SM62-1003-01E
ENGINE FRAME ELECTRICAL SYSTEM Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co., Ltd., GENERAL CONTENTS SERVICE INFORMATION 1 INSPECTIONS / ADJUSTMENTS 2 EXTERNAL PARTS 3 LUBRICATION SYSTEM 4 FUEL SYSTEM 5 ENGINE REMOVAL/INSTALLATION 6 LH.
SERVICE INFORMATION 1.
SERVICE INFORMATION SPECIFICATION ITEM DIMENSIONS FRAME OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION REAR SUSPENSION FRONT TIRE SIZE/TYPE REAR TIRE SIZE/TYPE TIRE PRESSURE 1 person FRONT REAR 2 persons FRONT REAR FRONT BRAKE REAR BRAKE FUEL TANK CAPACITY Full capacity Reserve capacity CASTER ANGLE TYPE CYLINDERS, ARRANGEMENT BORE X STROKE DISPLACEMENT COMPRESSION RATIO VALVES ENGINE OIL CAPACITY ENGINE TRANSMISSION OI
SERVICE INFORMATION ITEM TYPE/ VENTURY BORE CARBURETOR PD19J CHOKE TYPE Auto-bystarter MAIN JET #110 PILOTSCREWREVERSEREVOLUTIONSPEED 1 3/4 FLOAT LEVEL 11mm CLUTCH TYPE 1,700±100 rpm Automatic Transmission(V-belt type) PRIMARY REDUCTION 3.533 SECONDARY REDUCTION 3.714 IGNITION SYSTEM ELECTRICAL SYSTEM CV type(vacumm)/Φ16mm MODEL MARK IDLE SPPED DRIVE TRAIN SPECIFICATION AC-CDI IGNITION TIMING F MARK BTDC 14° BATTERY CAPACITY 12V 6Ah SPARK PLUG CR6HSA SPARK PLUG GAP 0.6~0.
SERVICE INFORMATION TORQUE VALUES ENGINE ITEM TAPPET ADJUSTING ROLL CAP OIL DRAIN PLUG BOLT VALVE ADJUST SCREW LOCK NUT CYLINDER HEAD BOLT FLYWHEEL NUT DRIVE FACE NUT CLUTCH OUTER BOLT SPARK PLUG DRIVE PLATE CAM SHAFT HOLDER NUT CAM CHAIN TENSIONER FLANGE BOLT CAM CHAIN TENSIONER PAN SCREW CYLINDER HEAD COVER BOLT MISSION COVER BOLT MISSION COVER DRAIN BOLT MISSION COVER CHECK BOLT COOLING FAN BOLT STARTER MOTOR FLANGE BOLT Q’TY THREAD DIA (mm) TORQUE VALUE 1 1 2 2 1 1 1 1 1 4 2 1 4 8 1 1 3 2 30 12 5
SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious WARNING CAUTION vehicle part damage may result if instruction accident may result if instructions are not are not followed. followed. Indicates general safety matters. Provides NOTE safety and appropriate handling procedures.
SERVICE INFORMATION LUBRICATION OIL ENGINE PARTS APPLICATION AREA VALVE GUIDE / VALVE STEM WORKING AREA REMARKS •SAE15W-40 or SAE10W-40 CONTACT AREA OF CAM SHAFT •API SL CONTACT AREA OF VALVE ROCKER ARM CAM SHAFT DRIVE CHAIN PISTON & PISTON RING GROVE INSIDE CYLINDER CONNECTING ROD PISTON PIN HOLE CONNECTING ROD CRANK SHAFT OIL PUMP DRIVE CHAIN COUNTER SHAFT GEAR FINAL GEAR BEARING SURFACE OF O-RING OIL SEAL AREA OF FRICTION SPRING WORK / SHAFT WORK AREA OF SHAFT WORK HEAT RESISTENT GREASE
SERVICE INFORMATION WIRING DIAGRAM WINKER RELAY MAGNETIC SWITCH REGULATOR RECTIFIER SAI PIPE SIDE STAND SPEEDOMETER CABLE FUEL TANK CDI UNIT FUEL COCK FUEL HOSE REAR BRAKE CABLE
SERVICE INFORMATION WINKER RELAY HORN FUEL TANK CDI UNIT MAGNETIC SWITCH IGNITION COIL REGULATOR RECTIFIER ACG COUPLER SAI PIPE MUFFLER FRONT BRAKE CALIPER
SERVICE INFORMATION MASTER CYLINDER SPEEDOMETER WINKER RELAY BRAKE HOSE KEY SET HORN
SERVICE INFORMATION BATTERY CABLE SAI PIPE ACG COUPLER REGURATOR RECTIFIER MAGNETIC SWITCH CDI UNIT FUEL TANK CARBURATOR
SERVICE INFORMATION GENERAL SAFETY WARNING 1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.
SERVICE INFORMATION 3. Store the parts of each system discriminatively to install each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation. 5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation. 6.
SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing. 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.
SERVICE INFORMATION 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. CAVITY MANUFACTURER’S NAME CLIP FITTING 21. Keep the pneumatic system interior or the engine interior from the infiltration of dust. 22.
SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. •Identify the two-colored cord by main color first and then spriped color . BLACK TUBE WHITE TUBE •When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler.
SERVICE INFORMATION •Turn off the main switch before connecting/disconnecting. •Release the lock to disconnect the lock of the coupler. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape. - Typical releasing method of the coupler is illustrated in the following. •When disconnecting the coupler, disconnect it while holding the coupler body.
SERVICE INFORMATION •Insert the connector until the vinyl cover is fully inserted into the terminal. •The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction. DRAINING HOLE •When removing 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.
SERVICE INFORMATION •In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. •The wire must not hang down or be pulled excessively. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts. •Do not twist the wire harness. •Wire the wire harness not to be pulled or expanded when the handle is turned to the right or the left completely.
2.
INSPECTIONS / ADJUSTMENTS TORQUE SPARK PLUG 1.2㎏f・m CYLINDER HEAD COVER BOLT 0.9㎏f・m VALVE ADJUSTING NUT 1.
INSPECTIONS / ADJUSTMENTS REGULAR INSPECTION SCHEDULE ● Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
INSPECTIONS / ADJUSTMENTS FUEL STRAINER FUEL FUELSTRAINER STRAINER FUEL STRAINER FUEL FUEL COCK COCK FUEL COCK FUEL TUBE FUEL FUELTUBE TUBE FUEL FUEL LINE(FUEL TUBE) ● Remove the luggage box. ● Check the fuel line connected to the fuel cock and carburetor. If the fuel line is cracked, damaged or leaks, replace it. CARBURETOR CARBURETOR CARBURETOR THROTTLE GRIP OPERATION ● Check to see if the throttle grip operates smoothly in any steering position.
INSPECTIONS / ADJUSTMENTS AIR AIR CLEANER AIRCLEANER CLEANER AIR CLEANER ● Loosen the 6 screws securing the air cleaner case cover and remove it. AIR CLEANER ELEMENT AIR AIRCLEANER CLEANERELEMENT ELEMENT AIR ● Remove the air cleaner element. ● Check the element, if it is dirty or damaged, replace it . CAUTION •Clean away dirt by tapping slightly the paper element if its surfae has very dirty or there is much dirty on it.
INSPECTIONS / ADJUSTMENTS CAUTION TURN TURN TURN •Inspect and adjust the valve clearance when the engine is cold(35℃). •Remove cooling fan cover. •Turn the flywheel counterclockwise , and align the “T” mark of the flywheel with index mark of the RH. crankcase cover. •Verify that the piston is located at the top dead center. ● Measure the valve clearance with feeler gauge. REMOVE REMOVE FAN COVER RUBBER PLUG REMOVEFAN FANCOVER COVERRUBBER RUBBERPLUG PLUG VALVE CLEARANCE : INTAKE 0.1±0.02MM EXHAUST0.1±0.
INSPECTIONS / ADJUSTMENTS CARBURETOR IDL SPEED THROTTLE THROTTLE STOP SCREW THROTTLESTOP STOPSCREW SCREW ● Turn the main key to the left , disassemble the lock nut and raise up the seat. ● Remove the carburetor maintenance cover on the luggage box. ● Connect to the ignition code ● Meet the speficied RPM by adjusting the throttle stop screw with the ⊕ screw driver.
INSPECTIONS / ADJUSTMENTS BRAKE FLUID BRAKE BRAKE FLUID CHECK WINDOW BRAKEFLUID FLUIDCHECK CHECKWINDOW WINDOW MASTER MASTER CYLINDER MASTERCYLINDER CYLINDER ● Check the oil level of front master cylinder. ● I f the oil level is near the lower limit level , remove the oil cup cap, diaphragm and fill DOT3 or DOT4 brake fluid to the top limit line. ● If the brake fluid reaches to the lower limit line, check the leaking of the brake system entirely.
INSPECTIONS / ADJUSTMENTS SIDE STAND ● Erect the main stand. ● If pull the lower end of side stand by hand, check whether it moves smoothly. ● If it doesn’t move freely, pour grease into its pivot side. ● If it moves too freely, check the side stand spring. ● Check the axial movement of side stand. SIDE SIDE STAND SIDESTAND STAND SUSPENSION NOTE •Do not ride motorcycle with an unsatisfactory suspension.
INSPECTIONS / ADJUSTMENTS WHEELS / TIRES NOTE •Check the tire pressure when the tires have been cooled off. Check the thread (the part making contact with the road surface)and side for being worn, cracked or damaged. Replace damaged tires. STANDARD PRESSURE ㎏f/㎠(psi) TIRE PRESSURE GAUGE TIRE TIREPRESSURE PRESSUREGAUGE GAUGE TIRE PRESSURE GAUGE ITEM DRIVER ONLY FRONT WHEEL REAR WHEEL 2.00(28psi) 2.00(28psi) DRIVERANDAPASSENGER 2.00(28psi) 2.
INSPECTIONS / ADJUSTMENTS LUBRICATION POINTS Unless specifically designated, use generd grease to lubricate the lubrication points. For stiding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean regularly the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it.
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3.
EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF FRAME COVERS FLOW CHART(ASSEMBLY/DISASSEMBLY) ● This chart shows arrows connected in the order of disassembling covers ① SEAT ⑥ BODY COVER ⑪ FRONT COVER ⑯ FRONT HANDLE COVER ② LUGGAGE BOX ⑦ REAR FENDER ⑫ INNER BOX ⑰ REAR HANDLE COVER ③ REAR CARRIER ⑧ FLOOR SIDE COVER ⑬ FRONT FENDER ⑱ REARWHEELMUDGUARD ④ BATTERY COVER ⑨ FLOOR PANEL ⑭ FRONT WHEEL ⑲REAR SPLASH COVER ⑤ CENTER COVER ⑩ UNDER COVER ⑮ FRONT UNDER COVER NOTE •At disassembling front w
EXTERNAL PARTS SEAT REMOVAL / ASSEMBLY ● Unlock the seat lock by turing the main key to the left.
EXTERNAL PARTS ● Loosen center cover ● Install in the reverse order of removal TAPPING TAPPINGSCREWS SCREWS TAPPING SCREWS . CENTER CENTER COVER CENTERCOVER COVER BODY BODY COVER BODYCOVER COVER TAPPING TAPPING SCREWS TAPPINGSCREWS SCREWS BODY COVER REMOVAL / ASSEMBLY ● Remove luggage box ● Remove rear carrier ● Loosen 2 tapping screws being installed at the RH / LH body side cover.
EXTERNAL PARTS ● Loosen 5 tapping screws installed at body cover and Disassemble rear fender ● Install in the reverse order of removal BODY COVER BODY BODYCOVER COVER BODY COVER REAR REAR FENDER REARFENDER FENDER FLOOR SIDE COVER REMOVAL / ASSEMBLY FLOOR FLOOR SIDE COVER FLOORSIDE SIDECOVER COVER ● Loosen 4 left-right special screws of floor side ● Loosen 2 tapping screws installed at left and right of floor side cover ● Disassemble floor side covers of RH/LH ● Install in the reverse order of removal.
EXTERNAL PARTS ● Untie 2 washer bolts in the side of floor panel. ● Pull backward and disassemble floor panel. ● Install in the reverse order of removal. FLOOR FLOOR PANEL FLOORPANEL PANEL WASHER WASHERBOLTS BOLTS WASHER BOLTS UNDER COVER REMOVAL / ASSEMBLY UNDER COVER UNDER UNDERCOVER COVER UNDER COVER ● Disassemble floor side cover. ● Loosen 4 left-right washer bolts installed at under cover. ● Disassemble under cover. ● Install in the reverse order of removal.
EXTERNAL PARTS INNER INNER COVER INNERCOVER COVER TAPPING SCREWS TAPPING TAPPINGSCREWS SCREWS TAPPING SCREWS FRONT UNDER COVER FRONT FRONTUNDER UNDERCOVER COVER INNER BOX REMOVAL / ASSEMBLY ● Remove the following parts. ① Luggage box ② Rear carrier ③ Center cover ④ Body cover ⑤ Floor side cover ⑥ Floor panel ⑦ Front cover ● Loosen 2 tapping screws installed at front under cover.
EXTERNAL PARTS FRONT UNDER COVER REMOVAL / ASSEMBLY WASHER BOLT WASHER WASHERBOLT BOLT FRONTUNDER UNDERCOVER COVER FRONT FRONT UNDER COVER WASHER SCREW WASHER WASHERSCREW SCREW WASHER SCREW ● Disassemble the following parts. - Front cover, Front fender / Front wheel ● Untie washer screw, tapping screw installed on inner cover. ● Untie 1 washer bolt installed at front under cover. ● Disassemble front under cover. ● Install in the reverse order of removal.
EXTERNAL PARTS SPEEDOMETER SPEEDOMETER SPEEDOMETER REAR REAR HANDLE COVER REARHANDLE HANDLECOVER COVER SPEEDOMETER REMOVAL / ASSEMBLY ● Disassemble front handle cover. ● Disassemble speedometer cable. ● Disconnect coupler and wires. ● Disassemble rear handle cover. ● Disassemble 3 tapping screws and speedometer cover. ● Disasemble speedometer. ● Install in the reverse order of removal.
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4. LUBRICATION SYSTEM SERVICE INFORMATION ··· 4-1 TROUBLE SHOOTING···· 4-1 ENGINE OIL LEVEL CHECK·····4-2 REPLACEMENT OF ENGINE OIL·· 4-3 OIL FUMP·········· 4-3 TRANSMISSION OIL·······4-5 SERVICE INFORMATION WARNING •The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long time. •Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
LUBRICATION SYSTEM TROUBLE SHOOTING Oil level low ●Natural oil consumption ●External oil leaking ●Worn piston ring or incorrect piston ring installation ●Worn valve guide or valve stem seal Oil contamination ●Oil or filter not changed often enough ●Faulty cylinder head gasket ●Piston ring worn Low or no oil pressure ●Clogged oil filter screen ●Incorret oil used
LUBRICATION SYSTEM OILLEVEL LEVELGAUGE GAUGE OIL OIL LEVEL GAUGE APPROPRIATE LINE APPROPRIATE APPROPRIATELINE LINE APPROPRIATE LINE UPPER UPPER UPPER UPPER ENGINE OIL LEVEL CHECK ● Erect the motorcycle on the main stand. ● Start the engine and let it be warm fully. ● Stop the engine, remove the oil gauge ● Check the oil level line. If the engine oil is insufficient, add the engine oil.
LUBRICATION SYSTEM OIL PUMP INSPECTION ● Drain the engine oil. ● Untie 1 flange bolt and 2 tapping screws installed at cooling fan cover. COOLING FAN COVER COOLING COOLING FAN FAN COVER COVER HEX BOLT HEX HEXBOLT BOLT AC ACGENERATOR GENERATOR AC GENERATOR ● Disassemble cooling fan. ● Disassemble AC generat. FRANGE BOLT FRANGE FRANGEBOLT BOLT FRANGE BOLT RH. RH. CRANK CASE COVER RH.CRANK CRANKCASE CASECOVER COVER ● Disassemble RH. Crank case cover. ● Untie hex nut installed at oil pump drive gear.
LUBRICATION SYSTEM OUTER ROTOR OUTER OUTERROTOR ROTOR PUMP BODY PUMP PUMPBODY BODY INNER INNER ROTOR INNERROTOR ROTOR OIL PUMP DISASSEMBLY DRIVE GEAR DRIVE DRIVEGEAR GEAR DRIVE GEAR ● Loosen the screw securing the oil pump plate. ● Remove the oil pump body and oil pump plate. ● Clean the oil pump body, inner rotor, outer rotor with fresh cleaning oil.
LUBRICATION SYSTEM ASSEMBLY ● Clean all parts with fresh cleaning oil. ● Install the inner and outer rotors into the oil pump body. ● Install the oil pump plate into the pump body. ● Tighten the fan screw. FAN SCREWS FAN FANSCREWS SCREWS FAN SCREWS NOTE •Check the oil pump to operate smoothly by turning pump shaft. INSTALLATION ● Assemble o-ring and dowel pin. ● Assemble oil pump to RH. Crank case. OIL OIL RINGS OILRINGS RINGS ● Assemble the following parts - Oil pump drive gear - RH.
LUBRICATION SYSTEM TRANSMISSION OIL INSPECTION ● Check the connection part of case for any leak. ● Loosen the oil check bolt and check to see if the oil overflows from the oil check hole. ● If the oil amount is not enough , loosen the oil check bolt and fill the recommended transmission oil to the oil filter hole. OIL CAPACITY : 0.12 L (After disassembly) 0.
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5. FUEL SYSTEM SERVICE INFORMATION ·· 5-1 TROUBLESHOOTING ···· 5-2 FUEL TANK········ 5-3 CARBURETOR·······5-3 CARBURETOR INSULATOR· 5-6 PILOT SCREW ADJUSTMENT·5-9 FUEL COCK········5-11 SERVICE INFORMATION GENERAL SAFETY CAUTION ● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore the evaporated(gasfied) gasoline is highly explosive. Work in a well-ventilated areas. ● Exhaust gas contains poisonous substance.
FUEL SYSTEM TROUBLESHOOTING The vehicle does not start. Back firing ● No gasoline in fuel tank. ● Fuel is not coming out of carburetor. ● Too much fuel is flowing into cylinder. ● No spark emitted from spark plug. ● Air cleaner is blocked. ● Ignition system is damaged or works improperly. ● Mixture is too lean. Insufficient power and high fuel consumption. Idle is unstable and engine turns off after starting. ● Idle is adjusted improperly. ● Air/fuel mixture is either too lean or rich.
FUEL SYSTEM FUEL TANK REMOVAL ● Remove luggage box. ● Untie 4 flange bolts installed at fuel tank. FRANGE FRANGE BOLT FRANGEBOLT BOLT ● Remove the fuel unit wire coupler. ● Remove the tube located fuel tank and fuel filter. ● Remove the fuel tank joint pipe tube. CAUTION •Gasoline is extremely flammable. Avoid fire during work and pay particular attention to electric sparks.Furthermore, the evaporated(vaporized) gasoline is highly explosive. Work in a wellventilated areas.
FUEL SYSTEM ● Untie screws installed at insulator. ● Disconnect carburetor. CARBURETOR CARBURETOR CARBURETOR TOP SET TOP TOPSET SET TOP REMOVAL ● Loosen the drain screw and drain the fuel. ● Remove the drain tube and air band hose. ● Loosen the 2 diaphragm cover setting screws. FANSCREWS SCREWS FAN FAN SCREWS COMPRESSION SPRING COMPRESSION COMPRESSION SPRING SPRING ● Disconnect top set cover. .
FUEL SYSTEM INSPECTION VACUUM VACUUM PISTON VACUUMPISTON PISTON JET NIDDLE COMP JET NIDDLE NIDDLE COMP COMP JET ● Check the jet needle for wear and replace if necessary. ● Check the vacuum piston for damage and replace if necessary. ● Check the diaphragm for damage, pin holes, bends and replace if necessary. NOTE •Check the diaphragm adequately for crack in the wrinkled and bent area. SPRING SPRING SEAT SPRINGSEAT SEAT ● Loosen 3 screws from float chamber set.
FUEL SYSTEM ● Remove the main jet, main jet holder, needle jet, slow jet, pilot screw. SLOW SLOW JET SLOWJET JET MAIN JET MAIN MAINJET JET MAIN CLEAN CLEAN COMPRESSED AIR CLEANCOMPRESSED COMPRESSEDAIR AIR ● Clean the all jet and hole of carburetor body with blow the compressed air. CAUTION •Turn in the pilot jet screw and record the number of turns it takes before it seats lightly. •Do not force pilot screw against its seat. The seat will be damaged.
FUEL SYSTEM COVER COVER COVER COVER COMPRESSION COMPRESSION COMPRESSION SPRING SPRING SPRING SPRING ● Disassemble accelerating pump. ● Loosen 2 screws, disconnect diaphragm, compression spring. ● Check whether there are pin role, twist, damage of diaphragm. ● Clean by compressed air fuel channel of diaphragm cover. DIAPHRAGM DIAPHRAGM COMP DIAPHRAGMCOMP COMP ASSEMBLY ● Assemble needle jet, needle jet holder, main jet, slow jet.. ● Assemble O-ring washer of pilot screw, spring screw.
FUEL SYSTEM ● Assemble accelerating pump. CAUTION •Assemble jet neeld fitting at assembled hole. TOM TOM SET TOMSET SET ● Assemble vacuum piston, jet needle, spring seat. ● Assemble compression spring. ● Assemble tom set and install 2 screws. CAUTION •Be careful for vaccum piston not to pinch to tom set. •By keeping spring straight and reducing its length, assemble cover. COMPRESSION SPRING COMPRESSION COMPRESSIONSPRING SPRING COMPRESSION INSTALL ● Install carburetor to carburetor insulator.
FUEL SYSTEM INSULATOR INSULATOR INSULATOR CARBURETOR INSULATOR DIASSEMBLY ● ● ● ● ● ● Disassemble luggage. Disassemble carburetor. Disassemble floating pressure fuel pump. Disassemble 2 fixed nuts of inlet pipe. Disassemble carburetor insulator. Disassemble fixed band of carburetor insulator. INLET PIPE INLET INLETPIPE PIPE INSPECTION ● Check abrasion or damage of carburetor insulator. ● Check abrasion or damage of inlet pipe o-riing. ● Install in the reverse order of removal.
FUEL SYSTEM THROTTLE STOP SCREW THROTTLE THROTTLESTOP STOPSCREW SCREW THROTTLE ④ Extend the hose(60mm) at the tail pipe and insert the probe of the emission analyzer to the tail pipe and adjust the pilot screw with a 1/8, the Co to became 3~4%. ⑤ Adjust by the throttle stop screw, repeat step ④ and ⑤ until according the idle rpm (1,700rpm) and the Co(3~4 %). ⑥ Snap lightly in idling and check to see if the rotation is smoothly and to return is normal. ● Install the carburetor maintenance cover.
FUEL SYSTEM ACCELERATING ACCELERATING ACCELERATING ④ When idling, check to see if the rotation is smoothly and to return is normal. ⑤ Turn the throttle stop screw until the 1000 rpm, and check the stopping of engine. If the engine is stop, adjust the pilot screw with a 1/8 and repeat step ④ and ⑤. (Check by snapping slightly and check whether RPM goes down naturally.) NOTE •If the engine cannot be adjusted by turning the pilot screw within a ¼ turn, check for other engine problems.
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6. ENGINE REMOVAL/INSPECTION SERVICE INFORMATION····· 6-1 ENGINE REMOVAL/ASSEMBLY·· 6-2 SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation. ● The following works can be carried out without removing the engine from the vehicle body. -TRANSMISSION (⇨SECTION 11) -A.C.
ENGINE REMOVAL/INSPECTION ENGINE REMOVAL / ASSEMBLY CARBURETOR CARBURETOR CARBURETOR ● Release the seat lock by turning the main key and open the seat. ● Remove the following parts. - Luggage box. - Air cleaner. - Carburetor. ● Disconnect the A.C generator coupler and connector wiring connected to the A.C generator, disconnect the starter motor wiring cable. ● Remove spark plug cap cord from the engine. ● Remove the bleeder tube from the cylinder head cover. ● Remove the EX. muffler.
ENGINE REMOVAL/INSPECTION ● Loosen rear cushion under bolt. REAR CUSHION UNDER BOLT REAR REARCUSHION CUSHIONUNDER UNDERBOLT BOLT ● Fix the jar-key for the motorcycles to under the vehicle. ● Loosen the flange bolt securing the engine hanger and remove the engine from the frame. JAR-KEY JAR-KEY JAR-KEY ASSEMBLY ● Install in the reverse order of removal. NOTE •Take precaution not to damage wiring and cable. •Take precaution not to damage the threaded part of bolts.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER
7. BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER SERVICE INFORMATION···7-1 SERVICE STANDARD· · · · 7-1 TROUBLESHOOTING· · · · 7-1 LH.CRANKCASECOVERREMOVAL· 7-2 KICK STARTER· · · · · · 7-2 DRIVE BELT· · · · · · · · 7-4 DRIVEN PULLEY ASS’Y· · · · 7-6 MOVABLE DRIVE FACE· · · 7-11 SERVICE INFORMATION GENERAL SAFETY ● Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced due to oil contact. ● Do not operate starter motor while the LH.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER LH. CRANK CASE COVER REMOVAL ● Loosen 10 flange bolts assemble at LH. Side cover. KICK KICK STARTER ARM KICKSTARTER STARTERARM ARM ● Disassemble LH. Side cover. ● Disassemble gasket and dowel pin. DOWELPIN PIN DOWEL DOWEL PIN GASKET GASKET GASKET ● Inspect LH. crank case cover. ● Install the new gasket and dowel pin after removing the gasket of crankcase surface. ● Install in the reverse order of removal. .
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER CIR CIR CLIP CIRCLIP CLIP KICK KICK SPINDLE BUSH KICKSPINDLE SPINDLEBUSH BUSH CHECK ● Check whether kick starter spindle worn, damage and gears worn, damage. ● Check whether return spring defect or damage. ● Check whether kick starter spindle bushing worn or damage.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVEFACE FACE DRIVE DRIVE FACE DRIVEN PULLEY ASS’ YY DRIVEN YY DRIVENPULLEY PULLEYASS’ ASS’ DRIVEN PULLEY ASS’ DRIVE BELT REMOVAL ● Disassemble LH. Side cover. (⇨7-2) ● Disassemble 2 dowel pins and gasket. CAUTION ·Be careful for missing of dowel pin. When disassembling gasket, be careful its torn. DRIVE BELT DRIVE DRIVEBELT BELT ● Diassemble start pinion ass’y in order to do easy repair.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER INSPECTION COG WIDTH ● Check the drive belt for cracks, cog seperation and wear ; Replace as necessary. ● Measure the width of the drive belt → replace the belt if the service limit is exceeded. SERVICE LIMIT : 16.5mm NOTE ·Use only a genuine DAELIM replacement drive belt. ·Do not get oil or greasde on the drive belt or pulley side. ·Clean off any grease or oil before reinstalling.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVEN PULLEY ASS’Y REMOVAL ● Remove the LH. crank case cover. (⇨7-2 ) ● By using universal holder, grip clutch outer and diassemble flange nut, then disassemble clutch outer. TOOL : UNIVERSAL HOLDER DRIVE FACE HOLDER ● Disassemble driven pulley ass’y from drive shaft. ● Disassemble drive belt. SPECIAL SPECIAL NUT SPECIALNUT NUT CLUTCH CLUTCH SPRING COMPRESSOR CLUTCHSPRING SPRINGCOMPRESSOR COMPRESSOR DISASSEMBLY ● Disassemble special nut 28mm.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Disassemble seal collar. DRIVEN FACE COMP DRIVEN DRIVENFACE FACECOMP COMP DRIVEN SEAL SEAL COLLAR SEALCOLLAR COLLAR ● Pull out roller guide pin and guide roller. MOVABLE MOVABLE DRIVEN DRIVEN FACE FACE MOVABLE DRIVEN FACE GUIDE GUIDE PIN GUIDEPIN PIN DRIVEN DRIVEN FACE DRIVENFACE FACE MOVABLE MOVABLE DRIVEN FACE MOVABLEDRIVEN DRIVENFACE FACE DRIVEN FACE DRIVEN DRIVENFACE FACE DRIVEN ● Pull out movable driven face.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER NIDDLE BEARING (INNER) NIDDLE NIDDLE BEARING BEARING (INNER) (INNER) BALL BALL BEARING (OUTER) BALLBEARING BEARING(OUTER) (OUTER) INSPECTION ● Check each part ● Check driven face needling bearing(inside) for damage or excessive play and replace necessary. Turn the inner race of the outer bearing with your finger. Check that the bearing turns smoothly and quietly, and that the bearing outer race fits securely.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Check damage or worn of movable drive face. ● Check whether worn of movable driven face guide home. ● Measure inner diameter of movable driven face. SERVICE LIMIT : 34.06MM MOVABLE DRIVEN FACE MOVABLE MOVABLEDRIVEN DRIVENFACE FACE MOVABLE DRIVEN FACE ● Check worn or damage of driven face. ● Measure outer diameter of driven face. SERVICE LIMIT : 33.94MM DRIVEN DRIVEN FACE DRIVENFACE FACE REPLACE DRIVEN FACE BEARING ● Replace inner bearing.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER MOVABLE MOVABLE DRIVEN FACE MOVABLEDRIVEN DRIVENFACE FACE DRIVEN FACE DRIVEN DRIVEN FACE FACE ASSEMBLY ● Assemble oil seal, o-ring to movable driven face. ● Assemble movable driven face to driven face. ● Assemble guide roller and roller pin. GUIDE PIN GUIDE GUIDEPIN PIN GUIDE PIN MOVABLE MOVABLE DRIVEN FACE MOVABLEDRIVEN DRIVENFACE FACE ● Assemble movable driven face to driven face. ● Assemble guide roller and roller pin.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVEN PULLEY ASSEMBLY DRIVEN PULLEY SUB DRIVEN DRIVEN PULLEY PULLEY SUB SUB DRIVEN DRIVEN PULLEY DRIVENPULLEY PULLEY ● Turn right driven pulley ass’y and widen maximumly assembled home for belt ● Assemble drive belt to drive pulley sub ass’y, then assemble to drive shaft. ● Assemble clutch outer to driven pulley sub ass’y, assemble temporarily special flange nut.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER CVT CVT COOLING FAN CVTCOOLING COOLINGFAN FAN ● ● ● ● ● Disassemble kick starter rachet. Disassemble CVT cooling fan. Disassemble drive face. Disassemble drive face boss. Disassemble movable drive face. KICKSTARTER STARTERRATCHET RATCHET KICK STARTER RATCHET KICK INSPECTION ● The weight rollers push on the movable drive face(by centrifugal force).
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER KICK KICK STARTER RATCHET KICKSTARTER STARTERRATCHET RATCHET DRIVE DRIVE FACE DRIVEFACE FACE ● Check drive face. ● Check worn or damage of CVT cooling fan. CVTCOOLING COOLINGFAN FAN CVT CVT COOLING FAN ASSEMBLY ● Assemble weight rollers to movable drive face. ● Assemble lamp plate. LAMP LAMP PLATE LAMPPLATE PLATE WEIGHTROLLER ROLLER WEIGHT ROLLER WEIGHT NOTE •Do not apply grease to the pulley side of movable drive face - If done, clean it.
BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Assemble drive face to the serration side of LH. Crank shaft, then assemble hext nut 12mm. FLANGE NUT FLANGE FLANGENUT NUT FLANGE NUT ● By using drive face holde, fasten drive face nut. TORQUE : 5.5kgf·m TOOL : DRIVE FACE NOTE •Assemble drive pulley nut as specified torque. •Assemble by completely fitting drive face and crankshaft sereration. •Fix fly wheel to universal holder if drive pulley holder can not be used.
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A.C. GENERATOR /RH.
8. A.C. GENERATOR /RH. CRANK CASE COVER SERVICES INFORMATION········8-1 COOLING FAN COVER··········8-2 AC GENERATOR·············8-4 RH. CRANK CASE COVER········8-4 SERVICE INFORMATION GENERAL SAFETY ● This section describes the removal and assembling of the A.C. generator. ● For the information of A.C. generator inspection, refer to the section 15. ● The charging systme can be maintained without removing the engine. TORQUE VALUES FLY WHEEL NUT RH. CRANK CASE COVER BOLT TOOL A.C.G. ROTOR PULLER 5.
A.C. GENERATOR /RH. CRANK CASE COVER COOLING COOLING FAN COVER COOLINGFAN FANCOVER COVER COOLING FAN COVER REMOVAL ● Remove the muffler. ● Loosen the 1 tapping screws and 2 flange bolts securing the cooling fan. UPPER UPPER HOOD UPPERHOOD HOOD COOLING COOLING FAN COOLINGFAN FAN ● Upper hood and low hood can be remove after removing the engine from the frame. LOW HOOD LOW LOWHOOD HOOD LOW FLYWHEEL WHEEL FLY FLY WHEEL A.C GERNERATOR REMOVAL ● Remove the cooling fan cover. ● Remove the cooling fan.
A.C. GENERATOR /RH. CRANK CASE COVER ● Loosen the flange nit securing the fly wheel and remove the flywheel using the A.C.G. rotor puller. CAUTION ACG ACG ROTOR PULLER ACGROTOR ROTORPULLER PULLER HEX HEX BOLT HEXBOLT BOLT FLANGE FLANGE BOLT FLANGEBOLT BOLT ACG ACG ACG •The flywheel may easily remove if you rotate the puller while tapping the roller shaft metal hammer. •Always use a holder and a puller to remove the flywheel. Do not try to remove the flywheel by hammering directly on it.
A.C. GENERATOR /RH. CRANK CASE COVER ● If the universal holder cannot be used, remove the LH.crankcase cover at left side of the crankshaft, and hold the drive face with the drive face holder. TORQUE : 5.5kgf·m TOOL : UNIVERSAL HOLDER ● Assemble cooling fan.(⇨8-2 ) ● Assemble ACG. cord coupler and connector at wire harness, and cramp cords. ● Assemble cooling fan cover. COOLING FAN COOLING COOLING FAN FAN RH. CRANK CASE COVER REMOVAL ● Disassemble the following parts.
A.C. GENERATOR /RH. CRANK CASE COVER ● Pull out gasket and dowel pin. DOWEL PIN DOWEL DOWELPIN PIN DOWEL OIL OIL PUMP REDUCTION GEAR OILPUMP PUMPREDUCTION REDUCTIONGEAR GEAR ● Check worn or damage of oil seal, if necessary, replace with the new oil seal. ● Disassemble RH. Crank case cover oil seal and replace with the new one. OIL OIL SEAL OILSEAL SEAL ASSEMBLY ● Assemble RH. Crank case cover. ● Assemble AC Generator. ● Assemble muffler. NOTE •Assemble completely by fitting correctly to the home.
CYLINDER HEAD / VALVES
9. CYLINDER HEAD / CYLINDER / PISTON SERVICE INFORMATION ···9-1 TROUBLE SHOOTING ····· 9-2 CAM SHAFT········· 9-3 CYLINDER HEAD·······9-5 VALVE SPRING········ 9-6 IN / EX VALVE ········9-6 VALVE GUIDE········ 9-7 VALVE SEAT·········9-8 IN / EX VALVE ASSEMBLY·· 9-8 CYLINDER HEAD ASSEMBLY· 9-10 CAM SHAFT ASSEMBLY··· 9-10 SERVICE INFORMATION GENERAL SAFETY ● The rocker arm and the camshaft can be served without removing the engine. ● The oil of camshaft is supplied through the cylinder head oil hole.
CYLINDER HEAD / VALVES TOOL -VALVE GUIDE REAMER -VALVE GUIDE DRIVER -VALVE SPRING COMPRESSOR TROUBLESHOOTING ● Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down test or by tracing noises to the top-end with a sounding rod or stethoscope.
CYLINDER HEAD / VALVES FLANGE FLANGE BOLTS FLANGEBOLTS BOLTS CYLINDER HEAD COVER CYLINDER CYLINDERHEAD HEADCOVER COVER CYLINDER CAMSHAFT REMOVAL ● ● ● ● Remove the luggage box. Remove the center cover. Untie 4 cylinder head cover bolts. Untie 2 SAI pipe cap nuts and cover. SAI SAI PIPE SAIPIPE PIPE NOTE •The camshaft can be maintained without removing the engine. MARK TTTMARK MARK ● Remove the cooling fan cover.
CYLINDER HEAD / VALVES CAM CAM SHAFT CAMSHAFT SHAFT CAM CAM CHAIN CAMCHAIN CHAIN ● Remove the cam chain from the cam shaft. NOTE •Take precautions not to allow the cam chain to drop into the crankcase. ● Install the 5mm bolt into the rocker arm shaft and by pulling bolt, remove the rocker arm shaft.. ● Remove the rocker arm. ● Remove the other side rocker arm in the same order.
CYLINDER HEAD / VALVES BEARING BEARING BEARING ● Manually turn the shaft bearing outer race, and check if it turns smoothly. ● Check damage or worn of bearing, if yes, replace it. ● Install in the reverse order of removal. CAUTION •Be sure to check the valve clearance. CYLINDER CYLINDER HEAD HEAD CYLINDER HEAD CYLINDER HEAD REMOVAL ● Remove the engine(6-2). ● Remove the shroud comp(upper, under hood). ● Remove the cylinder head cover. ● Remove the cam shaft holder. ● Remove the cam shaft.
CYLINDER HEAD / VALVES ● Remove the valve spring compressor, valve spring, valve cotter, retainer, sparing and valve. VALVE SPRING VALVE VALVESPRING SPRING TOOL: VALVE SPRING COMPRESSOR NOTE VALVE VALVE SPRING VALVESPRING SPRING COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR •To prevent the loss of tension, do not compree the spring more than necessary. •Mark the disassembled parts so that they can be reassembled in to the original position.
CYLINDER HEAD / VALVES VALVE GUIDE VALVE VALVE GUIDE GUIDE VALVE GUIDE REAMER REAMER REAMER REAMER VALVE GUIDE INSPECTION ● Insert the valve guide reamer from the combustion chamber side and ream the guide to remove any carbon built-up before measuring the guide. NOTE •Take care to tilt or lean the reamer in the guide while reaming. •Rotate the reamer clockwise, never counterclockwise when inserting and removing. TOOL: VALVE GUIDE REAMER ● Measure and record each valve guid inner diameter.
CYLINDER HEAD / VALVES ● Insert the valve guide at upside of cylinder head. TOOL: VALVE GUIDE DRIVE VALVE VALVE GUIDE REAMER VALVE GUIDE GUIDEREAMER REAMER ● Insert the valve guide at upside of cylinder head.Insert the valve guide at upside of cylinder head. NOTE •Take care not to tilt or lean the reamer in the guide while reaming.
CYLINDER HEAD / VALVES ● For valve spring with varying pitch, install the valve springs with the narrow pitch end facing down. ● Install the spring retainer. ● Compress the valve springs and install the valve cotter. NOTE •Compressing the valve spring more than necessary when installing the valve cotters may cause looss of valve spring tension. TOOL: VALVE SPRING COMPRESSOR VALVE VALVE STEM VALVESTEM STEM ● Tap the valve stems gently with a soft hammer to firmly seat the cotters.
CYLINDER HEAD / VALVES CYLINDER CYLINDER HEAD CYLINDERHEAD HEAD CYLINDER HEAD ASSEMBLY ● Clean the gasket material from the cylinder mating surface. ● Install the cam chain guide to the cylinder. ● Install the dowel pins and new gasket. ● Install the cylinder head. CAMSHAFT ASSEMBLY ● Apply engine to the rocker arm shaft, and assembly the rocker arm to the camshaft holder. ● Align cam shaft with the bolt hole of the camshaft holder and the fitting side of the rocker arm shaft.
CYLINDER HEAD / VALVES ● Apply engine oil to the camshaft and install it on the cylinder head with the cam thread facing downward. ● Assembly the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top pf the cylinder head. ● Slowly rotate the crankshaft counterclockwise and align the “T” mark of the flywheel with the index mark of the RH. crank case cover.
CYLINDER HEAD / VALVES ● Install flange nut and tighten them driving with 2-3 times. TORQUE : 2.0kgf·m BOLT BOLT BOLT SPRING SPRING SPRING PUSH PUSH PUSH ● Pull out spring from cam chain tensioner lifter. ● Push the tensioner shaft clockwise with a small driver like the right picture, and insert the shaft into the body completely. ● Assemble new gasket to tensioner lifter and tensioner lift to cylinder. ● Assemble flange bolt ● Insert tensioner lift spring and assemble with bolt. TORQUE : 1.
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CYLINDER / PISTON
10. CYLINDER / PISTON SERVICE INFORMATION···················10-1 TROUBLESHOOTING ····················10-1 CYLINDER··························10-2 PISTON· ··························10-3 PISTON / CYLINDER INSTALLATION··············10-5 SERVICE INFORMATION GENERAL SAFETY ● Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder.
CYLINDER / PISTON CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER REMOVAL ● ● ● ● ● ● Remove the engine from the engine. Remove the cylinder head cover. Remove the cam shaft holder Remove the cylinder head. Remove the cam chain guide from the cylinder. Remove the cylinder CAM SHAFT HOLDER CAM CAMSHAFT SHAFTHOLDER HOLDER CAM SHAFT HOLDER ● Remove the gasket and dowel pin. ● Remove any adhering gasket material from the cylinder/ head mating surface.
CYLINDER / PISTON ● Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT: 0.05MM PISTON PISTON PISTON PISTON REMOVAL ● Remove the piston clip. NOTE •Do not allow to drip the piston pin clip into the inside of crank case. PIN PIN CLIP PINCLIP CLIP ● After removing the piston pin, then remove the piston. ● Remove the piston ring.
CYLINDER / PISTON FEELER GAUGE FEELER FEELERGAUGE GAUGE FEELER GAUGE ● Inset the piston ring into the inside of cylinder, check the clearance of piston ring. NOTE PISTON PISTON RING PISTONRING RING •Inset the piston ring in parallel by the head of piston. SERVICE LIMIT: TOP/SECOND: 0.40MM OIL RING (SIDE RAIL): 0.8 MM TOOL: FEELER GAUGE ● Measure and record the piston outer 90° to the piston pin bore and the point specified(10 mm), near the bottom of the piston skirt. 90° 90° 90° SERVICE LIMIT: 38.
CYLINDER / PISTON PISTON / CYLINDER INSTALLATION TOP RING MARK SECOND RING PISTON ASSEMBLY ● Clean the piston head, ring lands and skirts. R NOTE TOP RING SECOND RING •Be careful not to damage the piston and rings during assembly •Carefully install the piston rings onto the piston with the markings facing up. •Do not confuse the top and second rings. SIDE RAIL SPACER SIDE RAIL 20mm ● Space the ring end gaps 120 degrees apart. ● Do not accord the side rail of oil ring.
CYLINDER / PISTON ● Install the new gasket and dowel pins. CYLINDER CYLINDER CYLINDER CYLINDER ● Coat the cylinder wall with clean the engine oil and lubricate the piston rings and install the cylinder. NOTE •Be careful not to damage the piston rings. •Be careful not to drop the cam chain into the crankcase. ● Install the lower part of the cam chain guide to the groove part of the crankcase and install the cam chain guide by aligning the projection part with the groove part of cylinder.
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TRANSMISSION/CRANKSHAFT/CRANKCASE
11. TRANSMISSION/CRANKSHAFT/CRANKCASE SERVICE INFORMATION····11-1 TROUBLE SHOOTING·····11-2 TRANSMISSION········11-3 TRANSMISSION BEARING···11-4 CRANKCASE REMOVAL····11-7 CRANK SHAFT REMOVAL····11-8 CRANK SHAFT INSTALLATION···11-9 CRANK CASE INSTALLATION··11-10 SERVICE INFORMATION GENERAL SAFETY ● This section describes how to remove the crank case and to maintain the transmission and the crankshaft. ● Service transmission without removing the engine from the vehicle. However, to prevent damage to the LH.
TRANSMISSION/CRANKSHAFT/CRANKCASE TORQUE CRANK CASE BOLT 1.1kgf·m TOOL - UNIVERSAL BEARING PULLER - CRANK SHAFT ASSEMBLER COLLAR SHAFT - DRIVE HANDLE - DRIVE OUTER - BEARING REMOVER SET TROUBLESHOOTING Engine Noise ● Connecting rod big and small ends loose. ● Crank pin bearing loose. Engine started but unable to move out ● Transmission damage. ● Transmission seized. Noise during operation ● Gear worn, overheated, cracked. ● Bearing worn. Oil leaks ● Excessive oil level. ● Oil seal worn, damaged.
TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION FLANGE FLANGE BOLT FLANGEBOLT BOLT DISASSEMBLY ● Loosen the drain bolt, drain the mission oil. ● Remove the LH. crankcase cover. ● Remove the driven pulley, drive face. ● Remove the muffler. ● Remove the rear wheel. ● Loosen the bolts assembled at LH. Crank case and remove the transmission cover. DRAIN BOLT DRAIN DRAIN BOLT BOLT RH. RH. CRANK CASE RH.CRANK CRANKCASE CASE DRIVE DRIVE SHAFT DRIVESHAFT SHAFT ● Remove the gasket and dowel pin in LH.
TRANSMISSION/CRANKSHAFT/CRANKCASE INSPECTION ● Check the drive shaft for wear or damage. DRIVE DRIVE SHAFT DRIVESHAFT SHAFT ● Check the final shaft and gear for wear or damage. COUNTER COUNTER SHAFT COUNTERSHAFT SHAFT FINAL FINAL SHAFT FINALSHAFT SHAFT ● Check the final shaft and the worn or damage of gears. TRANSMISSION BEARING ● Disassemble crank shaft and transmission.
TRANSMISSION/CRANKSHAFT/CRANKCASE ● Replace the bearings if necessary. ● Press the bearing to the case with special tool. TOOL: BEARING REMOVER SET ASSEMBLY ● Install the drive shaft on the transmission cover. ● Install a new drive shaft oil seal. TOOL: CRANK ASSEMBLY SHAFT CRANK ASSEMBLY COLLAR ● Check whether bearing, oil seal in LH. Crank case are worn or damaged.
TRANSMISSION/CRANKSHAFT/CRANKCASE ● Apply clean engine oil to the new bearing and insert by pressure to crank case. TOOL : DRIVER HANDLE, DRIVER OUTER ● Assemble the new final shaft oil seal. ● Assemble drive shaft to LH. Crank case. ● Assemble the new drive shaft oil seal. TOOL : DRIVER HANDLE ● Assemble final shaft and counter shaft to crank case mission cover. ● Assemble the new gasket and dowel pin. ● Install transmission cover by flange bolt. - Rear wheel.
TRANSMISSION/CRANKSHAFT/CRANKCASE CRANK CASE REMOVAL ● Remove the engine from the frame. ● Remove the RH./LH. crank case cover. ● Remove the parts to disassemble crankcase. ● Loosen the 1 flange bolt from the RH. crank case. FLANGE FLANGE BOLT FLANGEBOLT BOLT ● Face the LH. crankcase downward, and remove the RH. crankase from the LH. crankcase while tapping a new places on the LH. crankcase with a plastic hammer. NOTE •Be careful not to distort the mating surface of the crank case during removal. RH.
TRANSMISSION/CRANKSHAFT/CRANKCASE ● Check RH. Crank case. ● Check LH. Crank case. CRANK SHAFT REMOVAL ● If the bearing is left on the crankshaft, use a bearing puller to remove it. TOOL: UNIVERSAL BERING PULLER CRANK CRANK CRANK DIAL DIAL DIAL DIAL GAUGE GAUGE GAUGE INSPECTION ● Place the crankshaft on a stand or V-block, and measure the crankshaft runout using dial gauge. SERVICE LIMIT: RIGHT: 0.1MM LEFT: 0.
TRANSMISSION/CRANKSHAFT/CRANKCASE ● Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big ends. TOOL: FEELER GAUGE SERVICE LIMIT: 0.5MM FEELER FEELER GAUGE FEELERGAUGE GAUGE ● Measure the connecting rod radial clearance in both X and Y directions. SERVICE LIMIT: 0.6MM DIAL DIAL GAUGE DIALGAUGE GAUGE CRANK SHAFT INSTALLATION ● Put the LH. crank case toward the downward, hang the cam chain into the inside crankcase.
TRANSMISSION/CRANKSHAFT/CRANKCASE CRANK CASE INSTALLATION ● Install the dowel pins and a new gasket. ● Pulling the cam chain and check to see if the crankshaft installed correctly. ● Install the RH. Crankcase to the LH. crank case. NOTE •Make sure that the gasket is completely attached without any clearance. ● Assemble one RH. Crank case flange bolt. FLANGE BOLT FLANGE FLANGEBOLT BOLT FLANGE ● Regarding the installing the engine assy, refer to the manual.
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FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM
12. FR. WHEEL / FR. BRAKE / FR.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM TROUBLESHOOTING Hard steering Bad working brake ● Steering bearing adjustment nut too tight. ● Faulty steering stem bearings. ● Damaged steering stem bearings. ● Insufficient tire pressure. ● Rim deformed. ● Bad wheel bearing.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM FRONT FRONTHANDLE HANDLECOVER COVER FRONT HANDLE COVER WASHER SCREW WASHER WASHERSCREW SCREW WASHER SCREW STEERING HANDLE REMOVAL ● Remove the front handle cover 1 washer screw and 3 tapping screws. TAPPING TAPPING SCREW TAPPINGSCREW SCREW ● Remove Remove 2 tapping screws assembled at front handle cover.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Disconnect the throttle cable from the throttle grip and remove the throttle grip. ● Loosen the hex flange bolt securing handle bar and remove the handle bar. HANDLE HANDLE BAR HANDLEBAR BAR FRANGE BOLT FRANGE FRANGEBOLT BOLT FRANGE BOLT INSTALLATION HANDLE HANDLE BAR HANDLEBAR BAR ● Install the handle bar to the steering stem. ● Assemble handle bar bushing(setting collar) fit to the home. ● Insert the hex flange bolt and tighten the locknut..
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSPECTION ● Check the front axle for deflection. Place the front axle on a V-block, and measure deflection with a dial gauge. SERVICE LIMIT: 0.2 MM FRONT FRONT AXLE FRONTAXLE AXLE ● Place the front wheel on an inspection stand. Slowly turn the wheel, and check the rim for wobbles with a dial gauge. SERVICE LIMIT: RADIAL 2.0MM AXIAL 2.0 MM ROLL ROLL ROLL FRONT WHEEL BEARING INSPECTION ● Turn the inner race of each bearing with finger.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ASSEMBLY DRIVER HANDLE DRIVER DRIVERHANDLE HANDLEAA DRIVER HANDLE AA ● Apply sufficient amount of grease to the bearing. ● Insert the right bearing with its seal surface facing outside. ● Upon assembling the distance collar, insert the left bearing with its seal surface facing outside. TOOL: DRIVER HANDLE A OUTER DRIVER NOTE •Do not tilt the bearing. Insert accurately.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM SPEEDOMETER GEAR BOX SPEEDOMETER SPEEDOMETERGEAR GEARBOX BOX SPEEDOMETER GEAR BOX ● Align the wheel hub with the projection area of the speedometer gear box retainer, and install. ● Apply grease to the dust seal rim. ● Install the dust seal, and align the projection area of speedometer gear box retainer with the gear groove to assemble the speedometer gear box. FRONT WHEEL INSTALLATION ● Insert the front wheel between the front forks.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Measure the bent or twist of brake disk. TRANSMISSION OIL CAPACITY : 0.12 L ● If the bent or twist exceeds over the service limit, check the tolerance of wheel bearing ● If the wheel bearing works regularly, replace brake disk. MASTER SYLINDER FRONT BRAKE MASTER CYLINDER REMOVAL ● Remove the front handle cover. ● Drain the brake fluid. ● Remove the front stop switch coupler.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM MASTER CYLINDER BODY STOP SWITCH LEVER ● Remove the cylinder, spring from the master cylinder. ● Clean the inside of master cylinder, reserve, master piston with the brake fluid. DIAPHRAGM PLATE SPRING CYLINDER DIAPHRAGM CIR CLIP BOOT OIL CUP CAP INSPECTION PRIMARY PRIMARY CUP PRIMARYCUP CUP SECONDARY SECONDARY CAP SECONDARYCAP CAP ● Check the piston periphery for scores, scratched or nicks. ● Check the primary and secondary cups for wear.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM NOTE •When installing the cups, do not allow to close the cup ends. •nstall the spring with it’s smaller direction of coil ends toward the piston. ● Install the cir clip to the mater cylinder groove firmly. TOOL: SNAP RING PLIER ● Assemble boot to master cylinder. BOOT BOOT BOOT INSTALLATION ● Install the front master cylinder to the handle.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Remove the master cylinder cup cap. ● Remove the master cylinder cup cap, diaphragm plate, and diaphragm from the master cylinder. Connect the bleeder hose to the bleeder valve. Loosen the bleeder valve, and pump the brake lever repeatedly. ● When there is no more fluid flowing out of the bleeder valve. Stop pumping the brake lever.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM BLEEDER BLEEDER SCREW BLEEDERSCREW SCREW ② Release the brake lever slowly and wait several seconds after it reaches the end of its travel ③ Repeat the above steps ① and ② until bubbles cease to appear in the fluid at the end of the hose ● Check the fluid level often, and add fluid if the fluid lever is near the lower level. ● If no air leaks out of the bleeder hose, operate the brake lever to check the presence of air. ● Tighten the bleeder valve.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM REMOVAL AIRGUN GUN AIR GUN AIR ● Remove the pad spring, pad comp, caliper bracket, boot from the caliper body. ● If there is any wear or damage in the boot, replace it with a new one. ● Wrap the caliper with a piece of cloth to avoid piston and brake fluid leakage and facing the piston downward. ● Remove the piston from the caliper while blowing the low-pressure air in the opening of the brake hose.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Measure the caliper inner diameter. DIAL DIAL GAUGE DIALGAUGE GAUGE DUST SEAL PAD PISTON SEAL PISTON SERVICE LIMIT: 25.043 MM ● Clean the piston seal and dust seal with the brake fluid and install them in caliper. ● Install the piston in the caliper with the groove side of the piston facing the pad. PAD SPRING BRACKET CALIPER BODY PAD PAD SPRING PADSPRING SPRING ● Install the pad spring the caliper.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM FRONT FORK STEERING STEERING COMP STEERINGCOMP COMP FRONT FRONT FORK FRONTFORK FORK ● Remove the front under cover. ● Remove the front caliper. ● Remove the front fender. ● Remove the front rear wheel. ● When removing the front fork, loosen the fork pipe bolt lightly. NOTE •Support the vehicle securely under the engine not to turn over it. •Loosen the fork pipe bolt, but do not remove it.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Remove the dust seal. DUST DUST SEAL DUSTSEAL SEAL ● Remove the fork pipe from the bottom case. ● Remove the piston and rebound spring from the fork pipe. ● Remove the oil seal stop ring. OIL OIL SEAL STOP RING OILSEAL SEALSTOP STOPRING RING ● Remove the oil seal. NOTE OIL OIL SEAL OILSEAL SEAL •Take precaution not to damage the interior and exterior rim of the bottom case.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSPECTION ● Place the fork spring on a level place, and measure the free length. ● If the free length deviates from the service limit, replace the springs with now ones. SERVICE LIMIT: 232 MM FRONT FORK SPRING FRONT FRONTFORK FORKSPRING SPRING FRONT FORK SPRING BOTTOM CASE OIL LOCK PEACE OIL SEAL DUST SEAL ● Check components for damage or abnormal wear. Replace defective parts with new ones.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Assemble the fork pipe to the bottom case. ● Assemble the springs to the fork pipe. NOTE •Install the spring with the smaller pitch side facing downward. ● Accurately assemble the stop ring to the bottom case. ● Install the dust seal. ● Fix bottom case by wrapping cloth fix to vice. ● Assemble to fork piston by applying screw lock gell to the screw side of socket bolt. TORQUE VALUE : 2.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Fill a prescribed amount of automatic transmission fluid in to the fork pipe. CAPACITY: 90 ㎤ ● Slowly press the fork tube 2-3 times to discharge air. ● Check the oil level the fork tube is completely compressed condition. ● Install the fork pipe bolt toe the fork pipe. INSTALLATION ● Align the part of groove with the setting bolt connection. ● Install 8mm front fork setting bolt. TORQUE VALUE : 2.5kgf·m ● Install the brake hose clip to the RH.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM STEERING STEM REMOVAL ● ● ● ● ● HANDLE BAR BAR HANDLE HANDLE BAR BUSHING BUSHING BUSHING BUSHING Remove the handle cover. Remove the rear handle cover. Remove the front cover. Remove the handle bar. Remove the front wheel. NOTE •Be careful not to turn over the vehicle. ● Remove the steering lock nut. ● Remove the steering top nut. LOCK LOCK NUT LOCKNUT NUT TOP TOP NUT TOPNUT NUT BALL BALL COVER BALLCOVER COVER ● Remove ball cover.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSTALLATION ● Apply grease to steering bottom con race, then assemble steering stem ball ass’y. ● Assemble steering stem to frame body head pipe. ● Apply grease to frame body head pipe,then assemble steering stem ball ass’y. ● Assemble steering top con race ● Assemble temporarily top nut after doing ball cover.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM HANDLE HANDLEBAR BAR HANDLE BAR ● Assemble the following parts. - Front fork. - Front wheel. - Handle bar. - Handle cover. - Front cover. ● Check the followings after assembling ● By meeting the regular inspection schedule, check fixing of all nuts, bolts which are fixed based on the regular torque standards ● Check all pin, clips, hose clamps and cable stay.
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REAR WHEEL / REAR BRAKE / REAR CUSHION
13. REAR WHEEL / REAR BRAKE / REAR CUSHION SERVICE INFORMATION···13-1 TROUBLE SHOOTING····13-2 REAR WHEEL········13-3 REAR BRAKE·······13-4 REAR CUSHION······13-6 SERVICE INFORMATION GENERAL SAFETY ● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe. ● Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies.
REAR WHEEL / REAR BRAKE / REAR CUSHION TROUBLE SHOOTING Rear wheel wobbling or vibration ● Deformed wheel, rim ● Bad tire ● Axle bad fastening ● Bad tire air pressure ● Improper wheel balancing Soft rear suspension ● Bad spring ● Bad rear damper, oil leakage Hard suspension ● Twisted damper rod ● Bad tire air pressure Rear cushion noise ● Looseness of fastening and assmbled points
REAR WHEEL / REAR BRAKE / REAR CUSHION REAR WHEEL REMOVAL ● Erect the motorcycle on the main stand. ● Remove the muffler. MUFFLER MUFFLER MUFFLER MUFFLER ● Untie rear wheel flange lock nut 16mm. LOCK LOCK NUT LOCKNUT NUT REAR WHEEL REAR REARWHEEL WHEEL REAR ● Remove the rear wheel. INSPECTION ● Check the rim for wobbles by rotating the wheel. SERVICE LIMIT: RADIAL 2.0 MM AXIAL 2.
REAR WHEEL / REAR BRAKE / REAR CUSHION LOCK NUT LOCK LOCKNUT NUT LOCK NUT INSTALLATION ● Assemble rear wheel by flange lock nut 16mm. TORQUE : 1.2 kgf·m ● Install in the reverse order of removal. NOTE •After installing the rear wheel, be sure to adjust the brake lever free play. REAR BRAKE ● Remove the rear wheel. INSPECTION ● Measure the brake drum for inner diameter. SERVICE LIMIT: 110.5MM BRAKE LINING BRAKE BRAKELINING LINING BRAKE ● Measure the brake lining for thickness. SERVICE LIMIT: 2.
REAR WHEEL / REAR BRAKE / REAR CUSHION REMOVAL ● Manually open the brake shoe and remove it. ● Remove the shoe spring from the brake shoe. BRAKE SHOE SHOE SPRING SHOE SPRING BRAKE SHOE BRAKE CAM BRAKE BRAKE CAM BRAKECAM CAM ● Loosen the rear brake arm fixing bolt. ● Remove the rear brake arm. ● Remove the rear brake cam.. BRAKE ARM BRAKE BRAKEARM ARM BRAKE SHOE BRAKE BRAKESHOE SHOE BRAKE SHOE INSTALLATION ● ● ● ● ● Apply the small amount of grease to the brake cam. Install the brake.
REAR WHEEL / REAR BRAKE / REAR CUSHION REAR REAR CUSHION REARCUSHION CUSHION REAR CUSHION REMOVAL ● Loosen the top and bottom rear cushion setting bolt. REAR CUSHION BOLT REAR REARCUSHION CUSHIONBOLT BOLT REAR CUSHION BOLT NOTE •Support the frame firmly prior to working. REMOVAL COMPRESSOR COMPRESSORATTACHMENT ATTACHMENT COMPRESSOR ATTACHMENT ● Install the compressor attachment as shown in the picture. ● Install the cushion on the cushion compressor, and compress the spring.
REAR WHEEL / REAR BRAKE / REAR CUSHION INSPECTION ● Measure the rear cushion spring free length. ● Check the damper rod for deflection or damage. SERVICE LIMIT: 185 MM INSTALLATION ● Install the spring, stop rubber. ● Apply thread locking agent to the lock nut, and install the rear cushion compressor attachment on damper rod. ● Fix the upper metal, and tighten the lock nut. TORQUE: 3.5 kgf·m TOOL: REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT INSTALLATION ● Install the rear cushion.
CHARGING SYSTEM WINKER RELAY MAGNETIC SWITCH FUEL TANK CDI UNIT FUEL COCKE REGULATER RECTIFIER FUEL HOSE SAI PIPE SPEEDOMETER CABLE C H A R G I N G D I A G R A M W G R R REGURATOR RECTIFIER BATTERY (12V 3AH) Y Y REGISTER 5W 6.7 G FUSE(7A) AC.
14. CHARGING SYSTEM SERVICE INFORMATION·····14-1 TROUBLE SHOOTING· · · · · 14-2 B AT T E RY · · · · · · · · ·14-3 CHARGING SYSTEM INSPECTION· 14-4 AC GENERATOR INSPECTION·14-5 REGULATOR RECTIFIER INSPECTION·14-5 SERVICE INFORMATION WARNING ·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery. ·Do not allow battery acid to come into contact with clothes, skin or eyes.
CHARGING SYSTEM TROUBLE SHOOTING No power(key turned on) Low power(engine running) ● Dead battery - Low fluid level - Complete discharged ● Disconnected battery cable ● Main fuse cut ● Faulty ignition switch ● Battery undercharged ● Battery is failing ● Charging system failure Intermittent power ● Loose battery connection ● Loose charging system connection ● Loose starting systme connection ● Loose connection or short circuit in ignition system ● Loose connection or short circuit in lighting system Lo
CHARGING SYSTEM BATTERY BATTERY BATTERY BATTERY BATTERY SCREW SCREW SCREW SCREW ● Loosen the screws and remove the battery cover. ● Disconnect the negative ⊖ battery cable first, and then disconnect the positive ⊕ cable. ● Remove the battery. ● Install in the reverse order of removal. ⊕ ⊕ ⊖ ⊖ BATTERYCOVER COVER BATTERY BATTERY COVER BATTERY(OPEN-CIRCUIT VOLTAGE) INSPECTION ● Remove the battery cover. ● Measure the voltage between the battery terminals. FULL CHARGED : 12.6~13.
CHARGING SYSTEM CAUTION •Current flow larger than the range selected may blow out the fuse in the tester. •While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester. BATTERY⊖ TERMINAL BATTERY⊖TERMINAL TERMINAL BATTERY⊖ BATTERY⊖ TERMINAL CHARGING VOLTAGE INSPECTION CAUTION VOLT METER AM METER MAIN FUSE TERMINAL MAIN FUSE •Be sure that the battery is fully charged before performing this test.
CHARGING SYSTEM ● Measure the resistance between the yellow and white lead. ● If the resistance values are much larger than the specified value, or if there is continuity between terminals and earth terminals, replace the stator with a new one. RESISTANCE VALUE: 0.5~1.5Ω (20°C) REGULATOR RECTIFIER INSPECTION ● Remove the regulator rectifier coupler.
IGNITION SYSTEM WINKER RELAY FUEL TANK HORN CDI UNIT MAGNETIC SWITCH IGNITION COIL REGULATOR RECTIFIER ACG COUPLER FRONT BRAKE CALIPER SAI PIPE MUFFLER I G N I T I O N S Y S T E M SIDE STAND S/W KILL S/W G B/W B/R B/Y G L/Y IGNITION COIL G SPARK PLUG PULSE GENERATOR AC.
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IGNITION SYSTEM TROUBLE SHOOTING Spark plug does not emit sparks. UNUSUAL CONDITION POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER) IGNITION COIL PRIMARY VOLTAGE EXCITE COIL PULSE GENERATOR Low peak voltage. 1. Cranking speed is low. - Battery is low or kick power is weak. 2. Poorly connected connectors or an open circuit in ignition system 3. Faulty ignition coil 4. Faulty CDI unit(in case when above No. 1~4 are normal) No peak voltage. 1. Incorrect peak voltage adaptor connections. 2.
IGNITION SYSTEM CDI CDIUNIT UNIT CDI UNIT CDI UNIT INSPECTION CDI IGNITION CIRCUIT INSPECTION NOTE •Follow the step described in the troubleshooting flow chart when servicing the ignition system. ● Remove the front cover. ● Disconnect the coupler from the CDI unit, and check the ignition system circuits from the wiring coupler side.
IGNITION SYSTEM IGNITION COIL INSPECTION ● Remove the luggage box( 3-2) ● Remove the primary wire. NOTE •Since the resistance value of primary coil is inherently very small, it is difficult to distinguish it from a shorted wire. ● Measure the peak voltage of the ignition coil primary side first. ● If the resistance value is withtin the specified range the coil is good. ● It resistance ∞ (infinite), replace the coil with a new one STANDARD VALUE: 0.1~0.5Ω ● Remove spark plug cap from plug.
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STARTING SYSTEM WINKER RELAY MAGNETIC SWITCH FUEL TANK CDI UNIT FUEL COCK REGULATER RECTIFIER FUEL HOSE SAI PIPE SPEEDOMETER CABLE S T A R T E R SIDE STAND S Y S T E M R/W REAR BRAKE CABLE C I R C U I T R STARTER MOTOR FUSE R MAIN S/W M REAR STOP S/W STARTER S/W Y/R B G/Y STARTER RELAY G G FRONT STOP S/W BATTERY (12V3AH) G
16. STARTING SYSTEM SERVICE INFORMATION···· 16-1 TROUBLE SHOOTING ···· 16-2 STARTER MOTOR ······ 16-3 STARTER MAGNETIC SWITCH·16-6 SERVICE INFORMATION GENERAL SAFETY ● The starter motor can be maintained without removing the engine from the vehicle. ● Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
STARTING SYSTEM TROUBLE SHOOTING Starter motor does not rotate (No response from starter motor). ● Check to see if the fuse is burned out. ● Check to turn on the lamp of stop switch. With the main switch turned to ON, squeeze the brake lever. In this state push the starter button and check if a clicking noise then an operating noise is emitted from the starter relay.
STARTING SYSTEM FLANGE FLANGE FLANGE FLANGE BOLT BOLT BOLT BOLT STARTER STARTER STARTER MOTOR MOTOR MOTOR STARTER MOTOR REMOVAL ● Release the seat lock with the main key. ● Remove the luggage box. ● Remove the starter motor cable from the stater magnetic switch. ● Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor. ● Remove the starter motor. ● Install in the reverse order of removal.
STARTING SYSTEM ● the brush spring, and then remove the brush. ● Measure the brush length. Replace the brush if it is worn beyond the service limit. BRUSH BRUSH BRUSH BRUSH SERVICE LIMIT: 6.5 MM NOTE •If replacement, replace with a brush holder set. ● Check the commutator for - Damage or abnormal wear. → Replace with a new one. - Discoloration of the commuttor bar. → Replace with a ne one.
STARTING SYSTEM STARTER MOTOR ASSEMBLY ● Install the brush and brush spring to the brush hold set. ● Apply grease to both ends of the armature shaft, and install the 2 washers. FRONT BRACKET FRONT FRONTBRACKET BRACKET ● Push the brush, and insert the armature into the rear bracket groove. CAUTION •The sliding surfaces of the brushes can be damaged if they are not installed properly.
STARTING SYSTEM STARTER STARTER MAGNETIC MAGNETIC SWITCH SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH REMOVAL ● Remove the luggage box. ● Remove the battery (+) cable from the starter magnetic switch terminal. ● Remove the starter motor cable from the starter magnetic switch terminal. ● Disconnect the coupler connected to wire harness, and starter magnetic switch. INSPECTION ● Check if the starter magnetic switch “click” when it is turened ON. - Click but the engine does not start.
17. LIGHTS// SWITCHES / HORN SERVICE INFORMATION·····17-1 TROUBLE SHOOTING······17-1 HEADLIGHT BULB REPLACEMENT·17-2 FRONT WINKER·······17-2 REAR COMBINATION LIGHT·· 17-3 REAR WINKER········17-3 SPEEDOMETER ········17-3 MAIN SWITCH········17-4 HANDLE BAR SWITCH······17-4 HORN············17-5 FRONT/REAR STOP SWITCH···17-5 FUEL UNIT··········17-6 SERVICE INFORMATION GENERAL SAFETY ● Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
LIGHTS// SWITCHES / HORN HEADLIGHT BULB REMOVAL ● ● ● ● ● HEADLIGHT HEADLIGHT BULB HEADLIGHTBULB BULB Remove the front under cover. Disconnect the headlight wiring. Loosen the 4 setting bolts securing the front cover. Remove the headlight assembly. Install in the reverse order of removal. BULB REPLACEMENT ● Pull off the headlight socket.. ● Replace with a new bulb. ● Install in the reverse order of removal.
LIGHTS// SWITCHES / HORN REAR COMBINATION LIGHT TAIL TAIL LIGHT TAILLIGHT LIGHT REAR WINKER REAR REARWINKER WINKER REAR BULB REPLACEMENT ● Loosen the 2 taillight lens tapping screws of the rear combination light. ● Pull off the tailight lens and remove it from the groove. ● Remove the bulb from the socket and replace with a new bulb. ● Install in the reverse order of removal.
LIGHTS// SWITCHES / HORN SPEEDOMETER SPEEDOMETER SPEEDOMETER ● Disconnect the RH./LH.switch wire and remove the speedometer and the 3 tapping screws securing the rear handle cover. ● Remove the speedometer. ● Install in the reverse order of removal. REAR HANDLE COVER REAR REARHANDLE HANDLECOVER COVER REAR HANDLE COVER TAPPING TAPPING SCREW TAPPINGSCREW SCREW MAIN SWITCH KEY SET KEY KEYSET SET KEY ● Remove the front cover. ● Remove the main switch coupler.
LIGHTS// SWITCHES / HORN DIMMER SWITCH HI (N) LO COLOR BAT3 HI LO DG/Y BLUE PURPLE HANDLE HANDLE SWITCH COUPLER HANDLESWITCH SWITCHCOUPLER COUPLER HAZARD SWITCH HAZARD HAZARD SWITCH HAZARD HAZARDSWITCH SWITCH HAZARD SWITCH OFF HAZARD COLOR W R L GRAY SKY BLUE ORANGE STARTER SWITCH FREE PUSH COLOR STARTER SWITCH STARTER STARTER SWITCH SWITCH ST E YELLOW/RED GREEN/YELLOW HORN HORN HORN HORN ● Remove the wire connector from the horn. ● Connect the horn terminal with 12V battery.
LIGHTS// SWITCHES / HORN - When the brake lever is released - NO CONTINUITY ● Install in the reverse order of removal. RELEASE THE LEVER RELEASE RELEASE THE THE LEVER LEVER FUEL FUEL UNIT FUELUNIT UNIT FUEL FUEL UNIT RETAINER FUELUNIT UNITRETAINER RETAINER FUEL UNIT ● Remove the floor panel. ● Remove fuel unit coupler. ● Turn fuel unit retainer and remove. ● Remove fuel unit. ● Be careful not to damage the wire. ● Measure the resistance between the fuel unit upper and lower.
18. TROUBLESHOOTING ENGINE WON’T START OR HARD TO START ··········· 18-1 ENGINE STALLS, HARD TO START, ROUGH IDLING··········18-2 POOR PERFORMANCE AT LOW SPEED AND IDLING ········ 18-3 POOR OPERATION ·····················18-4 ENGINE WON’T START OR HARD TO START CAUSE OF TROUBLE Open the drain screw, and check fuel flow to the carburetor. Fuel not supplied to the carburetor. ·No fuel to fuel tank. ·Disconnected or damaged fuel pump negative pressure tube. ·Clogged fuel tube. ·Clogged float valve.
ENGINE STALLS, HARD TO START, ROUGH IDLING CAUSE OF TROUBLE Open the drain screw, and check fuel flow to the carburetor. Fuel not supplied to the carburetor. ·No fuel to fuel tank. ·Clogged fuel tube. ·Clogged float valve. ·Clogged fuel tank cap. ·Clogged fuel strainer. ·Disconnected or damaged fuel pump negative pressure tube. Contaminated or discolored. ·Contaminated spark plug. ·Using spark plug with an incorrect heat range. Weak or intermittent sparks. ·Faulty or contaminated spark plug.
POOR PERFORMANCE AT LOW SPEED AND IDLING CAUSE OF TROUBLE Smoothly accelerate engine. Engine speed does not increase sufficiently. ·Clogged air cleaner. ·Insufficient fuel supply. ·Clogged fuel tank cap air hole ·Clogged muffler. Abnormal ·Faulty CDI unit. ·Faulty A.C generator. Low ·Worn cylinder or piston ring. ·Damaged cylinder head gasket. ·Cracked cylinder or cylinder head. Clogged ·Poor carburetor maintenance. Contaminated or discolored.
POOR OPERATION CLUTCH DRIVE / DRIVEN PULLEY CAUSE OF TROUBLE Engine starts but vehicle won’t move. ·Worn or damaged drive belt. ·Damaged ramp plate. ·Faulty weight roller. ·Faulty movable drive face. ·Damaged driven pulley weight shoe spring. ·Faulty transmission. ·Seized transmission. Engine stalls or vehicle creeps. ·Broken driven pulley weight spring. ·Seized clutch outer and weight. Poor performance at start or lack of power. ·Worn or slipped drive belt. ·Worn weight roller.
POOR FRONT/REAR SUSPENSION PERFORMANCE CAUSE OF TROUBLE Soft suspension. ·Weak cushion spring ·Overloaded ·Oil leakage from damper unit Hard suspension. ·Bent fork pipe or cushion rod Suspension noisy.
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SERVICE MANUAL 2010. 03 PRINTED 2010.
SM62-1003-01E
