTING CAM AND FORK 3 41 RIGHT ENGINE REASSEMBLY 3 44 LEFT ENGINE REASSEMBLY 3 48 ENGINE 3 CONTENTS ...

Page 31: ...han the speci fications several causes may be considered Low oil pressure is usually the result of a clogged oil damaged oil seal a defective oil pump or a combination of these items filter oil leakage from the oil passage damaged oil seal a defective oil pump or a combination of these items High oil pressure is usually caused by a engine oil which is too heavy a weight a clogged oil passage impro...

Page 32: ...entially explained in the following steps Take off the seat by loose two volts below seat Take off the right and left frame cover Take off the right and left fuel cover CAUTION First disconnect the lead wire Disconnect the and lead wires of battery Take off the fuel tank by removing the mounting bolts Turn the fuel cock lever to the OFF position Take off the fuel hose Remove the fuel tank ...

Page 33: ...3 3 ENGINE Take off the clutch cable by removing the clutch lever bolts and adjuster lock nut Disconnect the lead wire of starter motor Take off the magneto Take off the spark plug cap ...

Page 34: ...ENGINE 3 4 Take off the breather hose Loosen the two clamp screws bolt and take off the carburetor Remove the engine sprocket cover Take off the drive chain by removing the clip ...

Page 35: ...bolt then take off the muffler Take out only one third of shaft after remove the swing arm pivot nut Remove engine mounting bolts after remove the swing arm pivot nut Use both hands and lift the engine from the frame CAUTION Take out only one third from the left side to the right side swing arm pivot nut NOTE The engine must be taken out from the right side ...

Page 36: ...engine after overhauling the engine Start up the engine and allow it run for several seconds at idle speed About one minute after stopping the engine check the oil level If the level is below the top limit mark add the oil until the level reaches the top limit mark Installing position for clutch release arm Align the release arm slit surface with the notch mark on the release cam shaft Engine moun...

Page 37: ...hain tensioner Loosen the cylinder head cover bolts and detach the head cover Loosen the camshaft holder lock nuts diagonal ly then detach the camshaft holder Remove the camshaft center bolt CAUTION This is a left hand thread nut ...

Page 38: ...e dowel pin with the long nose pliers CAMSHAFT HOLDER CAUTION Do not drop the camshaft drive chain key and sprocket into the crankcase Install the bolt by the rocker arm shaft and pull out the rocker arm shaft Remove the rocker arm and spring Remove the rocker arm shaft by the same man ner at the opposite side ...

Page 39: ... for prevent damage of the spring ten sion Take out the valve spring retainer and spring Pull out the valve from the other side Compress the valve spring by using the special tool Value spring compressor 09916 14510 Take off the valve cotters from the valve stem Tweezers 09916 84511 Value spring compressor attachment 09916 14910 Remove the oil seal using the long nose pliers Take out the spring se...

Page 40: ...cylinder base nuts and cylinder PISTON Place a clean rag over the cylinder base to pre vent the piston pin circlip from dropping into the crankcase and then remove the piston pin cir clip with the long nose pliers Remove the piston pin Remove the knock pin with the long nose pliers Piston pin puller 09910 34510 ...

Page 41: ...een noted to produce abnormal noise or vibration or a lack of output power Any of these abnormality could be caused by a worn camshaft Intake open B T D C T D C Exhaust close A T D C Exhaust open B B D C Intake close A B D C 44 37 65 52 B D C Valve timing diagram UPPER END COMPONENTS INSPECTION AND SERVICING CAMSHAFT HOLDER DISTORTION After removing the oil from the fitting surface of the camshaft...

Page 42: ...o the limit replace the valve Thickness gauge 09900 20806 Service limit 0 05 mm Cylinder head distortion Service limit 0 5 mm Valve face wear Service limit 0 05 mm Valve stem runout CAUTION Visually inspect each valve for wear of its seating face Replace any valve with an abnormally worn face CAMSHAFT CAM WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced outp...

Page 43: ...TEM O D Check face into end of valve stem and wear Service limit 0 35 mm 0 35 mm Standard 0 010 0 037 mm 0 030 0 057 mm valve IN EX Micrometer 0 25 mm 09900 20205 Standard 4 975 4 990 mm 4 955 4 970 mm valve IN EX VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head and measure the valve head radial runout If it measures more than limit replace the valve Service limit 0 ...

Page 44: ...e guide hole using the valve guide installer handle and valve guide installer attachment After fitting all valve guides re finish their guiding bores will a 5 0 mm reamer and handle Be sure to clean and oil the guides after reaming Install valve spring lower seat Be careful not to confuse the lower seat with the spring retainer 10 5 mm Reamer 09916H34575 Handle 09916 34541 Valve guide installer an...

Page 45: ...ecification VALVE SEAT SERVICING The valve seats for both intake and exhaust valves are angled to present two bevels 15 and 45 If either requirement is not met correct the seat by servicing it as follows Lubricate each seal and drive them into posi tion with the valve stem seal installer Do not reuse the oil seals CAUTION The valve seat contact area must be inspected after each cut CAUTION Valve g...

Page 46: ... burrs caused by the previous cutting operations DO NOT use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few sec onds of engine operation 5 Clean and assemble the head and valve com ponents Fill t...

Page 47: ...t six places If any one of the measurements exceeds the limit overhaul the cylinder and replace the piston with an oversize or replace the cylinder Valve spring free length Service limit 41 65 mm Valve spring free length IN EX Valve spring tension Assembly condition Standard 13 6 16 6 kg 36 6 mm Valve spring tension IN EX Service limit 0 05 mm Cylinder distortion Service limit 57 080 mm Cylinder b...

Page 48: ...ove clearance 1st 2nd Standard 1 01 1 03 mm 1 01 1 03 mm 2 01 2 03 mm Piston ring groove width 1st 2nd Oil PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings measure the free end gap of each ring using vernier calipers Next fit the ring in the cylinder and measure each ring end gap using a thickness gauge If any ring has an excess end gap replace the ring Piston ring f...

Page 49: ...ntify the side rail as there is no mark or numbers on it Piston pin bore PISTON PIN PIN BORE Using a caliper gauge measure the piston pin bore inside diameter and using a micrometer measure the piston pin outside diameter If the difference between these two measurements is more than the limits replace both piston and piston pin If the conrod small end bore inside diameter exceeds the limit replace...

Page 50: ...ing differ in the shape of ring face and the face of top ring is chrome plated whereas that of 2nd ring is not The color of 2nd ring appears darker than that of the top one Install expander ring into the 2nd ring groove Top and 2nd rings have the letter R or Y marked on the top Be sure to bring the marked side to the top when fitting them to the piston Position the gaps of the three rings as shown...

Page 51: ...iston ring with the piston rings prop erly spaced and insert them into the cylinder Check to insure that the piston rings are properly inserted into the cylinder skirt Use a new piston pin circlip to prevent circlip failure which will occur with a bent one CAUTION To prevent oil leakage do not use the old gas ket again always use new one CAUTION When mounting the cylinder after attaching camshaft ...

Page 52: ... is vary the pitch decreases from top to bottom as shown in the illustration Fit valve spring retainer compress spring with a valve spring compressor and insert cotters CYLINDER HEAD Fit dowel pins to cylinder head and then attach new gasket to cylinder head HYOSUNG MOLY PASTE When inserting each valve take care not to damage the lip of the stem seal CAUTION Use a new cylinder head gasket to preve...

Page 53: ...ut 6 8 N m 0 6 0 8 kg m When mounting the cylinder after attaching camshaft drive chain keep the camshaft drive chain taut The camshaft drive chain must not be caught between cam drive chain sprocket and crankcase when crankshaft is rotated CAUTION If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket CAUTION...

Page 54: ...cker arm and inserting the camshaft hold Fit the two dowel pins to the camshaft holder When fitting rocker arm spring hook part of rocker arm spring onto rocker arm and hook part of rocker arm spring onto the dowel pins Align the both end face of C ring and cylinder head face CAUTION Pay attention to the exhaust side rocker arm that have not confused the groove at the intake side rocker arm so tha...

Page 55: ...el pins and install the camshaft holder Tighten the camshaft holder nuts diagonally to the specified CHAIN TENSIONER Mount the tensioner body on the cylinder Install the spring and bolts Camshaft holder nut 25 35 N m 2 5 3 5 kg m ...

Page 56: ...he cylinder head cover bolts with the hexagon wrench Valve clearance specifications 0 08 0 13 mm IN and EX valve clearance Valve clearance is to be checked when the engine is cold Both the intake and exhaust valves must be checked and adjusted when the piston is at Top Dead Center TDC of the compression stroke CAUTION Cylinder head cover 12 16 N m 1 2 1 6 kg m Rotor remover 09930 30162 LEFT ENGINE...

Page 57: ...by using the impact drive and detach the stator Remove the roller spring and push piece from the stater clutch Clamp the rotor with a vise taking care not to damage it and remove the three bolts using the 5 mm T type hexagon wrench T type hexagon wrench 5 mm 09911 73730 ...

Page 58: ...ock washer then remove the sprocket nut by using the special tool CLUTCH Remove the kick starter by removing the bolt Remove the clutch cover bolts and oil filter cap bolts and detach the clutch cover by tapping with a plastic hammer When removing gear position switch do not lose the O ring switch contact and its spring CAUTION Rotor holder 09930 40113 ...

Page 59: ...by using the special tool OIL PUMP DRIVE GEAR DRIVEN GEAR AND PRIMARY DRIVE GEAR Flatten the lock washer then remove the nut lock washer and oil pump drive gear Remove the oil pump driven gear then remove the primary drive gear and key Clutch sleeve hub holder 09920 53710 Conrod holder 09910 20116 Take off the sleeve hub with the primary driven gear ass y This time well deposite the washer behind ...

Page 60: ...ter and cam guide screws with an impact driver KICK STARTER DRIVE GEAR AND IDLE GEAR Remove the kick starter drive gear and kick starter idle gear LOW END COMPONENTS DISASSEMBLY CRANK CASE Remove the sump filter cap and plug cam stopper Pull out the spring neutral stopper When removing the cam driven gear do not lose the gear shifting pawl pin and spring CAUTION Snap ring pliers 09900 06107 ...

Page 61: ...er spring Fit the crankcase separater so that the tool plate is parallel with the end face of the crankcase Crankcase separater 09920 13120 The crankshaft and transmission components must remain in the left crankcase half This is necessary because the gear shifting cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half CAUTION ...

Page 62: ...emove the clusters of gears and the gear shifting cam KICK STARTER SHAFT Remove the circlip spring guide and return spring Then pull out the kick starter shaft from the other side CRANKSHAFT Remove the crankshaft by using the crankcase separater Crankcase separater 09920 13120 ...

Page 63: ...E CLEARANCE Wear on the big end of the conrod can be estimat ed by checking the movement of the samll end of the rod This method can also check the extent of wear on the parts of the conrod s big end Oil seal remover 09913 50121 Service limit 3 0 mm Wear limit on the big end of conrod Magnetic stand 09900 20701 Dial gauge 1 100 mm 09900 20606 V block 09900 21304 ...

Page 64: ...NOUT Support the crankshaft with V blocks as shown with the two end journals resting on the blocks Position the dial gauge as shown and rotate the crankshaft slowly to read the run out Correct or replace the crankshaft if the runout is greater than the limit CLUTCH DRIVE PLATE Measure the thickness and claw width of each drive plate with vernier calipers Replace the drive plates found to have worn...

Page 65: ...ar ing Vernier calipers 09900 20101 Thickness gauge 09900 20803 Vernier calipers 09900 20101 SHIFTING FORK AND GEAR Using a thickness gauge check the shifting fork clearance in the groove of its gear If the clearance limit is exceeded by any of the three gears deter mine whether the gear or the gear shifting fork should be replace by measuring the thickness and groove width Checking distortion CLU...

Page 66: ...s generated between gear and housing causing abnormal noise If the play is extreme replace the primary driven gear assembly a new one Primary driven gear Damper Plate Rivet Clutch housing Spring Service limit 129 9 mm Cam chain 20 pitch length Checking groove width Checking thickness Shifting fork to groove clearance Standard 0 10 0 30 mm Serivice limit 0 50 mm Shifting fork groove width NO 1 NO 2...

Page 67: ...while fixing it in the case Rotate the inner race by hand to inspect for an abnormal noise and a smooth rotation Replace the bearing if there is something unusual STARTER CLUTCH BEARING Inspect the bearing for any abnormality particularly cracks to decide whether it can reused or should be replaced ...

Page 68: ...ebuilding the crankshaft When mounting the crankshaft in the crankcase it is necessary to pull its left end into the crankcase LOWER END COMPONENTS REASSEMBLY CRANKSHAFT Standard 53 0 0 1 mm Width between webs Crankcase installer 09910 32812 Conrod holder 09910 20116 53 0 0 1 mm ...

Page 69: ...fected CAUTION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new cir clip must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip cover the shaft After installing a circlip always insure that it is completely seated in its groove and securely fitted CAUTION ...

Page 70: ...e as a referance for correctly mounting the gears washers and circlips COUNTERSHAFT Mounting 2nd drive gear Press fit 2nd drive gear into the countershaft Before reassembling coat the internal face of the 2nd drive gear with THREAD LOCK 1324 and install it so that the length is as shown in Fig 88 0 0 1 mm 0 2 Countshaft length Low to 2nd This procedure may be performed only twice before shaft repl...

Page 71: ...3 41 ENGINE GEAR SHIFTING CAM AND FORK Fit the gear shifting cam on the crankcase Position the cam as shown in Fig So that the gear shifting fork can be installed easily ...

Page 72: ...each other very closely in external appearance and configura tion Carefully examine the illustration for correct installing positions and directions CAUTION After the cam stopper and gear shifting forks have been fitted hook the cam stopper spring into the crankcase KICK STARTER ...

Page 73: ... hole of the kick shaft Then fit the spring guide and circlip CRANKCASE When reassembling the crankcase pay attention to the following Coat SUPER GREASE A to the lip of oil seals Remove sealant material on the fitting surface of right and left halves of the crankcase and thor oughly remove oil stains Fit the dowel pins on the half Apply engine oil to the big end of the crankshaft conrod and all pa...

Page 74: ...shown in Fig RIGHT ENGINE REASSEMBLY CLUTCH KICK START DRIVE GEAR AND IDLE GEAR Install the kick starter idle gear and drive gear GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driven gear The large shoulder must face to the outside as shown Next install cam guide and pawl lifter Apply a samll quantity of THREAD LOCK 1324 to the threaded parts of the securing sc...

Page 75: ...aft If gear change is not obtained it means that assembly of gears or installation of gear shifting fork is incorrect If this is the case disassemble and trace the mistake CAUTION PRIMARY DRIVE GEAR AND OIL PUMP Fit the key in the slot on the crankshaft and install the primary drive gear Before mounting the oil pump apply engine oil to the sliding surfaces of the case outer rotor inner rotor and s...

Page 76: ... turns smoothy CAUTION After checking the oil pump install the oil pump drive gear lock washer and nut tighten it with a torque wrench to the specified torque and bend up to the washer CLUTCH Conrod holder 09910 20116 This is a left hand thread nut CAUTION Oil pump nut 40 60 N m 4 0 6 0 kg m Bend up ...

Page 77: ...g the spacer on the countershaft apply a small quantity of engine oil to both inside and outside of the spacer Tighten clutch sleeve hub nut using the special tool to the specified torque Be sure to lock the nut by firmly bending the tongue of the washer Install the drive plates and driven plates to the sleeve hub Insert push rod in the countshaft Clutch sleeve hub holder 09920 53710 Clutch sleeve...

Page 78: ...m that position turn out the release screw 1 4 1 2 turn and tighten the lock nut OIL SUMP FILTER Wash the sump filter with cleaning solvent and then bolw compressed air through it to dry off solvent After mounting the sump filter fit the cap and tighten it LEFT ENGINE REASSEMBLY NEUTRAL CAM STOPPER Put in the neutral stopper and spring Tighten the cam stopper plug ...

Page 79: ... Lock 1324 Apply THREAD LOCK 1324 to the bolts and tighten with the specified torque Thread Lock 1324 T type hexagon wrench 09911 73730 Starter clutch 15 20 N m 1 5 2 0 kg m Thread Lock 1324 MAGNETO ROTOR Fit the key in the key slot on the crankshaft Install the magneto rotor Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft ...

Page 80: ...On installation refer to Fig for correct posi tion and direction Replace O ring with a new one every disassembly CAUTION After reassembling the LOWER END COMPO NENTS install the O ring and spacer CAUTION DRIVESHAFT OIL SEAL AND ENGINE SPROCKET O ring Oil seal Tighten the magneto rotor nut to the specified torque Thread Lock 1324 Rotor holder 09930 40113 Rotor holder 09930 44511 Magneto rotor nut 5...

Page 81: ...NGINE GEAR POSITION SWITCH Install the gear position switch Tighten the engine sprocket nut to the specified torque and bend up the washer Rotor holder 09930 40113 Engine sprocket nut 80 100 N m 8 0 10 0 kg m ...

Page 82: ...FUEL SYSTEM FUEL COCK 4 1 CARBURETOR 4 2 THROTTLE VALVE 4 3 CARBURETOR 4 4 ACCELERATOR PUMP ADJUSTMENT 4 8 PILOT SCREW ADJUSTMENT 4 9 OIL COOLER 4 10 LUBRICATION SYSTEM 4 11 CONTENTS 4 ...

Page 83: ...mpressed air DISASSEMBLY Turn the fuel cock to OFF position and dis connect the fuel hose from the fuel cock Place a clean oil pan under the fuel cock assembly turn the fuel cock to ON position and drain the fuel Unscrew the fuel cock securing bolts and take off the fuel cock assembly Gasoline is highly explosive Extreme care must be taken WARNING Gasket must be replaced with a new one to prevent ...

Page 84: ...ight Main jet M J Main air jet M A J SPECIFICATION PD 18 F ф 24 HG58 1 450 100 rpm J 29 B 12 5 mm 98 90 ITEM Needle jet N J Pilot jet P J By pass B P Pilot air jet P A J Valve seat V S Starter jet Pilot screw P S SPECIFICATION AIFC 2nd 38 2 9 ф 1 0 ф 0 9 150 ф 2 0 MAX 500 2 CARBURETOR 2 ...

Page 85: ... and disconnect the throttle valve Remove the throttle cable from the throttle valve and disconnect the throttle cable Disconnect the throttle valve spring and carburetor top from the throttle cable Draw out the retainer clip and disconnect the jet needle Inspect the jet needle and wear damage of the throttle valve ...

Page 86: ...ments and inspection are necessary after installing the throttle valve Throttle cable play Refer to page 2 9 Idling adjustment Refer to page 2 9 CARBURETOR DISASSEMBLY Removetheseatandfueltank Refertopage3 2 Remove the carburetor top Refer to page 4 3 Remove the throttle cable Remove the carburetor drain screw and draw out in the carburetor Remove the choke cable Gasoline is highly explosive Extre...

Page 87: ...lamp screw Remove the carburetor DISASSEMBLY Disconnect the fuel tube and drain tube ACCELERATOR PUMP Loosen the screws and disconnect the pump cover Disconnect the spring Inspect the accelerator pump load damage of the diaphragm Clean the diaphragm ...

Page 88: ...aphragm and install the cover in the float chamber Adjust the accelerator pump FLOAT AND NEEDLE VALVE Loosen the screws and remove the float chamber Pull out the float arm pin Remove the float and needle valve Inspect the valve and valve seat for wear Inspect the float for transformation ...

Page 89: ...utions until tighten completely Disconnect the throttle stop screw Clean the jets with non flammable cleaning solvent Inspect the pilot screw and pilot jets Clean the jets and body passage with compressed air Install the pilot screw as revolutions to a case of disassemble CAUTION Install the needle jet needle jet holder main jet and slow jet Install throttle stop screw and pilot screw Adjust the p...

Page 90: ... slip off Check to be sure that the float moves freely Install the new O ring and float chamber groove Install the float chamber and screw ACCELERATOR PUMP ADJUSTMENT Adjust idling Refer to page 2 9 Adjust throttle grip Refer to page 2 9 Adjust clearance of the accelerator pump rod after loosen the lock nut and turn the adjust screw Tighten the lock nut Do not adjust except for exchange the adjust...

Page 91: ...e Standard turn back revolution of pilot screw PILOT SCREW ADJUSTMENT Loosen as standard turn back revolutions after lock the pilot screw suitable Start up the engine and set its speed at any where between 1 450 100 rpm by turning the throttle screw Adjust the engine speed at hight position as the pilot screw left right turning Repeat again Adjust the standard engine idle speed by the throttle sto...

Page 92: ... bolt of the cylinder head and inspect the air bleeding and oil Remove the screws Remove the union bolts and detach the oil cooler NOTE Draw out and push for face of the spring seat NOTE When reassemble after remove the union bolt do not remove except special case that fold of the hose the others are affected according to assemble angle Union bolt 20 25 N m 2 0 2 5 kg m ...

Page 93: ...FT JOURNAL AND CAM FACE CONROD SMALL END CONROD BIG END BEARING CLUTCH RELEASE CAM OIL HOSE OIL COOLER OIL HOSE DRIVESHAFT BEARING COUNTERSHAFT BEARING COUNTERSHAFT AND GEARS PRIMARY DRIVEN GEAR SPACER OIL FILTER BY PASS DRIVESHAFT AND GEARS OIL PUMP SUMP FILTER CLUTCH PLATES OIL PAN ...

Page 94: ...FUEL SYSTEM 4 12 Start motor Piston Cylinder Oil cooler Cylinder head Crankcase Transmission ...

Page 95: ...ELECTRICAL SYSTEM 5 1 IGNITION SYSTEM 5 1 CHARGING SYSTEM 5 5 STARTER SYSTEM 5 9 LAMP 5 12 SWITCHES 5 13 BATTERY 5 14 ELECTRICAL SYSTEM 5 CONTENTS ...

Page 96: ...niton coil and battery Ignite after permit signal at ignition timing of pick up as electric energy of this battery occur the 1st electric current Therefore a high voltage current is induced in the secondary winding of the ignition coil resultion in strong spark between the spark plug gap Spark plug Ignition coil Ignition switch Battery CDI UNIT MAGNETO C D I UNIT IGNITION COIL AND SPARK PLUG ...

Page 97: ...ng table L G R W Y B R L R R G W G W R Blue Green Red White Yellow Black with Red tracer Blue with Red tracer Red with Green tracer White with Green tracer White with Red tracer G L Approx 90 110 Ϊ Y Y Approx 0 6 0 9 Ϊ Charging coil Pick up coil Pocket Tester 09900 25002 When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1324 to the threaded parts of screws CAUTION...

Page 98: ...tance of the electro tester is set at 8 mm 0 3 in With the electro tester test the ignition coil for sparking performance If no sparking or orange color sparking occures in the above conditions it may be caused by the defective coil Electro tester 09900 28107 Over 8 mm 0 3 in Spark performance Do not touch the wire clips to prevent an elec tric shock when testing WARNING When using the electro tes...

Page 99: ...n Check the gap with a thickness gauge Thickness gauge 09900 20804 0 8 0 9 mm Spark plug gap IGNITION COIL Checking with Pocket Tester A pocket tester or an ohm meter may be used instead of the electro tester In either case the ignition coil is to be checked for continuity in both primary and secondary windings Exact ohmic readings are not necessary but if the windings are in sound condition their...

Page 100: ...he battery directly A C generator Ig switch Controlunit Battery LOAD Regulator Rectifier A C generator Ig switch Controlunit Battery Regulator Rectifier CHARGING SYSTEM The circuit of the charging system is indicated in figure which is composed of and the AC generator regulator rectifier unit and battery The AC current generated from the AC generator is converted by the rectifier and is turned int...

Page 101: ...ondition Then the SCR becomes conductive to the direction from point to point Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to the AC generator again At the end of this state since the AC current generated from the AC generator flows into the point reverse current tends to flow to SCR then the circuit of SCR turns ...

Page 102: ...AD PERFORMANCE Disconnect the three lead wires from the AC gen erator terminal Start the engine and keep it running at 5 000 rpm Using the pocket tester measure the AC voltage between the three lead wires If the tester reads under 70 V the AC generator is faulty Pocket tester 09900 25002 13 5 16 0 V at 5 000 rpm Standard charge When making this test be sure that the battery is full charged conditi...

Page 103: ...FF OFF OFF 7 8 OFF OFF OFF 7 8 OFF OFF OFF OFF 1 Probe of tester 2 3 4 5 REGULATOR RECTIFIER Using the pocket tester 1 Ϊ range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regulator rectifier Pocket tester 09900 25002 ...

Page 104: ...he starter button on the right handlebar switch box energizes the relay causing the contact points to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor Disassemble the starter motor as follows Starter motor Starter relay S button Ig switch ON Fuse ...

Page 105: ...commutator with 400 or similar fine emery paper when it is dirty After polishing it wipe the commutator with a clean dry cloth Check the commutator under cut Service limit 0 5 mm Under cut of commutator SEGMENT MICA ARMATURE COIL Using a pocket tester check the coil for open and ground by placing probe pins on each commutator segment and rotor core to test for ground and on any two segments at var...

Page 106: ...ON Disconnect the lead wire of the starter motor at the starter motor relay Turn on the ignition switch inspect the continuity between the terminals positive and negative when pushing the starter button If the starter motor relay is in sound condition continuity is found Thread Lock 1324 Pocket tester 09900 25002 STATER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to star...

Page 107: ...ACEMENT AND INSPECTION After installing a new bulb check for continuity If the bulb does not light inspect the wiring for open or short circuit Lamp switch low beam High beam Head lamp Tail lamp Battery Head lamp 12V 35 35W Tail lamp 12V 21 5W ...

Page 108: ...ay Black with yellow tracer Orange SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart ENGINE KILL SWITCH Pocket tester 09900 25002 COLOR POSITION B Y OFF RUN Frame Earth LAMP SWITCH COLOR POSITION Gr OFF ON O ...

Page 109: ...ome into being a hole or painting should take off Be cured from a doctor When the battery electrolyte was droped the surface of land wash a vast quantity of water Neutralize by hudroxide bicarbonate of soda and so on CAUTION OF MAINTENANCE FREE BATTERY TREATMENT Do not remove the aluminum tape what sealing the battery electrolyte filler hole untill use as battery of completely seal type Do not use...

Page 110: ...ot fall Take precaution not to allow any of the fluid to spill Confirm of pour Make sure that air bubbles are coming up each electrolyte container and leave in this position for about more than 20 minutes In no case pouring into if put in slopely the electrolyte container CAUTION If no air bubbles are coming up from afiller port tap the botton of the two or three times CAUTION Seal Cap Air bubble ...

Page 111: ...surface of the battery s top cover ASSISTANCE RECHARGING Use the battery that is maded after 2 years as the maintenance free battery Use the battery at condition of the high temperature Assistance recharging to the following points The main principle of assistance recharging Assistence recharging from rule of electric cur rent or voltage when the battery discharged Do not assistance recharge excep...

Page 112: ...CHASSIS FRONT WHEEL 6 1 FRONT BRAKE 6 6 FRONT FORK 6 14 STEERING STEM 6 20 REAR WHEEL AND REAR BRAKE 6 25 SUSPENSION 6 31 REAR SWING ARM 6 36 CONTENTS 6 ...

Page 113: ...6 1 CHASSIS FRONT WHEEL REMOVAL Support the machine by jack block or service stand Service stand 99000 99094 ...

Page 114: ...isconnect the speedo meter cable Disconnect the left side of the protector Disconnect the clamp Remove the brake hose Pull out the fixing bolt and remove the axle Draw out the front axle and take off the front wheel ...

Page 115: ... the wheel bearings inner race by hand while fixing it in the wheel hub Rotate the inner race by hand to inspect whether abnormal noise occurs or rotating smoothly Replace the bearing if there is something unusual Using the special tool drive out the wheel bear ings Wheel bearing remover 09941 50110 Play Play ...

Page 116: ...eplaced REASSEMBLY Reassemble and remount the front wheel in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearing before installing Install the wheel bearings by using the special tool Dial gauge 09900 20606 Dial gauge 1 100 09900 20606 Magnetic stand 09900 20701 Bearing installer 09913 75820 Service limit 0 25 mm Runout of a...

Page 117: ...6 5 CHASSIS Install the disk with four bolts as shown in photo Disk bolt 18 28 N m 1 8 2 8 kg m ...

Page 118: ...CHASSIS 6 6 FRONT BRAKE yyy yyy yyy yyy yy yy y y ...

Page 119: ...the pad Apply the silicone grease to the caliper holder Push in the piston and piston holder all the way to the caliper when remounting the caliper Tighten the caliper mounting bolts with specified torque Do not operate the brake lever while dismount ing the caliper CAUTION Replace the brake pad with a set otherwise braking performance will be adversely affected CAUTION Silicone gerase Caliper mou...

Page 120: ...CAUTION CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the caliper and catch the brake fluid in a suitable receptacle Remove the caliper mounting bolts and take off the caliper Loosen the screw and take off the carrier Take off the caliper carrier Remove the caliper holder from the caliper ...

Page 121: ...rag over piston to prevent popping up Force out the piston by using air gun Remove the piston piston boot and piston seal INSPECTION CALIPER CYLINDER Inspect the cylinder bore wall for nick scratches or other damage PISTON Inspect the piston surface for any scratches or other damage ...

Page 122: ...it line marked on the pad When the wear exceeds the limit line replace the pad with new ones Micrometer 0 25 mm 09900 20205 Service limit 3 0 mm Disc thickness With the disc mounted on the wheel check the disc for face runout with a dial gauge as shown Dial gauge 1 100 09900 20606 Service limit 0 3 mm Disc runout Replace the brake pad with a set otherwise braking performance will be adversely affe...

Page 123: ...silicone grease to the caliper holder Wash the caliper components with fresh brake fluid before reassembly Never use cleaning sol vent or gasoline to wash them Apply brake fluid to the caliper bore and all internal parts before inserting into the bore CAUTION Silicone grease Item 0 6 0 9 2 0 2 5 1 8 2 8 6 9 20 25 18 28 N m kg m Bleed the air from brake fluid circuit after reassembling the caliper ...

Page 124: ...mage Remove the two clamp bolts and take off the master cylinder Remove the two fitting screws and separate the cap and diaphragm Drain brake fluid Remove the dust seal boot Remove the circlip by using the special tool Remove the piston primary cup and spring Snap ring pliers 09900 06108 ...

Page 125: ...s When remounting the master cylinder to the handlebars first tighten the clamp bolts for upside as shown Wash the master cylinder components with fresh brake fluid before reassembly Never use clean ing solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all internal parts before inserting into the bore CAUTION Bleed air from the brake fluid circuit after reassembling maste...

Page 126: ...CHASSIS 6 14 FRONT FORK ...

Page 127: ...wer clamp bolts Remove the front brake hose clamp Pull down right and left front forks Remove the front fork cap O ring and seat lever To remove the O ring it will be necessary to push the seat lever inwards to remove spring pressure from the O ring The removed O ring should be replaced with a new one CAUTION ...

Page 128: ...olt by using the 19 mm socket Separate the inner tube from outer tube Remove oil lock piece and damper rod with rebound spring Remove the snap ring by using the special tool Snap ring pliers 09900 06108 Remove the oil seal by using the special tool Oil seal remover 09913 50121 The oil seal removed should be replaced with a new oil seal CAUTION ...

Page 129: ...fork spring free length If it is shorter than the service limit replace it REASSEMBLY Reassemble and remount the front fork in the reverse order of disassembly and removal and also carry out the following steps DAMPER ROD BOLT Apply Bond 1215 and Thread Lock 1324 to the damper rod bolt and tighten the bolt with specified torque by the 19 mm socket Service limit 555 mm Fork spring free length Bond ...

Page 130: ...nstall a new stopper ring it will be necessary to push the spring seat inward Fork oil seal installer 09940 50112 SS8 Oil Fork oil type Each leg 443 2 5 cc Fork oil capacity When adjusting oil level remove the fork spring and compress the inner tube fully CAUTION Front fork level gauge 09943 74111 At outer tube 146 mm Without Spring Front fork oil level Always use a new stopper ring After installi...

Page 131: ...NG Maintain equally right and level height Standard for upside surface of the upper bracket 7 mm 1 mm Tighten the upper and lower clamp bolts Upper clamp bolts 22 35 N m 2 2 3 5 kg m Lower clamp bolts 20 30 N m 2 0 3 0 kg m ...

Page 132: ...CHASSIS 6 20 STEERING STEM ...

Page 133: ...ff the front wheel See page 6 1 Take off the front fork See page 6 15 Remove the screws and the two headlight housing rubber packing Disconnect the lead wires Remove the two screws of the headlight housing Remove the four bolts and front fender ...

Page 134: ... Remove the steering stem head bolt and take off the steering stem upper nut Remove the steering stem nut and draw out the steering stem Remove the upper and lower bearing Hold the steering stem lower bracket by hand to prevent from falling CAUTION ...

Page 135: ...ts for the fol lowing abnormalities Handlebars distortion Handlebars clamp wear Abnormality operation of bearing Worn or damaged steel balls Distortion of steering stem REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal and also carry out the following steps INNER RACES Press in the upper and lower inner races using the special tool Steering race in...

Page 136: ...rn the steering stem right and left lock to lock five or six times Tighten the steering stem head bolt to the spec ified torque Clamp wrench 09940 10122 steering stem nut 40 50 N m 4 0 5 0kg m Steering stem head bolt 80 100 N m 8 0 10 0 kg m After performing the adjustment and installing the steering stem upper bracket rock the front wheel assembly forward and backward to ensure that there is no p...

Page 137: ...6 25 CHASSIS REAR WHEEL AND REAR BRAKE REMOVAL Support the machine by jack or block or service stand Service stand 99000 99094 ...

Page 138: ...lt Remove the rear brake adjuster nut Draw out the axle shaft and take off the rear wheel Separate the rear wheel from rear brake panel DISASSEMBLY REAR WHEEL Flatten the washers and loosen the four nuts Separate the rear sprocket from the rear wheel Remove the rear axle nut ...

Page 139: ...am lever nut Pull off the brake cam washer O ring and cam lever INSPECTION WHEEL BEARINGS Inspect the wheel bearings for play by hand Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly Replace the bearing if there are any defects Remove the right and left side wheel bearings Play Play ...

Page 140: ... wheel rim If properly tightening the spokes will not correct the runout replace the wheel rim SPROCKET Inspect the sprocket teeth for wear If they are worn as illustrated replace the sprocket and drive chain Dial gauge 1 100 09900 26006 Magnetic stand 09900 20701 V Block 09900 21304 Service limit 0 25 mm Axle shaft runout Worn or loose wheel bearings must be replaced before attempting to true whe...

Page 141: ...e order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the bearings before installling SPROCKET After tightening the four nuts to specification bend the washers to lock nuts Install the wheel bearings by using the special tool Service limit 130 7 mm Rear brake drum I D Replace the brake shoes as a set otherwise braking performance will be adversely ...

Page 142: ...r bolt with specified torque Super grease A Be careful not to apply too much grease to the brake cam shaft If grease gets on the lining brake slippage will result CAUTION Adjust the rear brake pedal play after installa tion of the rear wheel CAUTION Brake cam lever nut 8 12 N m 0 8 1 2 kg m ...

Page 143: ...6 31 CHASSIS SUSPENSION Service limit 10 20 mm Service limit 14 20 mm Service limit 10 20 mm ...

Page 144: ...overs Remove the rear wheel See page 6 26 Loosen the four screws and remove the mud flap Remove the rear cushion rod fitting nuts and bolts Remove the rear cushion lever nut and bolt Remove the rear shock absorber fitting bolt Pull up the suspension from the chassis ...

Page 145: ... cushion rod After drawing out the spacer remove the two bearings from the rear cushion lever by using the special tools INSPECTION Inspect the dust seals if they are found to be damaged replace them with new seals Bearing remover 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 ...

Page 146: ...ngs by using the spe cial tool See page 6 31 6 36 If the inside diameter of the spacer exceeds the service limit or flaws are discovered replace the spacer and O rings Service limit 14 20 mm Service limit 10 20 mm Spacer Bearing installer set 09924 84510 When installing two bearings punch marked side of bearing comes on outside CAUTION Super grease A SPACER AND DUST SEAL Apply grease to the spacer...

Page 147: ... the rear shock absorber by using the special tool Remount the air cleaner carburetor seat and frame cover Rear shock absorber nut Upper 40 60 N m 4 0 6 0 kg m Rear cushion lever center nut 70 100 N m 7 0 10 0 kg m Rear cushion rod nut and bolt Lower 84 120 N m 8 4 12 0 kg m Rear cushion rod nut and bolt Upper 84 120 N m 8 4 12 0 kg m Rear shock absorber nut Lower 40 60 N m 4 0 6 0 kg m Clamp wren...

Page 148: ... rear wheel See page 6 26 Loosen the four screws and remove the mud flap See page 6 32 Remove the rear cushion rod fitting nuts and bolts See page 6 32 Remove the rear shock absorber fitting nut and bolt See page 6 32 Service limit 14 20 mm Service limit 14 20 mm ...

Page 149: ... runout and replace it if the runout exceeds the limit REASSEMBLY Reassemble and remount the swing arm in the reverse order of disassembly and removal and also carry out the following steps SWING ARM SPACER Force fit the spacers into the swing arm by using the special tool Bearing remover 17 mm 09923 73210 Rotor remover sliding shaft 09930 30102 Dial gauge 1 100 09900 20606 Bearing installer set 0...

Page 150: ...CHASSIS 6 38 SPACER Apply grease to the spacer when installing Super grease A ...

Page 151: ...SERVICING INFORMATION TROUBLESHOOTING 7 1 SPECIAL TOOLS 7 8 TIGHTENING TORQUE 7 12 SERVICE DATA 7 14 WIRE AND CABLE ROUTING 7 21 WIRING DIAGRAM 7 23 CONTENTS 7 ...

Page 152: ...an or replace Replace Clean or replace Noisy engine Excessive valve chatter 1 Valve clearance too large 2 Weakened or broken valve springs 3 Worn down rocker arm or rocker arm shaft Noise appears to come from piston 1 Piston or cylinder worn down 2 Weakened or broken valve springs 3 Worn down rocker arm or rocker arm shaft 4 Piston rings or ring groove worn Noise seems to come from timing chain 1 ...

Page 153: ...t 2 Distorted or worn gearshift forks 3 Weakened stopper pawl spring on gearshift cam 4 Worn gearshift pawl Replace Replace Replace Replace Engine idles poorly 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Worn rocker arm or arm shaft 5 Spark plug gap too wide 6 Defective ignition coil resulting in weak sparking 7 Float chamber fuel level out of adjustment...

Page 154: ...ed valve springs 3 Valve timing out of adjustment 4 Worn piston ring or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Worn rocker arms or its shafts 8 Spark plug gap incorrect 9 Clogged jets in carburetor 10 Float chamber fuel level out of adjustment 11 Clogged air cleaner element 12 Too much enging oil 13 Defective air intake pipe Adjust Replace Adjust Replace Repair or replace Clean or...

Page 155: ...3 Defective regulator rectifier 4 Not enough electrolyte in the battery 5 Defective cell plates in the battery Repair or retighten Replace Replace Add distilled water between the level lines Replace the battery Generator overcharges 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defec tive 3 Regulator rectifier poorly grounded Replace the battery R...

Page 156: ...olyte 6 Battery is too old Check the generator regula tor rectifier and circuit con nections and make neces sary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte spe cific gravity Replace the electrolyte recharge the battery and then adjust specific gravity Replace the batter...

Page 157: ...ace Front suspension too soft 1 Weakened springs 2 Not enough fork oil Replace Refill Front suspension too stiff 1 Fork oil too viscous 2 Too much fork oil Replace Drain excess oil Noisy front suspension 1 Not enough fork oil 2 Loosen nuts on suspension Refill Retighten Rear suspension too soft 1 Weakened springs 2 Rear suspension adjuster impromerly set Replace Adjust Rear suspension too stiff 1 ...

Page 158: ...1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Loosen front wheel axle or rear wheel axle 5 Worn pads 6 Foreign material in brake fluid 7 Clogged return port of master cylinder Repair surface with sandpaper Modify pad fitting Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Leakage of brake fluid 1 Insufficient tightenin...

Page 159: ...easure height of cam 09900 20203 Micrometer 1 100mm 50 75mm Measure outside diameter of piston Special tools Part Number Part Name Description 09900 20205 Micrometer 1 100mm 0 25mm Measure outside diameter of piston pin 09900 20508 Cylinder gauge set 1 100mm 40 80mm Measure inside diameter of cylinder 09900 20602 Dial gauge 1 100mm 1mm Measure inside diameter of cylinder 09900 20605 Dial calipers ...

Page 160: ...cycle 09913 14541 Fuel level gauge set Measure height of carburetor 09913 50121 Oil seal remover Used to remove the oil seal Special tools Part Number Part Name Description 09913 60710 Bearing remover Removebearingwiththerotorremoveslidingshaft 09913 75520 Bearing installer Used to drive bearing in 09913 75821 Bearing installer Used to drive bearing in 09913 75830 Bearing installer Install rear ax...

Page 161: ...withtherotorremoveslidingshaft 09923 74510 Bearing remover 20 35mm Removebearingwiththerotorremoveslidingshaft Special tools Part Number Part Name Description 09924 84521 Bearing installer Used to drive small bearing in 09925 98221 Bearing installer Used to drive bearing in 09930 10121 Spark plug socket wrench set Remove and remounting spark plug 09930 30102 Rotor remove sliding shfat Used to with...

Page 162: ...installer Install steering outer race 09941 50110 Wheel bearing remover Remove wheel bearing 09943 74111 Front fork oil level gauge Used to drain the fork oil to the specified level 09943 88211 Bearing remover Remove rear axle shaft bearing 09951 76010 Bearing installer Used to drive bearnig in 09940 34561 Front fork assembling tool attachment D Used with T handle ...

Page 163: ...gine oil drain plug Engine sprocket nut Engine mounting bolt 17 mm Diam Engine mounting bolt 14 mm or 12 mm Diam Exhaust pipe clamp nut Muffler clamp bolt Starter clutch bolt 12 16 25 30 25 29 6 8 56 60 40 60 30 50 25 30 80 100 48 72 22 33 18 22 9 16 15 20 1 2 1 6 2 5 3 0 2 5 2 9 0 6 0 8 5 6 6 0 4 0 6 0 3 0 5 0 2 5 3 0 8 0 10 0 4 8 7 2 2 2 3 3 1 8 2 2 0 9 1 6 1 5 2 0 kg m N m TIGHTENING TORQUE ENG...

Page 164: ...r Rear axle nut Rear sprocket nut Rear brake cam lever bolt Front brake caliper mounting bolt Disc bolt Front brake mastet cylinder mounting bolt Brake hose union bolt Caliper bleeder bolt Oil cooler hose union bolt 10 M Oil cooler hose union bolt 12 M 50 80 15 25 30 40 20 30 22 35 80 100 18 28 50 80 10 15 40 60 70 100 84 120 50 80 20 30 8 12 18 28 18 28 5 8 20 25 6 9 20 25 20 25 5 0 8 0 1 5 2 5 3...

Page 165: ... 8 1 2 1 8 2 8 4 0 6 0 7 0 10 0 11 0 16 0 17 0 25 0 20 0 28 0 kg m N m kg m N m SERVICE DATA Unit mm ITEM Valve diam Valve lift Valve clearance or tappet clearance when cold Valve guide to valve stem clearance Valve guide I D Valve stem O D Valve stem runout Valve head thickness Valve stem end length Valve stem width Valve head radial runout Valve spring free length Valve spring tension Assembling...

Page 166: ...RN Piston diam Cylinder distortion Piston ring free end gap Piston ring end gap Assembling condition Piston ring to groove clearance Piston ring groove width Piston ring thickness Piston pin bore I D Piston pin O D STANDARD LIMIT ITEM Cam height Camshaft runout Cam chain 20 pitch length Rocker arm I D Rocker arm shaft O D Cylinder head distortion Cylinder head cover distortion 34 44 34 48 33 81 33...

Page 167: ...4 1 1 60 0 05 2 6 0 10 29 5 STANDARD LIMIT Unit mm Unit mm CONROD CRANKSHAFT ITEM Conrod small end I D Conrod deflection Conrod big end side clearance Conrod big end width Crank web to wed width Crankshaft runout 15 006 15 014 0 10 0 45 15 95 16 00 53 0 0 1 15 040 3 0 1 00 0 05 STANDARD LIMIT OIL PUMP ITEM Oil pump reduction ratio Oil pressure at 60 140 2 000 30 15 0 4 0 6 kg at 3 000 rpm STANDARD...

Page 168: ...0 2 Low 2nd 3rd 4th Top 2 750 33 12 1 785 25 14 1 368 26 19 1 045 23 22 0 913 21 23 No 1 NO 2 No 3 No 1 NO 2 No 3 5 0 5 1 5 5 5 6 4 8 4 9 5 3 5 4 Type Links 20 pitch length 50 60 428 H 132 Links 0 50 259 4 Shift fork to groove clearance Shift fork groove width Shift fork thickness Countershaft length Low to 2nd Drive chain Drive chain slack Gear ratios STANDARD LIMIT ...

Page 169: ...Throttle valve By pass Valve seat Stater jet Pilot screw Pilot air jet Needle jet ITEM Fuel type FUEL OIL Gasoline used should be graded 85 95 octane or higher An unleaded or low lead type is recommended 8 0 liter 1 0 liter SEA 10W 40 SF SG SH change Filter change Overhaul SS8 Oil 443 2 5 cc SAE J 1703 DOT 3 or DOT 4 950 ml 1 050 ml 1 400 ml Fuel tank including reserve Reserve Engine oil type Engi...

Page 170: ...nder bore Master cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam Brake drum I D Brake lining thickness Wheel rim runout Wheel axle runout Tire size Tire tread depth STANDARD LIMIT Front wheel Front wheel Front wheel Front wheel Front wheel Front wheel Rear wheel Rear wheel Axis direciton Circular direction Front wheel Rear wheel Front wheel Rear wheel Front wheel Rear wh...

Page 171: ...5 21 5 Front 10 Rear 10 3 4 1 7 1 7 Unit W LO HI SPECIFICATION Unit mm ELECTRICAL ITEM SPECIFICATION Ignition timing BTDC rpm Spark plug 15 2 250 and 35 4 000 C8EH 9 0 8 0 9 Type Gap Spark performance Ignition coil resistance Magneto coil resistance Generator no load voltage Regulated voltage Battery Fuse size Over 8 mm 0 19 0 24 Ϊ 5 4 6 6 G L Approx 90 110 Ϊ Y Y Approx 0 6 0 9 Ϊ 72 99 V 5 000 rpm...

Page 172: ...mp Starter cable Breather hose C D I Unit 09407 254A1 09407 14403 Front brake hose Clutch cable Handle switch L H Air vent hose Neutral switch License plate lamp Magneto Starter relay Handle switch R H 09407 14403 09404 06401 Magneto Neutral switch WIRE AND CABLE ROUTING WIRING HARNESS ...

Page 173: ...ery lead wire Clamp Starter motor lead wire Engine Engine Starter cable Speedometer cable Throttle cable Oil cooler Oil cooler Clutch cable Throttle cable Front brake hose View B View P View E View D View A 09407 14403 09407 14403 09407 14403 Battery lead wire Fuse assembly Rear brake switch Starter motor lead wire 09404 06401 09403H9304 09407 254A1 09407 14403 09404 06401 09497 11401 09407 14403 ...

Page 174: ...tracer L Blue W White LW Blue with White tracer YB Yellow with Black tracer Front turnsignal L Head lamp Front turnsignal R Dimmer Lighting Horn Handle switch LH Turnsignal Ignition switch Rear brake switch Gear position Ignition coil Starter motor Spark plug Starter relay Battery MF Engine earth Fuse 15A Rear turnsignal L Tail stop lamp License plate Rear turnsignal R C D I Unit Magneto Rectifier...

Page 175: ...Prepared by HYOSUNG MOTORS MACHINERY INC Overseas Technical Department 1st Ed Feb 1999 Manual No 99000 97100 Printed in Korea ...