Hyosung GT125 & GT250 Workshop Manual

HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
SERVICE MANUAL
99000-94710
FOREWORD GROUP INDEX
This manual contains an introductory description on

HYOSUNG / and proce-
GENERAL INFORMATION 1
dures for its inspection/service and overhaul of its main
components.
Other information considered as generally known is not
PERIODIC MAINTENANCE 2
included.
Read GENERAL INFORMATION section to familiarize
yourself with outline of the vehicle and MAINTENANCE
and other sections to use as a guide for proper inspec-
ENGINE 3
tion and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum FUEL SYSTEM 4
and quick service.
This manual has been prepared on the basis of the ELECTRICAL SYSTEM 5
latest specification at the time of publication.
If modification has been made since then,
difference may exist between the content of this
manual and the actual vehicle.
CHASSIS 6
Illustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual vehicle exactly SERVICING INFORMATION 7
in detail.
WARNING
This manual is intended for those who have
enough knowledge and skills 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. 2002.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.
2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you are look-
ing for.
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: Front wheel

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and
meaning associated with them respectively.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply THREAD LOCK 1324 .
Data beside it indicates specified torque.
Apply oil. Use engine oil unless otherwise

Apply or use brake fluid.
specified.
Apply SUPER GREASE A . Measure in voltage range.
Apply SUPER GREASE C . Measure in resistance range.
Apply SILICONE GREASE. Measure in current range.
Apply MOLY PASTE. Use special tool.
Apply BOND 1215 .

NOTE
Difference between photographs and actual motorcycles depends on the markets.
GENERAL INFORMATION
1
CONTENTS
INFORMATION LABELS 1-1
GENERAL PRECAUTIONS 1-1

SERIAL NUMBER LOCATION 1-3
FUEL AND OIL RECOMMENDATIONS 1-4
BREAK-IN PROCEDURES 1-5

CYLINDER CLASSIFICATION 1-5
EXTERIOR ILLUSTRATION 1-6
SPECIFICATIONS 1-8
1-1 GENERAL INFORMATION
WARNING / CAUTION / NOTE

Please read this manual and follow its instructions 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.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE
Indicates special information to make maintenance easier or instructions cleaner.
Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
WARNING
Proper service and repair procedures are important for the safety of the service machanic and the safe-
ty and reliability of the vehicle.
When 2 or more persons work together, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in is well-ventilat-
ed and that you follow all off the material manufacturer s instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a
while after engine operation.
After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system
for leaks.
GENERAL INFORMATION 1-2
WARNING
If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may
be reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean, and also lubricated when specified.
When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
When removing the battery, disconnect the negative cable first and then positive cable. When
reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal
cover on the positive terminal.
When performing service to electrical parts, if the service procedures do not require use of
battery power, diconnect the negative cable at the battery.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with small-
er 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 material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is com-
pletely seated in its groove and securely fitted.
Do not use self-locking nuts a few times over.
Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or
oil if a thread is smeared with them.
After reassembly, check parts for tightness and operation.
WARNING
To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
To protect Earth s natural resouces, properly dispose of used vehicles and parts.
SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine seri-
al number is located on the left upside of crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER

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
ENGINE OIL SPECIFICATION
Classification system Grade
API Over SG
SAE 10W/30 or 10W/40
If an SAE 10W/30 or 10W/40 motor oil is not available,

select an alternative according to the following chart.
Use a premium quality 4-stroke motor oil to ensure

longer service life of your motorcycle.
WARNING
Don t mix the unrecommended oil. It could damage the engine.
When refilling the oil tank, don t allow the dust to get inside.
Mop the oil spilt.
Don t put the patch on the cap. It could disturb the oil to be provided and damage the engine.
BRAKE FLUID
Specification and classification: DOT3 or DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-
tem, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL

Use fork oil : TELLUS #22
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard 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:
Keep to these break-in procedures:
Initial 800km Less than 1/2 throttle

Up to 1,600km Less than 3/4 throttle
Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation.
Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
CYLINDER CLASSIFICATION
The engine of / is composed of the two cylinder, is classified into the front cylinder and
rear cylinder as basis of the motorcycle ahead.
Rear cylinder
Front cylinder
FRONT
EXTERIOR ILLUSTRATION
890
395
315
800
795
795
760
635
1,045
960
890
895
1,120
795
180
1,455 325
2,080
EXTERIOR ILLUSTRATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length 2,080 mm (81.9 in)

Overall width 760 mm (29.9 in)
Overall height 1,120 mm (44.1 in)
Wheelbase 1,455 mm (53.7 in)
Ground clearance 180 mm (7.1 in)
Unladen mass 170 kg (375 lbs) 167 kg (368 lbs)
ENGINE
Type Four-stroke, DOHC, air-cooled and oil-cooled

Number of cylinder V-2 cylinder
Bore 57.0 mm (2.24 in) 44.0 mm (1.73 in)
Stroke 48.8 mm (1.92 in) 41.0 mm (1.61 in)
3
Piston displacement 249 (15.2 in ) 124.7 (7.6 in3 )
Carburetor BDS 26TYPE (DOUBLE)
Starter system Electric starter
Lubrication system Wet sump
TRANSMISSION
Clutch Wet multi-plate type

Transmission 5-speed constant mesh
Gearshift pattern 1-down, 4-up
Final reduction 3.286 3.714
Gear ratio, 1st 2.462 2.750
2nd 1.556 1.786
3rd 1.190 1.350
4th 0.957 1.091
5th 0.840 0.913
Drive chain 520 HO 112 links 428 HO 136 links
CHASSIS
Front suspension Telescopic type

Rear suspension Swingarm type
Steering angle 33 (right & left)
Caster 25.5
Trail 85 mm (3.35 in) 76 mm (2.29 in)
Front brake Disk brake
Rear brake Disk brake
Front tire size 110/70 - 17 54H
Rear tire size 150/70 - 17 69H
Front fork stroke 120 mm (4.72 in)
ELECTRICAL
Ignition type CDI type

13 B.T.D.C.at 2,000 rpm and
Ignition timing
30 B.T.D.C.at 6,000 rpm
Spark plug CR8E
Battery 12V 12Ah
Fuse 15 A
HI : 60 W HI : 35 W
Head lamp
LO : 55 W LO : 35 W
Turn signal lamp 10 W
Brake / Tail lamp 21 / 5 W
Speedometer lamp 1.7 W 3
High beam indicator lamp 1.7 W
Turn signal indicator lamp(right & left) 1.7 W 2
License plate lamp 5W
Neutral indicator lamp 1.7 W
CAPACITIES
Fuel tank 17.0

Engine oil, oil change 1,450
with filter change 1,500
overhaul 1,800 1,650
Front fork oil (One side) 400 2.5 cc 262 cc
NOTE
The specifications are subject to change without notice.
PERIODIC MAINTENANCE 2
CONTENTS
PERIODIC MAINTENANCE SCHEDULE 2- 1 2

PERIODIC MAINTENANCE CHART 2- 1
LUBRICATION POINTS 2- 2
MAINTENANCE PROCEDURES 2- 3
VALVE CLEARANCE 2- 3
SPARK PLUG 2- 5
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2- 5
AIR CLEANER 2- 6
CARBURETOR 2- 7
FUEL HOSE 2- 8
CLUTCH 2- 8
ENGINE OIL 2- 9
ENGINE OIL FILTER 2-10
DRIVE CHAIN 2-11

BRAKE SYSTEM 2-13
STEERING 2-17
FRONT FORK 2-17
REAR SUSPENSION 2-17
TIRE 2-18
CHASSIS BOLTS AND NUTS 2-18
COMPRESSION PRESSURE 2-19
OIL PRESSURE 2-20

2-1 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the
motorcycle operating at peak performance and economy.
CAUTION
More frequent servicing should be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

ENGINE
Interval
Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Air cleaner element Clean every 3,000 km Replace every 12,000 km 2- 6
Exhaust pipe nuts and
Tighten Tighten 2-5
muffler mounting bolts
Valve clearance adjust Inspect Inspect 2- 3
Cylinder head nut Tighten Tighten 3-48
Cylinder head & Cylinder Remove carbon 3-22
Spark plug Clean Clean Replace 2- 5
Inspect Inspect
Fuel hose 2- 8
Replace every 4 years
Engine oil filter Replace Replace 2-10
Engine oil Replace Replace 2- 9
Throttle cable Inspect Inspect 2- 7
Idle speed Inspect Inspect 2- 7
Clutch Inspect Inspect 2- 8
CHASSIS
Interval
Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Drive chain Clean and lubricate every 1,000km 2-11
Brake Inspect Inspect 2-13
Inspect Inspect
Brake hose 2-13
Inspect Inspect
Brake fluid 2-13
Tires Inspect Inspect 2-18
Steering Inspect Inspect 2-17
Front forks Inspect 2-17
Rear suspension Inspect 2-17
Chassis bolts and nuts Tighten Tighten 2-18
CAUTION
Using poor quality replacement parts can cause your motorcycle to wear more quickly and shorten its useful life.
Use only genuine Hyoung replacement parts or their equivalent.
PERIODIC MAINTENANCE 2-2
LUBRICATION POINT
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Clutch lever holder Front brake lever holder

Drive chain Throttle cable
Side stand pivot and spring hook Rear brake pedal pivot
Speedometer gear box
O - Motor oil, G - Grease
NOTE
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motor-
cycle has been operated under wet or rainy condition.
MAINTENANCE PROCEDURE
This section describes the service procedure for
each section of the periodic maintenance.
VALVE CLEARANCE
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km.
CAUTION
The clearance specification is for COLD state.
The valve clearance specification is different for

intake and exhause valves.
Valve clearance adjustment must be checked and
adjusted, 1) at the time of periodic inspection, 2)
when the valve mechanism is serviced, and 3)
when the camshaft is disturbed by removing it for
servicing.
Remove the spark plug. (Refer to page 2-5)
Remove the fuel tank. (Refer to page 4-1)
Remove the cylinder head cover and . [ FRONT CYLINDER ] [ REAR CYLINDER ]
Remove the magneto cover plug and the timing
inspection plug .
Rotate the magneto rotor to set the front cylinder s

piston at TDC (Top Dead Center) of the compression
stroke.
(Rotate the rotor until F line on the rotor is aligned
with the center of hole on the crankcase.)
To inspect the front cylinder s valve clearance, insert

the thickness gauge to the clearance between the
camshaft and the tappet.
Valve clearance (when cold)

IN. 0.1 0.2 mm (0.004~0.008 in)
EX. 0.2 0.3 mm (0.008~0.012 in)
Thickness gauge : 09900-20806

If the clearance is out of specification, first remove the

cam chain tensioner, camshaft housing, camshaft.
To install the tappet shim at original position, record
the shim NO. and clearance with A , B , C , D
mark on the cylinder head as the illustration.
Select the tappet that agree with tappet clearance

(vertical line) and shim NO.(horizontal line) as refer to the
tappet shim selection chart. (Refer to page 7-33 34)
Adjust valve timing, install the camshaft housing and the

tensioner.
After the crankshaft rotate about 10 times, measure the
valve clearance.
If the clearance be not agree, adjust the standard clea-
rance as the same manner above.
In case that valve adjustment which there is no the
tappet shim selection chart, please follow instructions
of example in the below.
For example, the intake clearance is 0.4 and the shim
is 170 (1.70 mm), select 195 (1.95 mm) of the shim
which 170 (1.70 mm) of the shim add up the excess
clearance 0.25 mm when adjust with the standard
0.15 as the intake standard clearance 0.1 0.2 mm.
CAUTION
Valve clearance should be checked when the
engine is cold.
If you don t rotate the crankshaft about 10
times before measuring the valve clearance,
there is no meaning of valve clearance.
Rotate the magneto rotor to set the rear cylinder s

piston at TDC(Top Dead Center) of the compression
stroke.
(Rotate the rotor 285 counter-clockwise from the
F line, and until the R line on the rotor is
aligned with the center of hole on the crankcase.)
Inspect the rear cylinder s valve clearance with the

same manner of the front cylinder.
SPARK PLUG
Inspect Interval
Clean Initial 1,000 km and Every 4,000 km,
Replace Every 8,000 km.
Disconnect the spark plug caps.

Remove the spark plugs.
TYPE SPARK PLUG SPECIFICATION

Hot type CR7E
Standard type CR8E
Cold type CR9E
Remove the carbon deposite with wire or pin and adjust

the spark plug gap to 0.7 0.8 mm, measuring with a
thickness gauge.
Spark plug gap 0.7 0.8 mm (0.028~0.032 in)
Check to see the worn or burnt condition of the elec-

trodes.
If it is extremly worn or burnt, replace the plug.
And also replace the plug if it has a broken insulator,
damaged thread, etc.
Install the spark plug, and then tighten it to specified
torque.
Spark plug : 20~25 N m (2.0~2.5 kg m)
0.7 0.8mm
(0.028 0.032 in)
EXHAUSE PIPE NUTS AND MUFFLER

MOUNTING BOLTS
Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km.
Tighten the exhaust pipe nuts , and muffler mount-

ing bolts to the specified torque.
Exhaust pipe nut

: 18~28 N m (1.8~2.8 kg m)
Muffler mounting bolt
: 20~30 N m (2.0~3.0 kg m) [ Front Cylinder ]
[ Rear Cylinder ]
AIR CLEANER
Inspect Interval
Clean Every 3,000 km,
Replace Every 12,000 km.
The air cleaner is located under the fuel tank.

Remove the fuel tank.
Remove the four screw
Pull up the air cleaner cover and the air cleaner ele-
ment
Clean the air cleaner element for the following:

When the air cleaner element clean with the air gun,
CAUTION
necessarily blow at the inside by compressed air. More frequent servicing may be performed on mo-
Carefully examine the air cleaner element for tears during torcycles that are used under severe condi-
cleaning. Replace it with a new one if it is torn. tions, also clean the air cleaner element when
Assemble the element completely or damage severely replacing the oil to prevent damage of the engine.
the engine.
Be careful not to allow water to go inside the air clea-
ner element.
CARBURETOR
Inspect Interval
IDLE SPEED
CAUTION
Make this inspection when the engine is hot.
Connect an engine tachometer to the high tension

cord.
Start up the engine and set its speed at anywhere
1,450 and 1,550 rpm by turning throttle stop screw .
Engine idle speed 1,450 1,550 rpm
Engine tachometer : 09900-26006
THROTTLE CABLE PLAY

There should be 0.5 1.0 mm play on the throttle cable.
To adjust the throttle cable play.
Tug on the throttle cable to check the amount of play.
Loosen the lock nut and turn the adjuster in or
out until the specified play is obtained.
Secure the lock nuts while holding the adjuster in
place.
Throttle cable play 0.5 1.0 mm (0.02~0.04 in)
FUEL HOSE
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km,
Replace every 4 years.
Remove the front and rear seat. (Refer to page 6-1)

Inspect the fuel hoses for damage and fuel leakage. If
any defects are found, the fuel hoses must be replaced.
[ ]
[ ]
CLUTCH
Inspect Interval
Clutch play should be 4 mm as measured at the clutch lever

holder before the clutch begins to disengage. If the play in
the clutch is incorrect, adjust it in the following way :
Loosen the lock nut and screw the adjuster on
the clutch lever holder all the way in.
Loosen clutch cable adjuster lock nut .
Turn the clutch cable adjuster in or out to acquire
the specified play.
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 cable play 4 mm (0.16 in)

GEARSHIFT LEVER HEIGHT ADJUSTMENT

Loosen the lock nut
With the link rod turned, adjust the gearshift lever
height.
ENGINE OIL
Inspect Interval
Replace Initial 1,000 km and Every 4,000 km.
Necessary amount of engine oil
Oil change 1,450 1,450

Filter change 1,500 1,500
Overhaul engine 1,800 1,650
Engine oil type SAE 10W/30 or 10W/40

API Over SG
Oil should be changed while the engine is warm. Oil fil-

ter replacement at the above intervals, should be
together with the engine oil change.
Keep the motorcycle upright.
Place an oil pan below the engine, and drain the oil
by removing the filler cap and drain plug .
Tighten the drain plug to the specified torque, and
pour fresh oil through the oil filler. Use an API classi-
fication of Over SG oil with SAE 10W/30 or 10W/40
viscosity.
Oil drain plug : 18~20 N m (1.8~2.0 kg m)
Start up the engine and allow it to run for several

minutes at idling speed.
Turn off the engine and wait about three minutes,
then check the oil level through the inspection win-
dow. If the level is below mark F , add oil to F level.
If the level is above mark F , drain oil to F level.
CAUTION
Never operate the motorcycle if the engine oil level
is below the Lower line mark(L) in the inspec-
tion window. Never fill the engine oil above the
Upper line mark(F) .
Engine oil level being most suitable about 1mm under
the Upper line mark(F) of the engine oil lens. In
case of the engine oil pouring in excessively, the
engine output being made insufficient.
Be careful not to pouring in the engine oil exces-
sively.
CAUTION
Necessarily, confirm and clean the oil strainer
when replace the engine oil (specially, when first
replacement).
CAUTION
More frequent servicing may be performed on mo-
torcycles that are used under severe conditions.
ENGINE OIL FILTER

Inspect Interval
Replace Initial 1,000 km and Every 4,000 km.
Drain the engine oil as described in the engine oil

replacement procedure.
Remove the oil filter cap .
Remove the oil filter.
Install the new O-ring .
Install the new oil filter.

Install the new O-ring and spring to the oil filter
cap.
Install the oil filter cap.
CAUTION
Before installing the oil filter cap, apply engine
oil lightly to the new O-ring .
OIL FILTER INSTALLATION

INSERTION
DIRECTION
LUSTER MATERIAL
CAUTION
When install the oil filter, necessarily, HYOSUNG
character and 16510H05240 part s NO. install to-
ward the outside, otherwise can damage the engine.
HYOSUNG
WARNING 16510H05240 OUTSIDE
Engine oil and exhaust pipes can be hot enough to
burn you.
Wait until the oil drain plug and exhaust pipes are
cool enough to touch with bare hands before drain-
ing oil.
Add new engine oil and check the oil level as

described in the engine oil replacement procedure.
CAUTION
Use HYOSUNG MOTORCYCLE GENUINE OIL FIL-
TER only, since the other make s genuine filters
and after-market parts may differ filtering perfor-
mance and durability, which could cause engine
damage or oil leaks. Hyosung motors genuine oil
filter is also not usable for the motocycles.
DRIVE CHAIN
Inspect Interval
Clean and Lubricate Every 1,000 km.
Visually check the drive chain for the possible defects
listed below. (Support the motorcycle by the jack or
block, turn the rear wheel slowly by hand with the trans-
mission shifted to Neutral.)
Loose pins
Excessive wear
Damaged rollers
Improper chain adjustment
Dry or rusted links
Kinked or binding links
If any defects are found, the drive chain must be
replaced.
NOTE
When replacing the drive chain, replace the
drive chain and sprocket as a set.
Loose the axle nut .
Tense the drive chain fully by turning both chain

adjusters , .
Count out 21 pins (20 pitches) on the chain and mea-

sure the distance between the two points. If the dis-
tance exceeds the service limit, the chain must be
replaced.
Service limit
Drive chain
20pitch length 319.4 mm 256.5 mm
(12.58 in) (10.10 in)
Loosen or tighten both chain adjusters , until the

chain has 20 30 mm of slack in the middle
between the engine and rear sprockets. The marks
, on both chain adjusters must be at the same
position on the scale to ensure that the front and rear
wheels are correctly aligned.
Drive chain slack 20 30 mm (0.79 ~ 1.18 in)

Place the motorcycle on jack or block for accurate

adjustment.
After adjusting the drive chain, tighten the axle nut
to the specified torque.
Tighten both chain adjusters , securely.
Rear axle nut : 90~140 N m (9.0~14.0 kg m)
Recheck the drive chain slack after tightening the

axle nut.
20~30mm
(0.79~1.18 in)
Wash the drive chain with kerosine. If the drive chain

tends to rust quickly, the intervals must be shortened.
After washing and drying the chain, oil it with a
engine oil or chain lubricating oil.
CAUTION
The drive chain for this motorcycle is made of the
special material.
The chain should be replaced with a 520HO for
and 428SO for
Use of another chain may lead to premature
chain failure.
BRAKE SYSTEM
Inspect Interval
[ BRAKE ]
[ BRAKE HOSE & BRAKE FLUID ]

Replace the brake hoses Every 4 years,
Replace the brake fluid Every 2 years.
BRAKE FLUID LEVEL CHECK

Keep the motorcycle upright and place the handle- LOWER LIMIT LINE
bars straight.
Check the brake fluid level by observing the lower
limit line (LOWER) on the front brake fluid reservoir.
When the level is below the lower limit line (LOWER),
replenish with brake fluid that meets the following
specification.
Specification and Classification : DOT 3 or DOT 4
CAUTION
[ Front Brake ]
The brake system of this motorcycle is filled with
a glycol-based brake fluid. Do not use or mix dif-
ferent types of fluid such as silicone-based or
petroleum-based. Do not use any brake fluid
taken from old, used or unsealed containers.
Never re-use brake fluid left over from the last
servicing or stored for a long period.
CAUTION
Brake fluid, if it leaks, will interfere with safe run-
ning and immediately discolor painted surfaces.
Check the brake hoses and hose joints for cracks
[ Rear Brake ]
and oil leakage before riding.
BRAKE PAD WEAR

The extend of brake pad wear can be checked by
observing the grooved limit on the pad. When the
wear exceeds the grooved limit, replace the pads with
new ones.
CAUTION
Replace the brake pad as a set, otherwise braking
performance will be adversely affected.
FRONT AND REAR BRAKE PAD REPLACEMENT

Remove the brake caliper.
Remove the brake pads.
To reassmble, reverse the above sequence.
Front brake caliper mounting bolt
: 18~28 N m (1.8~2.8 kg m)
Rear brake caliper mounting bolt
: 18~28 N m (1.8~2.8 kg m)
[ Front Brake ]
FRONT AND REAR BRAKE FLUID REPLACEMENT

Place the motorcycle on a level surface and keep the
handlebars straight.
Remove the master cylinder reservoir cap and diaphragm.
Suck up the old brake fluid as much as possible.
Fill the reservoir with new brake fluid.
Specification and Classification
: DOT 3 or DOT 4
Connect a clear hose to the air bleeder valve and

insert the other end of the hose into a receptacle.
[ Rear Brake ]
Loosen the air bleeder valve and pump the brake

lever until the old brake fluid is completely out of the
brake system.
Close the air bleeder valve and disconnect the clear

hose. Fill the reservoir with new brake fluid to the
upper line.
Replace the rear brake s fluid with the same manner
of the front brake.
Front brake caliper air bleeder valve
:6~9 N m (0.6~0.9 kg m)
Rear brake caliper air bleeder valve
:6~9 N m (0.6~0.9 kg m)
AIR BLEEDING OF THE BRAKE FLUID

CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full brak-
ing performance of the brake caliper. The presence of
air is indicated by sponginess of the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider,
it is essential that, after remounting the brake and
restoring the brake system to the normal condition, the
brake fluid circuit be purged of air in the following manner :
Fill the master cylider reservoir to top of the inspec-
tion window. Replace the reservoir cap to prevent dirt
from entering it.
Attach a hose to the air bleeder valve, and insert the
free end of the hose into a receptacle.
Bleed air from the brake system.
Squeeze and release the brake lever several times in
rapid succession and sqeeze the lever fully without
releasing it. Loosen the bleeder valve by turning it a
quarter of a turn 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,
close the air bleeder valve, pump and squeeze the
brake lever, and open the valve. Repeat this process
until the fluid flowing into the receptacle no longer
contains air bubbles.
NOTE
While bleeding the brake system, replenish the
brake fluid in the reservoir as necessary. Make
sure that there is always some fluid visible in
the reservoir.
Close the air bleeder valve, and disconnect the hose.

Fill the reservoir with brake fluid to the upper line.
Bleed the rear brake s air with the same manner of
front brake.
Front brake caliper air bleeder valve
: 6~9 N m (0.6~0.9 kg m)
Rear brake caliper air bleeder valve
: 6~9 N m (0.6~0.9 kg m)
CAUTION
Handle brake fluid with care : the fluid reacts
chemically with paint, plastics, rubber materials, etc.
FRONT BRAKE LAMP SWITCH

The front brake lamp switch is located beneath the front
brake lever. Loosen the switch fitting screws and adjust the
timing by moving the switch body forward or backward.
REAR BRAKE LAMP SWITCH

Adjust the rear brake lamp switch so that the brake lamp
will come on just before pressure is felt when the brake
pedal is depressed.
STEERING
Inspect Interval
Steering should be adjusted properly for smooth turning

of handlebars and safe running. Overtight steering pre-
vents smooth turning of the handlebars and too loose
steering will cause poor stability. Check that there is no
play in the steering stem while grasping the lower fork
tubes by supporting the machine so that the front wheel
is off the ground, with the wheel straight ahead, and pull
forward. If play is found, perform steering bearing
adjustment as described in page 6-29 of this manual.
FRONT FORK
Inspect Interval
Inspect Every 4,000 km.
Inspect the front forks for oil leakage, scoring or scratch-

es on the outer surface of the inner tubes. Replace any
defective parts, if necessary.
REAR SUSPENSION
Inspect Interval
Inspect Every 4,000 km.
Inspect the rear shock absorber for oil leakage and

mounting rubbers including engine mounting for wear
and damage. Replace any defective parts, if neces-
sary.(Refer to page 6-36)
TIRE
Tire wear indicator
Inspect Interval
TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and can lead to loss of control. Tire wear indicator mark
Inspect shortage of tire thread s depth by the tire
wear indicator .
Replace the front and rear tires at once when appear
the tire wear indicator .
TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
CAUTION
adversely affected and tire wear increased. Therefore, The standard tire on
maintain the correct tire pressure for good roadability or is 110/70-17 54H for front and
shorter tire life will result. Cold inflation tire pressure is 150/70-17 69H for rear.
as follows. The use of tires other than those specified
may cause instability. It is highly recommended to
COLD INFLATION SOLD RIDING DUAL RIDING use a HYOSUNG Genuine Tire.
TIRE PRESSURE KPa kgf/cm2 psi KPa kgf/cm2 psi
Front 196 2.00 29.0 196 2.00 29.0
Rear 221 2.25 32.0 245 2.50 36.0
CHASSIS BOLTS AND NUTS

Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km.
Check that all chassis bolts and nuts are tightened to

their specified torque.(Refer to page 7-12)
COMPRESSION PRESSURE
The compression of a cylinder is a good indicator of its

internal condition.
The decision to overhaul the cylinder is often based on
the results of a compression test. Periodic maintenance
records kept at your dealership should include compres-
sion reading for each maintenance service.
Compression pressure Compression pressure

2
Standard 14~16 kg/cm (at 500 rpm) Standard 11~13 kg/cm2 (at 500 rpm)
Service limit 12 kg/cm2 (at 500 rpm) Service limit 10 kg/cm2 (at 500 rpm)
Low compression pressure can indicate any of the fol-

lowing conditions :
Excessively worn cylinder wall
Worn-down piston or piston rings
Piston rings stuck in grooves
Poor seating of valves
Ruptured or otherwise defective cylinder head gasket
COMPRESSION TEST PROCEDURE
NOTE
Before testing the engine for compression
pressure, make sure that the cylinder head
bolts are tightened to the specified torque
values and valves are properly adjusted.
Have the engine warmed up by idling before test-
ing.
Be sure that the battery used is in fully-
charged condition.
Remove the parts concerned and test the compression

pressure in the following manner.
Loosen the oil cooler mounting bolts from the frame.
Remove all the spark plug.
Fit the compression gauge in one of the plug holes,
while taking care that the connection is tight.
Keep the throttle grip in full-open position.
Crank the engine a few seconds with the starter, and
record the maximum gauge reading as the compres-
sion of that cylinder.
Compression gauge : 09915-64510

OIL PRESSURE
Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.
Standard Standard
Oil pressure 2.0 0.5 / Oil pressure 0.9 1.1 /
(at 65 3,000 rpm) (at 65 3,000 rpm)
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE

Oil leakage from the oil passage
Damaged O-ring
Defective oil pump
Combination of above items
HIGH OIL PRESSURE

Engine oil viscosity is too high
Clogged oil passage
Combination of the above items
OIL PRESSURE TEST PROCEDURE

Check the oil pressure in the following manner.
Remove the oil check plug and install the adapter of oil
pressure gauge at the removed position.
Connect an engine tachometer.
Warm up the engine as follows :
Summer : 10 min. at 2,000 rpm.
Winter : 20 min. at 2,000 rpm.
After warming up, increase the engine speed to
3,000 rpm. (with the engine tachometer), and read
the oil pressure gauge.
Oil pressure gauge : 09915-74510

Engine tachometer : 09900-26006
ENGINE
CONTENTS
ENGINE REMOVAL AND REINSTALLATION 3- 1
ENGINE REMOVAL 3- 1
ENGINE REINSTALLATION 3- 5 3
ENGINE DISASSEMBLY 3- 7
STARTER MOTER 3- 7
CYLINDER HEAD COVER 3- 8

PISTON 3-12
MAGNETO COVER 3-13

MAGNETO ROTOR 3-13
CLUTCH COVER 3-14
CLUTCH 3-15
PRIMARY DRIVE GEAR 3-16
OIL PUMP 3-16
GEARSHIFT SHAFT 3-17
ENGINE COMPONENT INSPECTION AND SERVICE 3-19

ENGINE REASSEMBLY 3-36
CAUTION
Mark an identification of assembly location on each removed part so that each will be restored
to the original position during reassembly.
Wash clean and dry the removed parts before inspecting and measuring.
Oil the rotating or sliding parts before assembly.
Make sure to use the correct type of lubricant where specified.
Check that each rotating or sliding part moves or operates smoothly after assembly.
Make sure to follow the bolt tightening order where specified.
If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the bolts
and check that the tightening margin is equal in each bolt.
3-1 ENGINE
ENGINE REMOVAL AND

REINSTALLATION
ENGINE REMOVAL
NOTE
If the engine is dirtied, wash the machine
with a suitable cleaner before removing the
engine.
Remove the front seat.(Refer to page 6-1)

Remove the fuel tank.(Refer to page 4-1)
Drain the engine oil.(Refer to page 2-9)
Disconnect the battery lead wire .
CAUTION
First, disconnect the lead wire.
AIR CLEANER
With the two screw loosened, remove the air
cleaner case.
Loosen the clamp screw.
CARBURETOR
Remove the carburetor after removed the intake pipes.
(Refer to page 4-5)
Disconnect the vacuum hoses . ( )
ENGINE 3-2
CLUTCH CABLE
Disconnect the clutch cable end out of clutch lever.
Disconnect the clutch cable end out of clutch release
arm.
EXHAUST PIPE AND MUFFLER

With the exhaust pipe bolts and muffler mounting
bolts removed, remove the exhaust pipes and muf-
flers.
[ Front Cylinder ]
[ Rear Cylinder ]
3-3 ENGINE
ELECTRIC PARTS
With take out the spark plug caps, remove the spark
plug.
[ Front Cylinder ] [ Rear Cylinder ]

Remove the starter motor lead wire.
Remove the engine ground lead wire .
Disconnect the magneto coupler .

ENGINE 3-4
ENGINE SPROCKET
Remove the engine sprocket cover.
Remove the breather hose.
Loosen the bolt and remove the link rod.

Flatten the lock washer.
Remove the engine sprocket nut and washer.
NOTE
When loosening the engine sprocket nut,
depress the brake pedal.
Remove the engine sprocket.
NOTE
If it is difficult to remove the engine
s p r o c k e t , loosen the rear axle nut, c h a i n
adjusters to provide additional chain
slack.(Refer to page 2-11)
3-5 ENGINE
Remove the oil cooler.
Support the engine using an engine jack.

Remove the engine mounting nuts and bolts.
Remove the engine from the frame.
CAUTION
Remove the carburetor when removing or
installing the engine necessarily.
When removing the carburetor , loosen the
intake pipe mounting bolts at the same time.
ENGINE REINSTALLATION
Reinstall the engine in the reverse order of engine
removal.
Install the engine mounting bolts and nuts.
Tighten the engine mounting bolts and nuts to the
specified torque.
Engine mounting bolt
: 40 60 N m (4.0 6.0 kg m)
ENGINE 3-6
ENGINE SPOCKET
Loosen the rear axle nut and chain adjusters, left
and right.
Install the engine sprocket.
Tighten the engine sprocket nut to the specified

torque.
Engine sprocket nut

: 80~100 N m (8.0~10.0 kg m)
NOTE
When tightening the engine sprocket nut,
depress the rear brake pedal.
Bend the lock washer securely.
Install the gearshift arm and adjust the gearshift lever

height.(Refer to page 2-9)
Connect each electric part and its couplers.(Refer to

page 7-23~30)
Install the exhaust pipes and mufflers.
Install the carburetor and air cleaner.
After remounting the engine, the following adjust-

ments are necessary.
Engine idling speed Refer to page 2-7
Throttle cable play Refer to page 2-7
Clutch cable play Refer to page 2-8
Drive chain Refer to page 2-11
Gearshift lever height Refer to page 2-9
Engine oil level Refer to page 2-9
3-7 ENGINE
ENGINE DISASSEMBLY
STARTER MOTOR
Remove the starter motor.
Remove the gear position switch.

Remove the contacts and springs .
Remove the three union bolts.

ENGINE 3-8
CYLINDER HEAD COVER

Remove the cylinder head cover.
To set the piston at TDC(Top Dead Center).
CAUTION
Align the index mark on the magneto rotor with
the index mark on the magneto cover as turn the
crankshaft counter-clockwise.
To set piston at TDC(Top Dead Center) of the
compression stroke as align the F mark for
front cylinder and the R mark for rear cylin-
der.
Remove the cam chain tensioner.
[ Front Cylinder ]
[ Rear Cylinder ]
3-9 ENGINE
With the three bolts removed, remove the cam chain

guide NO.2.
Remove the camshaft housing.
Remove the camshaft (IN. EX.).
Remove the C-ring.

ENGINE 3-10
Loosen the two cylinder head base cover nuts.
Loosen the three cylinder head base nuts.
Loosen the four cylinder head stud bolts.
Remove the chain guide NO.1 and cylinder head.

3-11 ENGINE
Remove the tappet and the shim.
CAUTION
Draw out the tappet and shim with the strong
magnet not to be scratched.
CAUTION
The tappet and shim should be lined so that each
will be restored to the original position during
reassembly.
Compress the valve spring by using the special tool.
Valve spring compressor : 09916-14510

Valve spring compressor attachment
: 09916H35C00
: 09916H5100
Take out the valve cotter from the valve stem.

Remove the valve spring retainer.
Pull out valve from the other side.
ENGINE 3-12
Remove the two cylinder base nuts and cylinder.
CAUTION
If tapping with the plastic hammer is necessary,
pay attention to break the fins.
Remove the rear cylinder head and cylinder with the Rear Cylinder
same manner of the front cylinder head and cylinder
removal.
Front Cylinder
PISTION
Place a clean rag over the cylinder base to prevent
piston pin circlips from dropping into crankcase.
Remove the piston pin circlips with long-nose pliers.
Remove the piston pin by using the special tool.
Piston pin puller : 09910-34510
NOTE
Make an identification on each piston head so
that confirmed the cylinder.
3-13 ENGINE
MAGNETO COVER
Remove the magneto cover.
Remove in the order of spacer , shaft , starter

idle gear .
MAGNETO ROTOR
With the magneto rotor held immovable using the
special tool, loosen the rotor nut.
Conrod holder : 09910-20115
Remove the magneto rotor by using the special tool.

Rotor remover
: 09930-30164
Rotor remover
: 09930-30162
Rotor remove sliding shaft
: 09930-30102
ENGINE 3-14
Remove the key .

Remove the starter driven gear .
Remove the cam chain tensioner and cam chain

.
CLUTCH COVER
Remove the clutch release arm .
Remove the clutch cover bolts.

Remove the clutch cover.
3-15 ENGINE
CLUTCH
With the primary drive gear held immovable, remove
the clutch spring mounting bolts diagonally.
Remove the disk pressure .
Remove the clutch drive and driven plates.
Flatten the lock washer .
With the clutch sleeve hub held immovable using

special tool, remove the clutch sleeve hub nut.
Clutch sleeve hub holder : 09920-53710

ENGINE 3-16
Remove the clutch sleeve hub and primary driven

gear assembly .
PRIMARY DRIVE GEAR

With the magneto rotor held immovable using special
tool, remove the primary drive gear nut.
CAUTION
This bolt has left-hand thread. If turning it
counter-clockwise( ), it may cause damage.
Pay attention at the primary drive gear with two
washer.
Remove the key and cam chain .

Remove the cam chain tensioner .
OIL PUMP
Remove the circlip and oil pump driven gear.
3-17 ENGINE
Remove the pin .

With the three screws loosened, remove the oil pump
.
GEARSHIFT SHAFT
Draw out the gearshift shaft .
With the cam guide screws loosened, draw out the

guide and lifter.
Remove the cam driven gear.
CAUTION
Pay attention to not lost the gearshift pawl, pin,
spring with the cam driven gear removal.
With the neutral cam stopper plug loosened, remove

the washer, spring, stopper.
ENGINE 3-18
Remove the crankcase securing bolts.

Separate the crankcase into 2 parts, right and left,
with a special tool.
Crankcase separator : 09920-13120
CAUTION
When separating the crankcase , necessarily,
remove it after installed the special tool (Crankcase
separator) on the side of clutch.
In case separate oppositely, the gearshift cam stop-
per will be damaged in the side of magneto.
NOTE
Fit the crankcase separater, so that the tool
arms parallel the side of the crankcase.
Remove the gearshift fork shaft and gearshift fork

.
Remove the gearshift cam .
Remove the driveshaft assembly , countershaft
assembly .
Remove the oil pump idle gearshaft .
Remove the crankshaft by using the special tool.

Crankcase separator : 09920-13120
3-19 ENGINE
ENGINE COMPONENT INSPEC-

TION AND SERVICE
CAUTION
Be sure to identify each removed part as to its loca-
tion, and lay the parts out in groups designated as
Front cylinder , Rear cylinder , Exhaust ,
Intake , so that each will be restored to the origi-
nal location during assembly.
CYLINDER HEAD DISTORTION

Decarbonate in combustion chamber.
Check the gasketed surface of the cylinder head for dis-
tortion with a straightedage and thickness gauge, taking
a clearance reading at several places as indicated. If the
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder head.
Cylinder head Service limit

distortion 0.05 mm (0.002 in)
VALVE FACE WEAR

Visually inspect each valve face for wear. Replace any
valve with an abnormally worn face. The thickness of
the valve face decreases as the face wears. Measure
the valve head . If it is out of specification, replace the
valve with a new one.
Service limit
Valve head thickness
0.5 mm (0.02 in)
Vernier calipers : 09900-20101
VALVE STEM RUNOUT (T.D.C)

Check the valve stem for abnormal wear or bend. (B.T.D.C) (A.T.D.C)
Place the valve on V-blocks and measure runout. Intake open Exhaust close
19 32
If the service limit is exceeded or abnormal condition
exists, replace the valve.
Service limit
Valve stem runout
0.05 mm (0.002 in)
(A.B.D.C)
Intake close 57 38 (B.B.D.C)
Dial gauge : 09900-20606 Exhaust open
Magnetic stand : 09900-20701 (B.D.C)
V-block : 09900-21304 Valve timing diagram
ENGINE 3-20
CAMSHAFT (T.D.C)
The camshaft should be checked for runout and also for (B.T.D.C)
Intake open (A.T.D.C)
wear of cams and journals if the engine has been noted Exhaust close
to produce abnormal noise or vibration or a lack of out-
17 45
put power. Any of these abnormality could be caused by
a worn camshaft.
14 48
(B.B.D.C)
Exhaust open
(A.B.D.C)
Intake close
(B.D.C)
Valve timing diagram
CAMSHAFT WEAR
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power.
The limit of cam wear is specified for both intake and
exhaust cams in terms of cam height , which is to be
measured with a micrometer. Replace camshafts if
found it worn down to the limit.
Cam height Service limit

Intake cam 34.170 mm (1.345 in)
Exhaust cam 34.120 mm (1.343 in)
Micrometer 25~50 mm : 09900-20202
Tappet & shim wear

When measuring the valve clearance, the clearance
should be within the standard range.
Valve clearance Standard(When cold)

0.1~0.2 mm
Intake valve
(0.004~0.008 in)
0.2~0.3 mm
Exhaust valve
(0.008~0.012 in)
Inspect the tappet for wear and scratch.

If modification or scratch is present, replace the tap-
pet.
The shim has various size.
Replace the thin shim to valve clearance is narrow, or
the thick shim to valve clearance is wide as that shim
thickness was installed with standard at present.
(Refer to page 7-33 34)
SHIM KIND
There are 41 kinds of shim which thickness is increased
by each 0.025 mm from 1.20 mm to 2.20 mm.
3-21 ENGINE
VALVE HEAD RADIAL RUNOUT

Place a dial gauge as shown and measure valve head
radial runout.
If the service limit is exceeded, replace the valve.
Valve head radial Service limit

runout 0.03 mm (0.0012 in)
Dial gauge : 09900-20606
Magnetic stand : 09900-20701
V-block : 09900-21304
VALVE GUIDE-VALVE STEM CLEAR-
ANCE
Measure the clearance in the valve guide-valve stem, by
rigging up the dial gauge as shown. If the clearance
is measured exceeds the limit specified below, then
determine whether the valve or the guide should be
replaced to reduce the clearance to within the standard
range:
Valve guide-valve stem clearance Standard
0.010~0.037 mm
IN.
(0.0004~0.0015 in)
0.030~0.057 mm
EX.
(0.0012~0.0022 in)
Dial gauge : 09900-20606
VALVE STEM DIAMETER
Measure the valve stem outside diameter.
If the diameter measured exceeds the standard, replace
the valve.
Standard
Valve stem diameter
4.475~4.490 mm 3.975~3.990 mm
IN.
(0.1762~0.1768 in) (0.1565~0.1571 in)
4.455~4.470 mm 3.955~3.970 mm
EX.
(0.1754~0.1760 in) (0.1557~0.1563 in)
Micrometer(0~25 mm) : 09900-20201
VALVE SPRING
The force of the coil spring keeps the valve seat tight. A
weakened spring results in reduced engine power out-
put and often accounts for the chattering noise coming
from the valve mechanism.
Check the valve springs for proper strength by measur
ing their free length and also by the force required
to compress them. If the spring length is less than the
service limit or if the force required to compress the
spring does not fall within the specified range, replace
both the inner and outer springs as a set.
ENGINE 3-22
Service limit
Valve spring free
length(IN. & EX.) 37.80 mm 37.64 mm
(1.488 in) (1.482 in)
Venier calipers : 09900-20101

Standard
Valve spring
tension
(IN. & EX.) 12.0~13.9 kgf 30.0 kgf
(26.7~30.6 lbs) (66.1 lbs)
at length 33.7 mm (1.33 in) at length 27.95 mm (1.10 in)
CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distor-
tion with a straightedge and thickness gauge, taking a
clearance reading at several places as indicated.
If the largest reading at any position of the
straightedge exceeds the limit, replace the cylin-
der.
Service limit
Cylinder distortion
0.05 mm (0.002 in)
CYLINDER BORE
Measure the cylinder bore diameter at six place. If any
one of the measurements exceeds the limit, overhaul
the cylinder and replace the piston with an oversize, or
replace the cylinder.
Standard Service limit

Cylinder bore 57.000~57.015 mm 57.080 mm
(2.2441~2.2447 in) (2.2473 in)

Cylinder bore 44.000~44.015 mm 44.080 mm
(1.7323~1.7329 in) (1.7354 in)
Cylinder gauge set : 09900-20508
CAM CHAIN TENSION ADJUSTER

Check that the push rod slides smoothly with the lock
shaft handle clockwise.
If it does not slide smoothly, replace the cam chain ten-
sion adjuster with a new one.
3-23 ENGINE
CAM CHAIN TENSIONER

Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
CAM CHAIN AND CAM CHAIN GUIDE

Check the cam chain for wear, damage and kinked or bind-
ing links. If any defects are found, replace it with a new
one.
Check the cam chain guide for wear and damage. If it is
found to be damaged, replace it with a new one.
PISTON DIAMETER INSPECTION

Measure the outside diameter of piston in the direction per-
pendicular to the piston pin axis at the height from the skirt
as shown in the illustration using a micrometer.
If the measurement is found less than the service
limit, replace the piston.
Service limit
Piston diameter
56.880 mm 43.890 mm
(2.2394 in) (1.7280 in)
Piston oversize 0.5, 1.0 mm (0.02, 0.04 in)

(0.6 in)
Micrometer(50~75 mm) : 09900-20203
Micrometer(25~50 mm) : 09900-20202
PISTON-TO-CYLINDER CLEARANCE
To determine the piston-to-cylinder clearance, calculate
the difference between the cylinder bore and outside
diameter of the piston.

Piston-to-cylin-
0.05~0.06 mm 0.120 mm
der clearance
(0.0020~0.0024 in) (0.0047 in)

Piston-to-cylin-
0.03~0.04 mm 0.1 mm
der clearance
(0.0012~0.0016 in) (0.0040 in)
ENGINE 3-24
PISTON PIN HOLE BORE

Using a dial calipers, measure the piston pin hole bore
both in the vertical and horizontal directions.
If the measurement exceeds the service limit, replace
the piston.
Service limit
Piston pin hole
bore
15.030 mm (0.5917 in) 13.030 mm (0.513 in)
Dial calipers : 09900-20605

PISTON PIN DIAMETER INSPECTION
Using a micrometer, measure the piston pin outside
diameter at three position, both the ends and the center.
If any of the measurements is founds less than the ser-
vice limit, replace the pin.
Service limit
Piston pin
diameter
14.980 mm(0.5898 in) 13.980 mm(0.550 in)
Micrometer(0~25 mm) : 09900-20201

PISTON RING FREE END GAP
INSPECTION
Before installing piston rings, measure the free end gap
of each ring using vernier calipers. If the gap is less than
the service limit, replace the ring.
Piston ring free Standard
end gap
1st 7.2 mm (0.284 in) 5.0 mm (0.197 in)
2nd 5.8 mm (0.228 in) 6.0 mm (0.236 in)
Piston ring free Service limit

end gap
1st 5.7 mm (0.224 in) 4.0 mm (0.158 in)
2nd 4.6 mm (0.181 in) 4.8 mm (0.189 in)
PISTON RING END GAP INSPECTION
Insert the piston ring squarely into the cylinder using the
piston head.
Measure the end gap with a thickness gauge.
If the gap exceeds the service limit, replace the piston ring.
Piston ring end gap Standard
(Assembly condition)
0.20~0.32 mm 0.10~0.25 mm
1st
(0.008~0.013 in) (0.004~0.010 in)
0.20~0.32 mm 0.25~0.40 mm
2nd
(0.008~0.013 in) (0.010~0.016 in)
3-25 ENGINE
Piston ring end gap(Assembly condition) Service limit

1st 0.5 mm (0.02 in)
2nd 0.5 mm (0.02 in)
PISTON RING-TO-GROOVE CLEAR-

ANCE INSPECTION
Remove carbon deposit both from the piston ring and its
groove.
Fit the piston ring into the groove. With the ring com-
pressed and lifted up, measure the clearance on the
bottom side of the ring using a thickness gauge.
Piston ring-groove clearance Service limit
1st 0.180 mm (0.007 in)
2nd 0.150 mm (0.006 in)
Piston ring-groove width Standard

1.01~1.03 mm
1st
(0.040~0.041 in)
1.01~1.03 mm
2nd
(0.040~0.041 in)
2.01~2.03 mm
Oil
(0.079~0.080 in)
Piston ring thickness Standard

0.970~0.990 mm
1st
(0.0382~0.0390 in)
0.970~0.990 mm
2nd
(0.0382~0.0390 in)

Micrometer(0~25 mm) : 09900-20201
OVERSIZE RINGS
Oversize piston ring
The following two types of oversize piston ring are used.
They bear the following identification numbers.
Oversize piston ring 1st 2nd
0.5 mm 05 05
1.0 mm 10 10
Oversize oil ring

The following two types of oversize oil ring are used.
They bear the following identification marks.
Oversize oil ring Color classification

0.5 mm Painted red
1.0 mm Painted yellow
ENGINE 3-26
CONROD SMALL END INSIDE DIAM-

ETER INSPECTION
Using a dial calipers, measure the conrod small end
inside diameter both in vertical and horizontal directions.
If any of the measurements exceeds the service limit,
replace the conrod.

Conrod small
15.006~15.014 mm 15.040 mm
end I.D.
(0.5908~0.5911 in) (0.5921 in)

Conrod small
13.006~13.014 mm 13.040 mm
end I.D.
(0.5121~0.5124 in) (0.5134 in)
Dial calipers : 09900-20605

CONROD DEFLECTION INSPECTION
Move the small end sideways while holding the big end
immovable in thrust direction.
Measure the amount of deflection.
Turn the conrod and see if it moves smoothly without
play and noise. This method can check the extent of
wear on the parts of the conrod s big end.
Service limit
Conrod deflection
3.0mm (0.12 in)
CONROD BIG END SIDE CLEARANCE

INSPECTION
Using a thickness gauge, measure the side clearance at
the conrod big end. If the measurement is out of stan-
dard value, measure the conrod big end and the crank
pin widths individually to determine which one is to be
replaced.

Conrod big end
0.40~0.85 mm 1.0 mm
side clearance
(0.016~0.034 in) (0.040 in)

Conrod big end
0.15~0.40 mm 1.0 mm
side clearance
(0.006~0.016 in) (0.040 in)
CRANKSHAFT RUNOUT INSPEC-

TION
With the right and left crank journals supported with V-
block, turn the crankshaft slowly. At this time, measure
the crankshaft end runout using a dial gauge. If the
runout exceeds the service limit, replace the crankshaft.
3-27 ENGINE
Service limit
Crankshaft runout
0.05 mm (0.002 in)

Dial gauge : 09900-20606
V-block : 09900-21304
CRANKSHAFT REASSEBLY
Measure the width between the webs referring to the fi-
gure below when rebuilding the crankshaft.
(2.84 0.004 in)
Standard
Width between webs 72 0.1 mm
(2.84 0.004 in)
MAGNETO COVER
MAGNETO INSPECTION(Refer to page 5-4)
DISASSEMBLY
Remove the stator
STARTER CLUTCH
Install the starter driven gear onto the starter clutch and
turn the starter driven gear by hand(the gear turns in
only one direction). The starter driven gear should
turn smoothly. If excessive resistance is felt while turn-
ing the starter driven gear, inspect the starter
clutch. Also, inspect the surface of the starter driven
gear which contacts the starter clutch, for wear or dam-
age. If any wear or damage is found, replace the
defective parts.
DISASSEMBLY
Hold the magneto rotor with the rotor holder and
remove the starter clutch bolts.
Rotor holder : 09930-44510
ENGINE 3-28
REASSEMBLY
Apply a small quantity of THREAD LOCK 1324 to
the starter clutch bolts and tighten them to the spec-
ified torque while holding the rotor with the rotor
holder.
Thread Lock 1324
Rotor holder : 09930-44510
Starter clutch bolt
: 15~20 N m(1.5~2.0 kg m)
STARTER DRIVEN GEAR

STARTER DRIVEN GEAR BUSHING
Install the starter driven gear bushing and gear
onto the crankshaft and turn the starter driven
gear by hand. Inspect the starter driven gear bushing
for smooth rotation and any abnormal noise. If the
bushing does not turn smoothly or there is any abnor-
mal noise, replace it.
DISASSEMBLY
Remove the bushing using the special tool.
Bearing remover(20~35 mm)

: 09923-74510
CLUTCH COVER
OIL FILTER REPLACEMENT(Refer to page 2-10)
DISASSEMBLY
Remove the circlip and right crankshaft oil seal.
Oil seal remover : 09913-50121
3-29 ENGINE
REASSEMBLY
Drive in the oil seal using the special tool.
Bearing installer : 09913-75820
Install the circlip.
CLUTCH DRIVE PLATES

Measure the thickness and claw width of the clutch drive
plates using vernier calipers. If a clutch drive plate is not
within the service limit, replace the clutch plates as a
set.
Clutch drive plate Standard

thickness 2.9~3.1 mm (0.114~0.122 in)
Clutch drive plate Service limit

thickness 2.6 mm (0.102 in)
Clutch drive plate Standard

claw width 11.8~12.0 mm (0.465~0.472 in)
Clutch drive plate Service limit

claw width 11.0 mm (0.433 in)
CLUTCH DRIVEN PLATES

Measure each clutch driven plate for distortion using
the thickness gauge. If a clutch driven plate is not within
the service limit, replace the clutch plates as a set.
Clutch driven plate Service limit

distortion 0.1 mm (0.004 in)

ENGINE 3-30
CLUTCH SPRING FREE LENGTH

Measure the free length of each clutch spring using
vernier calipers. If any spring is not within the service
limit, replace all of the spring.
Service limit
Clutch spring
free length
36.2 mm (1.43 in) 29.5 mm (1.16 in)
CLUTCH RELEASE BEARING

Inspect the clutch release bearing for any abnormality,
especially cracks. When removing the bearing from the
clutch, decide whether it can be reused or if it should be
replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
PRIMARY DRIVEN GEAR

Inspect the primary driven gear bearing for any damage.
If any abnormal condition are found, replace the primary
driven gear.
OIL PUMP
Turn the oil pump shaft and check that rotation is
smooth. If any abnormal condition is found, replace the
oil pump with new one.
3-31 ENGINE
GEARSHIFT SHAFT
Disassemble and reassemble the gearshift shaft as
shown in right picture.
TRANSMISSION
INSPECTION
GEAR-SHIFTING FORK
Using a thickness gauge, check the clearance between
in the groove of its gear and shifting fork.
The clearance for each of the three shifting forks plays
an important role in the smoothness and positiveness of
shifting action.
If the clearance checked is noted to exceed the limit
specified, replace the fork or its gear, or both.

Shift fork-groove
0.10~0.30 mm 0.5 mm
clearance
(0.004~0.012 in) (0.020 in)

Shift fork groove Standard
width
5.0~5.1 mm 5.0~5.1 mm
NO.1 & NO.2
(0.197~0.201 in) (0.197~0.201 in)
5.0~5.1 mm 5.5~5.6 mm
NO.3
(0.197~0.201 in) (0.217~0.221 in)
Shift fork Standard

thickness
4.8~4.9 mm 4.8~4.9 mm
NO.1 & NO.2
(0.189~0.193 in) (0.189~0.193 in)
4.8~4.9 mm 5.3~5.4 mm
NO.3
(0.189~0.193 in) (0.209~0.213 in)
REASSEMBLY
Assemble the countershaft and drive shaft in the reverse
order of disassembly. Pay attention to following points :
NOTE
Before installing the gears, coat lightly engine oil
to the driveshaft and countershaft.
ENGINE 3-32
CAUTION
Never reuse a circlip. After a circlip has been
removed from a shaft, it should be discarded Thrust
and a new circlip 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 over the shaft.
After installing a circlip, always ensure that it
is completely seated in its groove and securely
fitted.
When installing a new circlip, pay attention to the

direction of the circlip. Fit it to the side where the
thrust is as shown in figure.
TRANSMISSION GEARS AND RELATED PARTS
Thickness for washers, circlips and spacers

1.0mm 1.0mm
1.2mm 1.0mm
0.5mm
3-33 ENGINE
Thickness for washers, circlips and spacers

1.2mm 6.0mm
0.5mm 1.0mm
1.0mm
CRANKCASE
play play
BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for
abnormal play, noise and smooth rotation while the
bearings are in the crankcase.
Replace the bearing in the following procedure if there is
anything unusual.
ENGINE 3-34
DISASSEMBLY
RIGHT CRANKCASE BEARING
Remove the bearing retainer.
Remove the bearings and .

Bearing remover(17 mm) : 09923-73210
Bearing remover(20~35 mm) : 09923-74510
Remove the bearing .

CAUTION
The removed bearing should be replace with a
new one.
LEFT CRANKCASE BEARING

Remove the oil seals and .
3-35 ENGINE
Remove the bearing retainer.
Remove the bearings and .

Bearing remover(17 mm) : 09923-73210
Bearing remover(20~35 mm) : 09923-74510
REASSEMBLY
RIGHT CRANKCASE BEARING
Drive in the bearings and
LEFT CRANKCASE BEARING

Drive in the bearings and

ENGINE 3-36
Install the oil seals and

Apply SUPER GREASE A on the lip of oil seal.
SUPER GREASE A
ENGINE REASSEMBLY
The engine reassembly can be performed in the reverse

order of disassembly procedures. However, the follow-
ing points must be observed in the reassembly opera-
tion.
CAUTION
Make sure to coat the rotating and sliding sec-
tions with engine oil.
CRANKSHAFT
Using the special tool, press in the crankshaft into the
left crankcase.
Crankshaft installer : 09910-32812
CAUTION
Never fit the crankshaft into crankcase by strik-
ing it with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.
TRANSMISSION
Install the transmission.
3-37 ENGINE
GEARSHIFT CAM AND GEARSHIFT

FORKS
Install the gearshift fork NO.1 , NO.2 , and NO.3
.
Install the gearshift cam , and gearshift fork shaft
.
Install the oil pump idle gear shaft .
Install the dowel pins .

Before assembling the crankcase, apply the engine
oil to each gear and bearing.
Apply BOND 1215 to the right crankcase.

BOND 1215
CAUTION
Application of BOND 1215 must be per-
formed within a short period of time.
Take extreme care not to let BOND 1215
enter into the oil hole or bearing.
Install the crankcase.

Install the crankcase bolts.
Crankcase bolt
: 8~12 N m(0.8~1.2 kg m)
ENGINE 3-38
NOTE
After the crankcase bolts have been tight-
ened, make sure that the crankshaft, counter-
shaft and driveshaft rotate smoothly.
If these shafts do not rotate smoothly, try to
free it by tapping with a plastic hammer.
Apply the SUPER GREASE A to the driveshaft O-

ring and oil seal lip.
Install the driveshaft spacer.
SUPER GREASE A
Install the oil seal retainer.
GEARSHIFT CAM DRIVEN GEAR

When installing the gearshift into the cam driven
gear, the big shoulder face toward outside as A
shown in figure.
Install the cam guide and pawl lifter.
When installed, apply the THREAD LOCK 1324 to
the securing screw.
THREAD LOCK 1324 A
3-39 ENGINE
GEARSHIFT SHAFT
Install the gear shifting shaft. Match the center teeth of
the gear on the shifting shaft with the center teeth on the
shifting driven gear as shown.
CAUTION
After the cam driven gear, cam guide, gear shift
shaft and neutral cam stopper have been fitted,
confirm that gear change is normal while turning,
the countshaft and driveshaft. If gear change is
not obtained, it means that assembly of gears or
installation of gear shifting fork is incorrect. In
this case, disassemble and trace the mistake.
OIL PUMP
Before installing the oil pump, apply the engine oil to
the contact face of case, outer rotor, inner rotor and
shaft.
Apply a small quantity THREAD LOCK 1324 to the
oil pump securing screws.
THREAD LOCK 1324
Tighten the oil pump securing screws.
Install the oil pump pin.
Put in the oil pump driven gear, and install the circlip.
ENGINE 3-40
CAUTION
When installing the oil pump to the crankcase,
turn the pump gear and check that rotation is
smooth by the hand.
CAM CHAIN TENSIONER

Install the washer and cam chain tensioner ,
tighten the cam chain tensioner bolt.
Cam chain tensioner bolt
: 6~8 N m(0.6~0.8 kg m)
Install the cam chain and key.
Install the primary drive gear and NO.2 gear to the

crankshaft, put in the key to the key groove. Align the key groove
and mark.
CAUTION
When installing the NO.2 gear, install so that the
mark on the gear align the key groove as shown
in figure.
No.2 Gear
3-41 ENGINE
CAUTION
Pay attention to the two washer to lower end of the
primary drive gear nut in times of assemblage.
With the magneto rotor held immovable using special

tool, tighten the primary drive gear nut.
Primary drive gear nut

: 40~60 N m(4.0~6.0 kg m)
PRIMARY DIRVEN GEAR
NOTE
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.
Install the primary driven gear assembly.
CLUTCH
Install the clutch sleeve hub , lock washer .

ENGINE 3-42
Install the clutch sleeve hub nut, and tighten it to the

specified torque using the special tool.
Clutch sleeve hub holder : 09920-53710
Clutch sleeve hub nut

: 30~50 N m(3.0~5.0 kg m)
Bend the lock washer securely.
Install the clutch drive plates and driven plates.
Install the clutch release rack , bearing and

washer .
3-43 ENGINE
Install the clutch pressure plate clutch springs

and clutch spring mounting bolts.
Hold the primary drive gear nut and tighten the clutch
spring mounting bolts in a crisscross pattern.
NOTE
Make sure that the clutch pressure plate is
installed correctly.
CLUTCH COVER
Install the two dowel pins and new gasket
Apply engine oil to each gears, bearings and clutch
plates.
Install the clutch cover, and tighten the clutch cover

bolts securely.
Install the clutch release arm as following:

Turn the clutch release shaft toward(This time,
Stopper screw
mark on the shaft align outside contact line the
stopper screw) the right.
Install that the cable connecting center line of the Clutch release Release camshaft
arm bolt notch mark
clutch release arm align matching mark rightside of
the case as shown in the right figure. Clutch release
arm
Crankcase
matching mark
ENGINE 3-44
NEUTRAL CAM STOPPER

Put in the neutral cam stopper, spring and washer,
tighten the cam stopper plug to the specified torque.
Neutral cam stopper plug
: 20~25 N m(2.0~2.5 kg m)
OIL DRAIN PLUG

Tighten the oil drain plug to the specified torque.
Engine oil drain plug
: 18~20 N m(1.8~2.0 kg m)
STATOR
the threaded parts of screws.
THREAD LOCK 1324
STARTER CLUTCH
When installing the starter clutch and rotor, apply the
THREAD LOCK 1324 to the bolts and tighten to
the specified torque.
THREAD LOCK 1324
Starter clutch bolt
: 15~20 N m(1.5~2.0 kg m)
MAGNETO ROTOR
Fit the key in the key slot on the crankshaft.
With the magneto rotor, install the starter clutch
on the crankshaft.
the threaded parts of crankshaft.
THREAD LOCK 1324
3-45 ENGINE
Tighten the magneto rotor nut to the specified torque.

Magneto rotor nut
: 50~60 N m(5.0~6.0 kg m)
STARTER IDLE GEAR AND MOTOR

Install the starter idle gear, shaft and spacer.
Install the starter motor.
MAGNETO COVER
Install the new gasket and dowel pin.
Apply oil to the each gear, bearing and starter clutch.
ENGINE 3-46
Install the magneto cover and tighten the magneto

cover bolts.
Magneto cover bolt
: 8~12 N m (0.8~1.2 kg m)
PISTON RING
Install the piston ring in order of oil ring, 2nd ring and
1st ring at first at the front cylinder.
CAUTION
Be careful not to cause scratch on the piston
when inserting the piston ring to the piston.
Also, do not expand the piston ring more than
necessary as the ring can break.
When all the piston rings have been assem-

bled, check that each can turn smoothly.
To minimize compression and oil leaks, locate each
piston ring end gap in the position as shown in the
right illustration
2nd ring / side rail(Upper side)
Side rail(Lower side)
1st ring / spacer
PISTON
Apply the MOLY PASTE to the piston pin.
MOLY PASTE
When installing the piston, turn the mark on the
piston head to exhaust side.
After the piston pin has been inserted through the
conrod, install the circlip .
CAUTION
Replace the circlip with a new one.
Place a piece of rag under the piston when
installing the circlip to prevent it from falling
into the crankcase.
Front Rear
tire side tire side
CAUTION
Exhaust Exhaust
is equipped with the two cylinder pipe pipe
installation installation
engine, which is composed of the two piston for side side
the front and rear.
The classification is F for the front and R for
the rear.
[Front piston] [Rear piston]
3-47 ENGINE
CYLINDER
Apply BOND 1215 to the parting line of crankcase.
BOND 1215
Place the dowel pin and new gasket on the
crankcase.
CAUTION
Make sure to replace the gasket with a new one.
Apply the engine oil to the conrod big end, piston and
the piston rings.
Coat the cylinder wall with oil.
Install the cylinder.
This cylinder is different from the front and rear. Broad pitch part
With the cam chain groove of cylinder face the left side,
it is the front cylinder when the cam chain tension adjuster
be existed at the back.
Head direction
VALVE AND SPRING
Insert the valve, with their stems coated with MOLY
PASTE.
Apply the oil to the lip of the stem seal.
Narrow pitch part
The narrow pitch side of each spring face to the head
when the valve spring install. The pitch of inside
spring and outside spring is changed. The pitch of
spring is decreased from the upper side to the lower
side.
Valve spring compressor : 09916-14510
: 09916H35C00
: 09916H5100
CYLINDER HEAD
Put in the valve spring and retainer, install the cotter
with compressed the spring by using the valve spring
compressor.
CAUTION
After installing the valve cotter, tap the valve
stem end by using the plastic hammer at 2~3
times for assembly of the valve and cotter.
Fit the cylinder head and tighten the stud bolts.
CAUTION
Pay caution to prevent the cam chain from drop-
ping into the crankcase.
Cylinder head stud bolt
: 21~25 N m (2.1~2.5 kg m)
ENGINE 3-48
Tighten the cylinder head base nuts.

Cylinder head base nut
: 7~11 N m (0.7~1.1 kg m)
Cylinder head base nut
: 15~20 N m (1.5~2.0 kg m)
Tighten the two cylinder base cover nuts.
Tappet
Install the tappet and shim.
CAUTION Shim
With fit the tappet, it should be replaced if turn
not smoothly by the hand.
CAUTION
The tappet and shim should be installed at the
original position when removed.
If otherwise, it is difficult to adjust the valve clear-
ance.
Fit the chain guide.
[ Front Cylinder ]
[ Rear Cylinder ]
Fit the C-ring.

3-49 ENGINE
CAMSHAFT ASSEMBLY
Distinguish the EX mark for the exhaust camshaft,
the IN mark for the intake camshaft. EX IN
Be distinguished always each camshaft what has
notch at the rightside end and leftside end of it.
When installing the camshaft and cam sprocket,
apply a small quantity THREAD LOCK 1324 to the
bolts and tighten with the specified torque.
THREAD LOCK 1324
Camshaft sprocket bolt EX IN
: 10~12 N m (1.0~1.2 kg m)
Apply the engine oil to the camshaft bearings.
With pull up the camshaft drive chain, align the F

mark of magneto rotor into the punching mark of mag-
neto cover to turn the crankshaft.(Front cylinder)
CAUTION
When adjusting the rear cylinder, align the R
mark of magneto rotor into turn counter-clock-
wise 285 at the postion of front cylinder.
CAUTION
If turn the crankshaft without pulling up the camshaft
drive chain, the chain may be fallen off between the
crankcase and cam chain drive sprocket.
The front cylinder head install first the exhaust

camshaft, following the intake camshaft.
The rear cylinder head install first the intake as the
cam chain tension adjuster exist exhaust side.
ENGINE 3-50
The notch mark of exhaust camshaft should be

aligned with the plane of cylinder head.
At that time, the 2 arrow of exhaust camshaft sprock-
et should be in a vertical position to the plane of
cylinder head when exhaust camshaft sprocket was
geared into camchain.
The notch mark of intake camshaft should be
toward the outside and aligned with the plane of
cylinder head. At that time, the 3 arrow of intake
camshaft sprocket should be in a vertical position to
the plane of cylinder head when the intake camshaft EX IN
sprocket was geared into the camchain.
Gear into the chain at the 3 arrow of intake sprock-
et that count the 16th of chain roller pin from the
roller pin on the 2 arrow of exhaust sprocket to the Exhaust Intake
16Pin
intake camshaft.
CAUTION
The rear cylinder gear into that count the 16th of
chain roller pin from the 3 arrow of intake
sprocket to the 2 arrow of exhaust sprocket.
Notch mark
Notch mark
Install the 3 arrow punching mark of intake

camshaft sprocket with the surface of cylinder head
vertically.
Pin installation
The camshaft sprocket use the intake and exhaust (the
front and rear is different) in common, but use to dis-
tinguish according as installation with the camshaft.
For example,
Front exhaust : Camshaft exhaust + Front sprocket
(Install the camshaft pin at the E marking hole.)
Rear intake : Camshaft intake + Rear sprocket
(Install the camshaft pin at the RI marking hole.)
Exhaust Intake
[ Front Cylinder ]
Pin installation
Exhaust Intake
[ Rear Cylinder ]
3-51 ENGINE
CAUTION
The cam chain is installed to the all of three sprocket.
Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely.
16 Pin
Notch mark
Exhaust Intake
[Front cylinder]
16 Pin
Notch mark
Exhaust Intake
[Rear cylinder]
NOTE
The camshaft housing should be installed in the same manner with the front engine.
ENGINE 3-52
Each camshaft housing is punched with A B

C D .
Put on the housing A to the A of head surface,
the housing B to the B , the housing C to the
C and the housing D to the D as that A
B C D is punched also to the cylinder head
upper surface.
Fix the four camshaft bearing holder and cam chain
guide by tightening of the bolt in order.
Install each bolt diagonally by using the wrench
pulling the shaft down.
Tighten the bolt of each camshaft bearing holder with
the same torque.
CAUTION
If get damaged the head or surface of camshaft
bearing housing thrust, produce an result that the
bearing housing not was tightened.
Tighten the camshaft housing bolt with the specified

torque.
CAUTION
The camshaft housing bolt is made of the special
material.
This bolt is superior at the degree of hardness
more than the different high tension bolt.
Lock shaft handle
Pay special caution that the different type of bolt
should not be used.
This bolt head is punched the 9 mark.
Camshaft housing bolt

: 8~12 N m(0.8~1.2 kg m)
If turn the lock shaft handle in clockwise ( )

direction, the pushrod is inserted in.
Turn the mechanial spring continually until the handle
is turned to the end.
Fix the adjuster into the cylinder block.

3-53 ENGINE
Get out the pushrod for the front to turn the lock shaft
handle in counter-clockwise ( ).
Turn the crankshaft about 10 times counter-clock-

wise ( ) on the basis of the magneto rotor.
If the valve clearance is within standard after measured
the valve clearance, begin the next operation.
If it is out of stanadard, adjust the valve clearance
within standard limit after disassembled the camshaft
and replaced the proper shim.
Valve clearance Standard

IN. 0.1~0.2 mm
EX. 0.2~0.3 mm
Adjust the valve clearance of rear cylinder with the
same manner of the front cylinder.(Refer to page 2-3)
CAUTION
If you don t turn the crankshaft about 10 times
before measured the valve clearance, there is no
meaning in valve clearance.
Apply BOND 1215 to the surface of cylinder head

cover packing block.
BOND 1215
Tighten the cylinder head cover bolts with the speci-

fied torque.
Cylinder head cover bolt
: 12~16 N m(1.2~1.6 kg m)
ENGINE 3-54
SPARK PLUG
Install the spark plug.(Refer to page 2-5)
Install the rear cylinder head and cylinder with the

same manner which installed the front cylinder head
and cylinder. Front Cylinder
Rear Cylinder
GEAR POSITION SWITCH

Install the spring and contact .
Apply SUPER GREASE A to the O-ring and install
the gear postion switch.
SUPER GREASE A
FUEL SYSTEM
CONTENTS
FUEL TANK / FUEL COCK 4- 1
FUEL PUMP 4- 2
CARBURETOR 4- 4
CAUTION
Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
4-1 FUEL SYSTEM
FUEL TANK / FUEL COCK
REMOVAL
WARNING
Gasoline is very explosive. Extreme care must be
taken.
Remove the front seat. (Refer to page 6-1)

Remove the fuel tank mounting bolt, and take off
the hooks.
Disconnect the fuel hose and remove the fuel
tank.
Remove the fuel cock.

FUEL SYSTEM 4-2
FUEL PUMP (
REMOVAL
Remove the front seat and fuel tank.
Turn the fuel cock to OFF .
Disconnect the fuel hoses
Remove the fuel pump mounting bolts.
Remove the fuel pump lead wire coupler .
INSPECTION
WARNING
Gasolin is very explosive. Extreme care must be
taken.
Disconnect the fuel hose connect the suitable
hose and insert the free end of the hose into a recep-
tacle.
Check the fuel flow when starting the engine for few
seconds by pressing the starter switch.
If the fuel flow is not found, check the fuel cock.
If the fuel cock and hoses are not fault, replace the fuel
pump. (Refer to page 5-21)
REASSEMBLY
Carry out the assembly procedure in the reverse order
of disassembly.
Connect the fuel pump lead wire coupler.
Tighten the fuel pump mounting bolts.
Connect the fuel hoses securely.
FUEL HOSE ROUTING :
Fuel hose (To fuel cock)
Fuel hose (To carburetor)
FUEL PUMP RELAY
Remove the fuel pump relay mounting bolts and cou-
pler.
Disconnect the fuel hose and check the fuel
flow when starting the engine for few seconds by
pressing the starter switch.
If the fuel pump are not fault, check the fuel pump relay.
(Refer to page 5-21)
4-3 FUEL SYSTEM
FUEL PUMP (
REMOVAL
Turn the fuel cock to OFF .
Disconnect the fuel hoses and vacuum hose
INSPECTION
WARNING
Gasolin is very explosive. Extreme care must be
taken.
Disconnect the fuel hose , connect the suitable

hose and insert the free end of the hose into a recep-
tacle.
Check the fuel flow when starting the engine for few
seconds by pressing the starter switch.
If the fuel flow is not found, check the fuel cock.
If the fuel cock and hoses are not fault, replace the fuel
pump.
REASSEMBLY
Carry out the assembly procedure in the reverse order
of disassembly.
Tighten the fuel pump mounting bolts.
Connect the fuel hoses and vacuum hose
securely.
FUEL HOSE ROUTING :

Fuel hose (To fuel cock)
Fuel hose (To carburetor)
Vacuum hose (To intake pipe).
FUEL SYSTEM 4-4
CARBURETOR
4-5 FUEL SYSTEM
LOCATION OF CARBURETOR I.D.

NO.
The carburetor I.D. is stamped on the location on the
carburetor as shown in the right photo.
REMOVAL
Remove the fuel tank. (Refer to page 4-1)
Remove the fuel hose.
Remove the throttle cables and choke cable

Loosen the clamp screw and remove the carburetor.
DISASSEMBLY
Remove the diaphragm cover
Remove the spring and piston valve along with

diaphragm
FUEL SYSTEM 4-6
Remove the jet needle cap spring retainer

and jet needle
Remove the float chamber body
Remove the float assembly along with the needle

valve by removing the pin.
Remove the valve seat

Remove the main jet jet holder and pilot jet
4-7 FUEL SYSTEM
Remove the throttle cable bracket
Remove the pilot screw with count and tighten the

number of turn.
NOTE
Record the number of turn for the pilot screw
when install to confer.
INSPECTION
Check the following parts for damage and clogging.
Pilot jet Piston valve
Check for
Main jet Starter jet stopped wear
Main air jet Gaskets and O-rings
Pilot air jet Pilot outlet and bypass
Needle jet holder Float
Needle valve Jet needle
Foreign
Valve seat substance
If any abnormal condition is found, wash the part clean.

If damage or clogging is found, replace the part with a
new one. Needle valve
CLEANING
Clean all jets by using compressed air.
After cleaning, reassemble the carburetor with new
seals and gaskets.
FUEL SYSTEM 4-8
FLOAT HEIGHT ADJUSTMENT

To check the float height, turn the carburetor upside
down. Measure the float height while the float arm is
just contacting the needle valve using vernier calipers.
Float height 17mm (0.67 in)
Bend the float arm as necessary to bring the

height to the specified level.
After adjustment, check the float height and the fuel
level again.
REASSEMBLY
Carburetor reassembly can be performed in the reverse
order of disassembly. When reassembling, carefully
observe the following instructions.
After cleaning, reinstall the pilot screw to the original

number of turn that is recorded during disassembly.
Fit the seal rings securely to the float chamber and

install the float chamber to the carburetor body.
Install the eight screw
4-9 FUEL SYSTEM
Install the jet needle with the pin on the spacer

securely engaged with the hole on the piston
valve.
Align the hole of the diaphragm with passage way

on the carburetor body.
Install the eight screw
CAUTION
Never adjust CO adjust screw of the carbure-
tor. If adjust at discretion, have a bad influence
upon output of the engine as the two carburetor
is disharmonious.
After the assembly and installation on the engine

have been completed, perform the following adjus-
ment.
Throttle cable adjustment. (Refer to page 2-7)
Idle speed adjustment. (Refer to page 2-7)
ELECTRICAL SYSTEM
CONTENTS
LOCATION OF ELECTRICAL COMPONENTS 5- 1
IGNITION SYSTEM 5- 3
CHARGING SYSTEM 5- 7
STARTER SYSTEM AND

SIDE STAND IGNITION INTERLOCK SYSTEM 5- 11
SWITCHES 5- 15
LAMP 5- 16
BATTERY 5- 18
5
FUEL SYSTEM( ) 5- 21
5-1 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
Battery Front brake lamp switch

Turn signal relay
Head lamp relay
C.D.I Unit
Rear brake lamp switch Side stand switch Starter motor

ELECTRICAL SYSTEM 5-2
Ignition coil (NO.1 & NO.2) Regulator / Rectifier
Magneto Gear position switch Fuse

Fuel pump relay ( )
IGNITION SYSTEM
is started as the battery discharged ignition system without a contact point. The battery igni-
tion system is composed a rotor with five rotor tip, the D.C CDI, the ignition coil and battery. This system ignites after get
signal from ignition timing of pick-up with the electric energy of this battery and occur the 1st electric current. Therefore, a
high voltage current is induced in the secondary winding of the ignition coil and results in strong spark between spark plug
gap.
Magneto C.D.I Unit
RELAY
IG.
ENGINE STOP SWITCH SWITCH
REAR FRONT
IGNITION IGNITION C.D.I UNIT
MAGNETO FUSE
COIL COIL
Ignition coil & Spark plug

INSPECTION
MAGNETO
Using the pocket tester, measure the resistance
between the lead wires in the following table.
Pick-up coil G - L Approx 90 110

Charging coil Y - Y Approx 0.6 0.9
Pocket Tester : 09900-25002
CAUTION
When mounting the stator on the magneto cover,
apply a small quantity of THREAD LOCK 1324
to the threaded parts of screws.
THREAD LOCK 1324
WIRE COLOR
L : Blue
G : Green
BY : Black with Yellow tracer
OB : Orange with Black tracer
Br : Brown
BW : Black with White tracer
WL : White with Blue tracer
YG : Yellow with Green tracer
CDI UNIT
Using the pocket tester(R 1 range), measure the
resistance between the terminal in the following table.
Pocket Tester : 09900-25002
CAUTION
Numberical value may differ a little according
to the tester.
Please remind that there may be a defect
which can not be identified even though the
measurement by using the tester indicates a
low voltage.
The range of measurement adjust a [ X 1 ]
unit.
Front cylinder ignition coil Rear cylinder ignition coil

IGNITION COIL
Pull out the spark plug.
Place it on the cylinder head after installing it at the
plug cap to obtain ground.
Push in the electric starter switch to rotate the starter
motor, to have the test of sparking performance.
If not emited spark or the spark bring out the orange
color, replace the ignition coil.
CAUTION
The ignition coil is marked the F for front, and
the R for rear.
If otherwise, it may occure severe damage to the
engine.
IGNITION COIL (Checking with Pocket Tester) B/R

A pocket tester or an ohm meter may be used,
instead of the electro tester. In either case, the igni-
tion coil is to be checked for continuity in both prima-
ry and secondary windings. Exact ohmic readings are Ground
not necessary, but, if the windings are in sound
Plug cap
condition, their continuity will be noted with approxi-
mate ohmic values.
Ignition coil resistance

Primary 0.19 0.24 Tester knob indication 1 range
Secondary 5.4 6.6 Tester knob indication 1 range
Check to attached plug cap
Pocket tester : 09900-25002

SPARK PLUG
Clean the plug with a wire brush and pin. Use the pin to
remove carbon, taking care not to damage the porce-
lain.
Check the gap with a thickness gauge.
0.7 0.8 mm
Spark plug gap
(0.028 0.032 in)
0.7 0.8 mm
(0.028 0.032 in)
CHARGING SYSTEM
The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator / rec-
tifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is
turned into the DC current, then it charges the battery.
IG. switch
Battery
L
O
Control A
A. C generator unit D
Regulator / Rectifier
FUNCTION OF REGULATOR
While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage of
the regulator, the regulator does not function, incidentally the generated current charges the battery directly.
IG. switch
Battery
L
O
Control A
unit D
A. C generator
When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the
voltage between points and of the regulator according becomes high, and when it reaches the adjusted
voltage of the control unit, consequently the control unit becomes ON condition. On the ON condition of the
control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become ON condition. 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 to OFF mode and begins to charge the battery again.
Thus these repetitions maintain charging constant voltage to the battry and protect it from overcharging.
IG. switch
Battery
L
O
Control A
unit D
A. C generator
INSPECTION
CHARGING OUTPUT CHECK
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the DC voltage
between the battery terminal and .
If the tester reads under 14.0 V or over 15.0 V, check
the magneto no-load performance and regulator /
rectifier.
CAUTION
When making this test, be sure that the battery is
full-charged condition.
IG. switch
Standard charge 14.0 15.0 V (at 5,000 rpm) Regulator

Rectifier
Battery DCV
MAGNETO NO-LOAD PERFORMANCE

Disconnect the three lead wires from the magneto
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 67 V or over 99 V the magneto
is faulty.
Standard NO-load perfor-

67 99 V (at 5,000 rpm)
mance of magneto
REGULATOR / RECTIFIER
Disconnect the coupler.
Using the multi-tester ( 1 range), measure the
resistance between the terminals in the following
table.
If the resistance checked is incorrect, replace the regu
lator / rectifier.
Unit :
Probe of tester
Probe of tester
0.8 2 0.8 2 0.8 2 30 55

0.8 2 0.8 2
0.8 2 0.8 2
0.8 2 0.8 2
30 55 0.8 2 0.8 2 0.8 2
STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM

STARTER SYSTEM DESCRIPTION
The starter system consists of the following components : the starter motor, starter relay, clutch lever position
switch, C.D.I unit, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery.
Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact
points to close, thus completing the circuit from the starter motor to the battery.
START RELAY
FUSE
START ENGINE STOP
SWITCH SWITCH
CLUTCH LEVER SIDE STAND MAIN SWITCH

BATTERY
SWITCH SWITCH
NEUTRAL
SWITCH
SIDE STAND / IGNITION INTERLOCK SYSTEM DESCRIPTION

This side stand / ignition interlock system prevents the motorcycle from being started with side stand down.
The system is operated by an electric circuit provided between the battery and ignition coil.
The circuit consists of the C.D.I unit, neutral indicator light and switches.
The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whe-
ther the side stand is either up or down.
The gear position and side stand switches work together in this system.
The ignition coil work only in two situations as follows.
IGNITION ENGINE STOP

FUSE SWITCH SWITCH
IGNITION COIL
CDI
NEUTRAL
Unit
INDICATOR LIGHT
BATTERY
GEAR SIDE STAND SWITCH
POSITION DOWN POSITION
SWITCH
TRANSMISSION : Neutral - ON
Side stand - Down ( OFF )
IGNITION SWITCH
ON
BATTERY IGNITION COIL

CDI
NEUTRAL Unit
INDICATOR LIGHT
GEAR POSITION SIDE STAND SWITCH

SWITCH ON DOWN POSITION
TRANSMISSION : Neutral - OFF

Side stand - Up ( ON )
IGNITION SWITCH
ON
BATTERY IGNITION COIL
CDI
NEUTRAL Unit
INDICATOR LIGHT
SIDE STAND SWITCH

GEAR POSITION
UP POSITION
SWITCH OFF
is equipped with the side stand ignition interlock system.

1. If the transmission is in neutral, you can start the engine regardless of clutch lever and side stand.
2. If the transmission is not in neutral, you can only start the engine with pulling in clutch lever and side stand up.
No Neutral switch Clutch lever Side stand Engine Start

1 Possible NOTE
2 Possible On or Up.
3 Impossible Off or Down
4 Impossible
STARTER MOTOR REMOVAL AND

DISASSEMBLY
Disconnect the starter motor lead wire .
With loosen the bolt , remove the starter motor.
Disassemble the starter motor.
STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect the brushes for abnormal wear, crack
or smoothness in the brush holder.
If the brush has failed, replace the brush sub assy.
COMMUTATOR
Inspect the commutator for discoloration, abnormal
wear or undercut .
If the commutator is abnomally worn, replace the Segment
armature.
When surface is discolored, polish it with #400
sand paper and clean it with dry cloth.
ARMATURE COIL INSPECTION

Check for continuity between each segment.
Check for continuity between each segment and
the armature shaft.
If there is no continuity between the segments or
there is continuity between the segment and shaft,
replace the starter motor with a new one.

STARTER MOTOR REASSEMBLY

Reassemble the starter motor. Pay attention to the following points :
Reassembly the starter motor as shown in the illustration.
Align the mark on the housing with the line

on the housing end.
Apply SUPER GREASE A to the O-ring

and remount the starter motor.
SUPER GREASE A
SWITCHES
Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch
assemblies with new ones.
IGNITION SWITCH ENGINE STOP SWITCH

R O BW BR O OB
ON
OFF
LOCK
LIGHT SWITCH STARTER SWITCH

O Gr OB YG
ON
OFF
DIMMER SWITCH HORN SWITCH

YW Y W G BW
HI ON
LO OFF
TURN SIGNAL SWITCH FRONT/REAR BRAKE LAMP SWITCH

Lg Sb B O WB
L ON
PUSH OFF
R
LAMP
HEADLAMP
TURN SIGNAL LAMP
Rear Front
TAIL / BRAKE LAMP

COMBINATION METER
Remove the combination meter.
Disassemble the combination meter as shown in the
illustration.
INSPECTION
Using the pocket tester, check the continuity between
lead wires in the following illustration.
If the continuity measured incorrect, replace the respec-
tive part.
CAUTION
When making this test, it is not necessary to
remove the combination meter.
BATTERY
CAUTION OF BATTERY TREATMENT
The battery needs attention generally as it occur flammability gas.
If you don t follow the instruction in the below, there may be a explosion and severe accident.
Therefore, please pay attention to the following points.
Prohibit positively battery from contacting to short, spark or firearms.

The recharge of battery should be done in the wide place where the wind is well ventilated.
Please don t recharge it at the sight of wind-proof.
CAUTION OF BATTERY ELECTROLYTE TREATMENT

Pay attention for the battery electrolyte not to stains the chassis or the humanbody.
If stains the chassis or the humanbody, at once wash a vast quantity of water.
When it be stained, clothes should come into being a hole or painting should take off.
Be cured from a doctor.
When the battery electrolyte was dropped to the surface of land, wash a vast quantity of water.
Neutralize by hydroxide, bicarbonate of soda and so on.
CAUTION OF MAINTENANCE FREE

BATTERY TREATMENT
Do not remove the aluminum tape to seal the battery
electrolyte filler hole untill use as battery of completely
seal type.
Do not use it except the battery electrolyte.
When pour into the battery electrolyte, necessarily
use the electrolyte of the specified capacity.
Do not open the sealing cap after recharge the bat-
tery eletrolyte.
Filling electrolyte.
Put the battery on even land and remove the alu-
minum tape sealing.
Remove the cap at the electrolyte container.
Aluminum tape
CAUTION
Do not remove the seal of the electrolyte Filler holes
container, not prick with sharp thing.
Cap Seal
Pouring of battery electrolyte

When insert the nozzles of the electrolyte container into
the battery s electrolyte filler holes, holding the container
firmly so that it does not fall.
Take precaution not to allow any fluid to spill.
CAUTION
The pouring of electrolyte may not be done if
the electrolyte container is pushed slopely.
Confirmation of pour
Make sure that air bubbles are coming up each
electrolyte container, and keep this position for more
than about 20 minutes.
CAUTION
If no air bubbles are coming up from a filler Air bubble
port, tap the buttom of the two or three times.
Separation of electrolyte container

After confirming that you entered the electrolyte into bat-
tery completely, remove the electrolyte containers from
the battery.
CAUTION
Draw the empty receptacle out slowly because
there may be a chance which remaining elec-
trolyte vaporize.
Insert of the caps

Insert the cap into the filler holes, pressing it firmly so
that the top of the caps do not protrude above the up per
surface of the battery stop cover.
Insert the caps firmly

SERVICING
Visually inspect the surface of the battery container. If
any signs of cracking or electrolyte leakage from the
sides of the battery have occurred, replace the battery
with a new one. If the battery terminals are found to be
coated with rust or an acidic white powdery substance,
then this can be cleaned away with sandpaper.
RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If
How to charge
the voltage reading is less than the 12.0V (DC),
recharge the battery with a battery charger. Standard 1.4 A 10 hours
Fast 6A 30 minutes
CAUTION
When recharging the battery, remove the battery
from the motorcycle.
NOTE
Do not remove the caps on the battery top while
recharging.
CAUTION
Be careful not to permit the charging current to
exceed 3A at any time.
After recharging, wait for more than 30 minutes and
check the battery voltage with a pocket tester.
If the battery voltage is less than the 12.5V, recharge
the battery again.
If battery voltage is still less than 12.5V, after
recharging, replace the battery with a new one.
When the motorcycle is not used for a long period,
check the battery every 1 month to prevent the bat-
tery discharge.
FUEL SYSTEM
FUEL PUMP
Remove the fuel pump lead wire coupler
Using the pocket tester (X 1 range), measure the

table.
If the resistance checked is incorrect, replace the
fuel pump.
Fuel pump resistance 4.5 10.0 (BW-BL)
FUEL PUMP RELAY

Remove the fuel pump relay coupler
Using the pocket tester (X 1 range), measure the
table.
If the resistance checked is incorrect, replace the
fuel pump relay.
Unit :
Probe of tester
1 2 3 4
Probe of tester
1
2 700~950
3 700~950
4

CHASSIS
CONTENTS
EXTERIOR PARTS 6- 1
FRONT WHEEL 6- 2
FRONT BRAKE 6- 6
HANDLEBARS 6- 12
FRONT FORK ( ) 6- 14
FRONT FORK ( ) 6- 20
STEERING 6- 27
REAR WHEEL 6- 30
REAR BRAKE 6- 34
REAR SHOCK ABSORBER 6- 36 6

SWING ARM 6- 37
6-1 CHASSIS
EXTERIOR PARTS
FRONT FENDER
With the bolts removed, remove the front fender.
REAR SEAT
Remove the rear seat with the ignition key.
FRONT SEAT
To remove the front seat, pull the knob located under
the rear seat.
CHASSIS 6-2
FRONT WHEEL
REMOVAL
Loosen the axle pinch bolt , right and left.
Loosen the front axle .
Raise the front wheel off the ground with a block
or jack.
CAUTION
When using a jack, take care not to cause
scratches on the chassis.
Remove the front wheel by removing the front axle

.
6-3 CHASSIS
Remove the brake disc.
INSPECTION AND DISASSEMBLY

TIRE
For inspection of the tire : Refer to page 2-18.
FRONT AXLE
Measure the front axle runout using the dial gauge. If
the runout exceeds the limit, replace the front axle.
Service limit
Axle shaft runout
0.25 mm (0.01 in)
Dial gauge : 09900-20606

V-block : 09900-21304
WHEEL
Make sure that the wheel runout (axial and radial) does
not exceed the service limit when checked as shown.
An excessive amount of runout is usually due to worn or
loose wheel bearings and can be corrected by replacing
the bearings. If bearing replacement fails to reduce the
wheel.
Wheel runout Service limit

(axial and radial) 2.0 mm (0.08 in)
WHEEL BEARING
Inspect the play of the wheel bearings by finger while
they are in the wheel. Rotate the inner race by finger to
inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is
anything unusual.
CHASSIS 6-4
WHEEL BEARING REMOVAL

Remove the wheel bearing by using the special tool.
Wheel bearing remover : 09941-50111
CAUTION
The removed bearing should be replaced with
new ones.
REASSEMBLY
Reassemble the front wheel in the reverse order of
removal and disassembly.
Pay attention to the following points :
WHEEL BEARING
Apply SUPER GREASE A to the wheel bearings.
SUPER GREASE A
Install the wheel bearings as follows by using the

special tools.
Steering race installer : 09941-34513
CAUTION
First install the right wheel bearing, then install
the left wheel bearing.
BRAKE DISC
Make sure that the brake disc is clean and free of any
greasy matter.
Apply THREAD LOCK 1324 to the disc mounting
bolts and tighten them to the specified torque.
Brake disc bolt

: 18~28 N m (1.8 ~2.8 kg m)
THREAD LOCK 1324
6-5 CHASSIS
Tighten the front axle bolt and axle pinch bolt to

Front axle bolt : 50~80 N m (5.0 ~8.0 kg m)
Front axle pinch bolt
: 15~25 N m (1.5 ~2.5 kg m)
CHASSIS 6-6
FRONT BRAKE
WARNING
Do not mix with brake fluid of different brand.
Do not use a brake fluid kept in an open container or stored for long period of time.
To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of
children.
When filling brake fluid, take care not to allow water or dirt to enter the system.
To wash the brake system parts, use brake fluid and not any other material.
Do not allow dirt and fluid to contact the brake disc or pad.
6-7 CHASSIS
CAUTION
Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause
discoloration or crack.
BRAKE FLUID REPLACEMENT

For replacing procedure of brake fluid : Refer to page 2-15
BRAKE PAD REPLACEMENT

For replacing procedure of brake pad : Refer to page 2-14
CALIPER DISASSEMBLY
Drain brake fluid. (Refer to page 2-15)
CAUTION
To prevent brake fluid from splashing on the
parts nearby, cover the parts with cloth.
Remove the union bolt and caliper mounting bolts

.
Remove the brake pad. (Refer to page 2-14)
Remove the brake caliper holder .
Using an air gun, push out the caliper piston.
WARNING
Place a rag over the piston to prevent it from
popping out and flying and keeping hand off
the piston.
Be careful of brake fluid which can possibly
splash.
Do not use high pressure air but increase the
pressure gradually.
CHASSIS 6-8
Remove the dust seal and piston seal .
CAUTION
Care not to cause scratch on the cylinder bore.
Do not reuse the piston seal and dust seal that
have been removed.
CALIPER INSPECTION
Inspect the caliper cylinder wall and piston surface for
scratch, corrosion or other damages.
If any abnormal condition is noted, replace the caliper.
CALIPER REASSEMBLY
Reassemble the caliper in the reverse order of disas-
sembly procedures and observe the following points.
CAUTION
Wash the caliper components with fresh brake
fluid before reassembly. Do not wipe off brake
fluid after washing the components.
Replace the piston seal and dust seal with new
ones with brake fluid applied.
Brake fluid specification and classification

: DOT 3 or DOT 4
Install the brake pad spring.

6-9 CHASSIS
Apply SILICONE GREASE to the brake caliper hold-

er.
SILICONE GREASE
Install the brake pads. (Refer to page 2-14)
Tighten the caliper mounting bolts .

With the hose end seated to the stopper, tighten the
union bolt
Front brake caliper mounting bolts
:18~28 N m (1.8~2.8 kg m)
Front brake hose union bolts
:20~25 N m (2.0~2.5 kg m)
Fill the system with brake fluid and bleed air. (Refer to
page 2-16)
Inspection after reassembly : Refer to page 2-14
BRAKE DISC INSPECTION

Check the brake disc for damage or cracks. Measure the
thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if damage is found.
Micrometer (0 25 mm) : 09900-20201
Service limit
Brake disc thickness
3.0 mm (0.12 in)
Measure the runout using the dial gauge.

Replace the brake disc if the runout exceeds the service
limit.
Dial gauge : 09900-20606

Service limit
Brake disc runout
0.3 mm (0.012 in)
If either measurement exceeds the service limit,

replace the brake disc. (Refer to page 6-3)
CHASSIS 6-10
MASTER CYLINDER DISASSEMBLY

Drain brake fluid the master cylinder.
Disconnect the brake lamp switch lead wire coupler.
Remove the union bolt .
CAUTION
Place a rag under the union bolt so that brake
fluid can not contact the parts.
Remove the two clamp bolts and take off the master
cylinder.
Remove the two fitting screws and separate the cap

and diaphragm.
Detach the dust seal boot and remove the circlip.

Pull out the piston/cup set and spring .
6-11 CHASSIS
MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or
other damage.
Inspect the piston surface for any scratches or other
damage.
MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse order of
disassembly.
CAUTION
Wash the master cylider components with new
brake fluid before reassembly.
When washing the components, use the speci-
fied brake fluid. Never use different types of
fluid or cleaning solvents such as gasoline,
kerosine, etc.
Specification and Classification

: DOT 3 or DOT 4
NOTE
When installing the circlip, make sure that the sharp
edge of the circlip faces outside.
Master Cylinder
When remounting the master cylinder to the
handlebars, first tighten the clamp bolts for
upside as shown.
WARNING Up
Bleed air from the brake fluid circuit after

reassembling master cylinder.(See page 2-16)
Handlebar
Clearance
CHASSIS 6-12
HANDLEBARS
HANDLEBARS RIGHT SIDE PARTS
REMOVAL
Remove the right handlebar switches.
Disconnect the brake lamp switch lead wires and
remove the master cylinder. (Refer to page 6-10)
Remove the handlebar balancer and grip .
HANDLEBARS LEFT SIDE PARTS

REMOVAL
Remove the left handlebar switches.
Remove the handlebar balancer and grip .
Remove the clutch lever holder.
Remove the clamp bolts and detach the handlebar

holders.
Remove the handlebar.
REMOUNTING
Perform the remounting work in the reverse order of the
removal procedures while observing the following
instructions.
Install the handlebars with the punch mark aligned
with the handlebar clamp as shown.
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolts
: 18~28 N m (1.8 ~2.8 kg m)
6-13 CHASSIS
NOTE
The gap between the handlebar clamp and
holder should be even.
Align the mating face of clutch lever holders with the

respective punch marks and tighten the bolt.
Install the brake master cylinder. (Refer to page 6-
11).
Apply SUPER GREASE A to the throttle cables
and assemble them.
SUPER GREASE A
CHASSIS 6-14
FRONT FORK
6-15 CHASSIS
REMOVAL AND DISASSEMBLY

Take off the front wheel. (See page 6-2)
Loosen the front fork upper and lower 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.
CAUTION
To remove the O-ring , it will be necessary to
push the seat lever inwards, to remove the
spring pressure from the O-ring.
The removed O-ring should be replaced
with a new one.
Straighten the fork and stroke it several times to

remove the oil.
Hold the fork inverted for a few minutes.
CHASSIS 6-16
Remove the damper rod bolt by using the special tool.

T Handle : 09940-34520
D Attachment : 09940-34561
T Type hexagon wrench (6mm)
: 09914-25811
Separate the inner tube from outer tube.

Remove oil lock piece and damper rod with
rebound spring.
Remove the snap ring by using the snap ring plier.
Remove the oil seal by using the special tool.

CAUTION
The oil seal removed should be replaced with a new
one.
6-17 CHASSIS
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE

Inspect the inner tube and outer tube sliding surfaces
for any scuffing or flaws.
FORK SPRING
Measure the fork spring free length If it is shorter
than the service limit, replace it.
Standard
Fork spring free length
433.3 mm (17.1 in)
REASSEMBLY
Reassemble and remount the front fork in the
reverse order of disassembly and removal, and also
carry out the following steps :
CHASSIS 6-18
DAMPER ROD BOLT

Apply Bond 1215 and Thread Lock 1324
to the damper rod bolt and tighten the bolt
with specified torque by the Special tool
Bond 1215
Thread Lock 1324
T Handle : 09940-34520
D Attachment : 09940-34561
T Type hexagon wrench (6mm) : 09914-25811
Front fork damper rod bolt
: 30 40 N m (3.0 4.0
OIL SEAL
Install the oil seal to the outer tube by using the
special tool as shown.
Fork oil seal installer : 09940-50112
FORK OIL
For the fork oil, be sure to use a front fork oil whose
viscosity rating meets specifications below.
Front fork oil specification : TELUS #22
Fornt fork Each leg

oil capacity 400 2.5cc
Hold the front fork vertical and adjust the fork oil level
with the special tool.
Standard
Front fork oil level
146 mm (5.8 in)
Front fork level gauge : 09943-74111
CAUTION
When adjusting oil level, remove the fork spring and
compress the inner tube fully.
6-19 CHASSIS
FORK SPRING
The narrow pitch side of spring face to the upper side
when installing the front fork spring.
Up side
STOPPER RING
To install a new stopper ring, it will be necessary to
push the spring seat inward.
CAUTION
Always use a new stopper ring.
After installing a stopper ring, always insure that
it is completely seated in its groove and securely
fitted.
REMOUNTING
Tighten the upper and lower clamp bolts.
Front fork upper clamp bolts : 22~35 N m
(2.2~3.5 kg m)
Front fork lower clamp bolts : 22~35 N m
(2.2~3.5 kg m)
CHASSIS 6-20
FRONT FORK
6-21 CHASSIS
DISASSEMBLY
Remove the front wheel. (Refer to page 6-2)
Remove the brake caliper. (Refer to page 6-7)
CAUTION
Secure the brake caliper to the frame with a string
etc., taking care not to bend the brake hose.
Remove the front fender. (Refer to page 6-1)
Remove the front fork after loosening the front fork

upper and lower clamp bolts .
NOTE
Slightly loosen the front fork upper bolt to
facilitate later disassembly.
Remove the front fork upper bolt , O-ring , front

fork inner spacer and spring guide .
Invert the front fork and stroke it several times to

drain out the fork oil.
Hold the front fork in the inverted position for a few
minutes to allow the fork oil to fully drain.
CHASSIS 6-22
With the damper rod held immovable, remove

the damper rod bolt.
Remove the damper rod and rebound spring
from the inner tube.
Remove the dust seal and oil seal stopper ring
Separate the inner tube from the outer tube.
Remove the following parts.

Oil seal
Slide metal
Oil lock piece
CAUTION
The removed oil seal and slide metal should be
replaced with new ones.
6-23 CHASSIS
INSPECTION
FRONT FORK SPRING
Measure the free length of the front fork spring .
If the length is found shorter than the service limit,
replace the spring.
Service limit
Fork spring free length
354 mm (13.9 in)
INNER TUBE AND OUTER TUBE

Check the sliding surface of the inner tube, outer
tube and damper rod ring for scratch, wear, bend-
ing, or other abnormal condition.
REASSEMBLY
Perform the reassembly and remounting work in the
reverse order of the disassembly and removal proce-
dures while observing the following instructions.
CAUTION
Thoroughly wash all the component parts being assembled.
Insufficient washing can result in oil leakage or premature wear of the parts.
When reassembling the front fork, use new fork oil.
Use the specified fork oil for the front fork.
When reassembling, replace the slide metals, oil seal, dust seal and damper rod bolt gasket with new ones.
On the inner tube, assemble the following parts.

Dust seal
Oil seal stopper ring
Oil seal
Oil seal retainer
Slide metal
Guide bushing
CAUTION
To prevent the lip of oil seal from being dam-
aged, cover the inner tube with vinyl sheet dur-
ing installation.
CHASSIS 6-24
With the oil lock piece fitted to the inner tube, assem-
ble the inner tube to the outer tube.
Apply SUPER GREASE A to the lip of the oil seal

and install it into the outer tube using the front fork
oil seal installer.
SUPER GREASE A
Front fork oil seal installer set

: 09940-52861
CAUTION
Wash and clean the front fork oil seal installer
before using. If dirt is on the installer, the inner
tube may possibly be damaged during press-fit-
ting work.
Fit the stopper ring and dust seal .
CAUTION
Make sure that the stopper ring is securely fitted
into the groove on the outer tube.
Dust seal
Oil seal stopper ring
Oil seal
Oil seal retainer
Slide metal
Fit the rebound spring on the damper rod and

install them together to the inner tube.
6-25 CHASSIS
Apply THREAD LOCK 1324 to the damper rod bolt

.
With the damper rod held immovable, with the gasket
fitted, tighten the damper rod bolt .
Front fork damper rod bolt
: 30~40 N m (3.0~4.0 kg m)
THREAD LOCK 1324
CAUTION
Replace the gasket with a new one.
FRONT FORK OIL

With the inner tube in fully compressed position, pour
the specified amount of fork oil and stroke the tube
several times to expel air.
Front fork oil specification : TELLUS #22
Each leg
Front fork oil capacity
262 cc
With the front fork held in vertical position, compress

the inner tube all the way.
Wait until the fluid level stabilizes, measure and

adjust the level to specification using the special tool.
Standard
Front fork oil level
155 mm (6.1 in)
Front fork oil level gauge : 09943-74111
Install the front fork spring .

Install the spring guide , front fork inner spacer ,
and O-ring .
CHASSIS 6-26
Fit the O-ring to the front fork upper bolt and apply
SUPER GREASE A .
SUPER GREASE A
CAUTION
Use a new O-ring to prevent oil lieakage.
Install the front fork to the motocycle.

Align the upper surface of the inner tube with the
upper surface of the steering stem upper bracket.
Tighten the front fork lower clamp bolts and front

fork upper bolts to the specified torque.
Tighten the front fork upper clamp bolts to the
specified torque.
Front fork upper clamp bolt

: 22~35 N m (2.2~3.5 kg m)
Front fork lower clamp bolt
: 22~35 N m (2.2~3.5 kg m)
Front fork upper bolt
: 22~30 N m (2.2~3.0 kg m)
Install the front fender and tighten the mounting

bolts temporarily.
Install the front brake caliper. (Refer to page 6-8)
Install the front wheel. (Refer to page 6-4)
Move the front fork up and down several times.
Tighten the front fender mounting bolts securely.
6-27 CHASSIS
STEERING

Take off the front wheel. (See page 6-2)
Remove the four bolts and front fender.
Take off the front fork. (See page 6-15, 6-21)
CHASSIS 6-28
Remove the handlebar clamp bolts.

Remove the steering stem head nut and take off
the steering stem upper bracket .
Remove the steering stem nut and draw out the

steering stem.
Clamp wrench : 09940-10122
Take off the steering stem lower bracket .
CAUTION
Hold the steering stem lower bracket by hand to
prevent from falling.
Remove the upper and lower bearing .
Remove the outer race fitted on the steering stem.

This can be done with a chisel.
Draw out the two inner races fitted to the top and bot-
tem ends of the head pipe.
6-29 CHASSIS
INSPECTION
Inspect and check the removed parts for the following
abnormalities.
Handlebar distortion.
Handlebar clamp wear.
Abnormality operation of bearing.
Worn or damaged races.
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 :
Apply SUPER GREASE A to the upper bearing
and lower bearing .
SUPER GREASE A
Tighten the steering stem nut with the special tool.
Clamp wrench : 09940-10122
Steering stem nut : 80~100 N m (8.0~10.0kg m)
Turn the steering stem right and left, lock-to-lock, five or

six times.
Tighten the steering stem head nut to the specified
torque.
Steering stem head nult : 80~100 N m
(8.0~10.0 kg m)
CAUTION
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 play and that the procedure was
accomplished correctly. If play is noticeable, re-
adjust the steering stem nut.
Set the handlebars to match its punched mark to the

mating face of the holder.
Secure the each handlebar clamp bolts in such a way
that the clearances ahead of and behind the handle-
bars should be equalized.
Handlebar clamp bolts

: 18~28 N m (1.8~2.8 kg m)
CHASSIS 6-30
REAR WHEEL
REMOVAL
Raise the rear wheel off the ground with a jack or
block.
Loosen the drive chain adjuster right and left.
Disengage the drive chain from the rear sprocket.
6-31 CHASSIS
Remove the rear wheel by removing the rear axle

.
Remove the brake disc.
Remove the spacer .

Remove the rear sprocket with mounting drum
from the rear wheel.
NOTE
Before separating the rear sprocket and mounting
drum, slightly loosen the rear sprocket bolts.
Remove the rear wheel shock absorber

Remove the rear sprocket from the rear sprock-
et mounting drum.
WHEEL BEARING REMOVAL

Remove the bearing by using the special tool.
Wheel bearing remover : 09941-50111
CAUTION
The removed bearing should be replaced with
new one.
CHASSIS 6-32
INSPECTION
WHEEL AXLE : Refer to page 6-3
WHEEL : Refer to page 6-3
WHEEL BEARING : Refer to page 6-3
TIRE : Refer to page 2-18
REAR WHEEL SHOCK ABSORBER

Inspect the rear wheel shock absorber for wear and damage.
Replace the rear wheel shock absorber if there is any-
thing unusual.
SPROCKET
Inspect the sprocket s teeth for wear. If they are worn,
replace the sprocket and drive chain as a set.
Normal Excessive
wear wear
REASSEMBLY
Reassemble the rear wheel and rear brake in the
reverse order of disassembly.
Tighten the rear sprocket nuts to the specified torque.
Rear sprocket nut

: 20~30 N m (2.0~3.0 kg m)
6-33 CHASSIS
Install the rear wheel.

After installing the drive chain to the rear sprocket, adjust
the drive chain.
Tighten both chain adjusting nuts securely.
Tighten the rear axle nut to the specified torque.
Rear axle nut : 90~140 N m (9.0~14.0 kg m)

CHASSIS 6-34
REAR BRAKE
WARNING
Do not mix with brake fluid of different brand.
Do not use a brake fluid kept in an open container or stored for long period of time.
To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of
children.
When filling brake fluid, take care not to allow water or dirt to enter the system.
To wash the brake system parts, use brake fluid and not any other material.
Do not allow dirt and fluid to contact the brake disc or pad.
6-35 CHASSIS
Brake fluid replacement : Refer to page 2-15

Brake pad replacement : Refer to page 2-14
Disassembly of caliper : Refer to page 6-7
Inspection of caliper : Refer to page 6-8
Reassembly of caliper : Refer to page 6-8
Inspection of brake disc : Refer to page 6-9
CHASSIS 6-36
REAR SHOCK ABSORBER
REMOVAL
Remove the rear shock absorbers by removing
their nuts.
INSPECTION
Inspect the rear shock absorber for damage and
oil leakage. If any defects are found, replace the rear
shock absorber with a new one.
CAUTION
Do not attempt to disassemble the rear shock
absorber. It is unserviceable.
REMOUNTING
Install the rear shock absorber and tighten the nuts to
Shock absorber mounting nut (upper)

: 40~60 N m (4.0~6.0 kg m)
Shock absorber mounting nut (lower)
: 40~60 N m (4.0~6.0 kg m)
6-37 CHASSIS
SWINGARM

Remove the rear wheel. (See page 6-30)
Remove the rear shock absorber fitting nut and bolt.
(See page 6-36)
Remove the swing arm pivot nut.
Draw out the pivot shaft and take off the swing arm.
CHASSIS 6-38
Remove the chain case.

Remove the two spacers.
Remove the bearing by using the special tools.
Bearing remover (17 mm) : 09923-73210
Rotor remover sliding shaft : 09930-30102
INSPECTION
SWINGARM
Inspect the swingarm for damage.
If any defects are found, replace the swingarm with a
new one.
CHAIN BUFFER
Inspect the chain buffer for wear and damage. If any
defects are found, replace the chain buffer with a new
one.
SWINGARM PIVOT SHAFT

Measure the pivot shaft runout using the dial gauge.
If the pivot shaft exceeds the service limit, replace it
with a new one.
Dial gauge : 09900-20606

V-block : 09900-21304
Swingarm pivot shaft Service limit

runout 0.6 mm (0.024 in)
6-39 CHASSIS
REASSEMBLY
Reassemble the swingarm and rear shock absorber in
the reverse order of disassembly.
Press the needle bearings into the swingarm pivot
using the special tool.
Steering race installer : 09941-34513
Apply SUPER GREASE A to the needle bearing

and spacers.
SUPER GREASE A
Install the swingarm and tighten the swingarm pivot

nut to the specified torque.
Swingarm pivot nut

: 45~70 N m (4.5~7.0 kg m)
Install the rear wheel. (Refer to page 6-32)

Install the rear shock absorber. (Refer to page 6-36)
Adjust the following points :
Drive chain slack : Refer to page 2-13
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 7- 1
SPECIAL TOOLS 7- 8
TIGHTENING TORQUE 7-11
SERVICE DATA 7-13
WIRE AND CABLE ROUTING 7-23
WIRE AND CABLE ROUTING 7-27

WIRING DIAGRAM 7-31
WIRING DIAGRAM 7-32
7
7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not Compression too low

start, or is hard 1. Valve clearance out of adjustment. Adjust.
to start. 2. Worn valve guides or poor seating of valves. Repair or replace.
3. Valves mistiming Adjust.
4. Piston rings excessively worn. Replace.
5. Worn-down cylinder bore. Replace or rebore.
6. Poor seating of spark plug. Retighten.
7. Starter motor cranks but too slowly. Consult electrical complaints
Plug not sparking

1. Fouled spark plug. Clean or replace.
2. Wet spark plug. Clean and dry.
3. Defective ignition coil. Replace.
4. Open or short circuit in high tension cord. Replace..
No fuel reaching the carburetor

1. Clogged hole in the fuel tank cap. Clean.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float valve. Replace.
4. Clogged fuel pipe. Clean or replace.
Engine stalls 1. Fouled spark plug. Clean.

easily. 2. Clogged fuel hose. Clean.
3. Clogged jets in carburetor. Clean.
4. Valve clearance out of adjustment. Adjust.
Noisy engine. Excessive valve chatter

1. Valve clearance too large. Adjust.
2. Weakened or broken valve springs. Replace.
3. Worn down camshaft. Replace.
Noise appears to come from piston

1. Piston or cylinder worn down. Replace.
2. Weakened or broken valve springs. Replace.
3. Worn down piston pin or piston pin bore. Replace.
4. Piston rings or ring groove worn. Replace.
Noise seems to come from timing chain

1. Stretched chain. Replace.
2. Worn sprockets. Replace.
3. Tension adjuster not working. Repair or replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub. Replace.
2. Worn teeth of cluth plates. Replace.
3. Distorted clutch plates, driven and drive. Replace.
Noise seems to come from crankshaft

1. Worn or broken bearings. Replace.
2. Big-end bearings worn and broken. Replace.
3. Thrust clearance too large. Replace.
SERVICING INFORMATION 7-2
Noisy engine. Noise seems to come from transmission

1. Gears worn or rubbing. Replace.
2. Badly worn splines. Replace.
3. Primary gears worn or rubbing. Replace.
3. Badly worn bearings. Replace.
Slipping clutch. 1. Clutch control out of adjustment or too much play. Adjust.
2. Weakened clutch springs. Replace.
3. Worn or distorted pressure plate. Replace.
Dragging clutch. 1. Clutch control out of adjustment or too much play. Adjust.
2. Weakened clutch springs. Replace.
Transmission will 1. Broken gearshift cam. Replace.

not shift. 2. Distorted gearshift forks. Replace.
3. Worn gearshift pawl. Replace.
Transmission will 1. Broken return spring on shift shaft. Replace.

not shift back. 2. Shift shafts are rubbing or sticky. Repair.
3. Distorted or worn gearshift forks. Replace.
Transmission 1. Worn shifting gears on driveshaft or countershaft. Replace.

jumps out of gear. 2. Distorted or worn gearshift forks. Replace.
3. Weakened stopper pawl spring on gearshift cam. Replace.
4. Worn gearshift pawl. Replace.
Engine idles 1. Valve clearance out of adjustment. Adjust.

poorly. 2. Poor seating of valves. Replace.
3. Defective valve guides. Replace.
4. Defective pick-up coil. Replace.
5. Spark plug gap too wide. Adjust or replace.
6. Defective ignition coil resulting in weak sparking. Replace.
7. Float-chamber fuel level out of adjustment in carburetor. Adjust.
8. Clogged jets. Clean.
Engine runs 1. Valve springs weakened. Replace.

poorly in high 2. Valve timing out of adjustment. Adjust.
speed range. 3. Worn cams. Replace.
4. Spark plug gap too narrow. Repair.
5. Defective ignition coil. Replace.
6. Float-chamber fuel level too low. Adjust .
7. Clogged air cleaner element. Clean.
8. Clogged fuel hose, resulting in inadequate fuel supply to carburetor. Clean or replace.
Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win-
exhaust smoke. dow, drain out excess oil.
2. Worn piston rings or cylinder. Replace.
3. Worn valve guides. Replace.
4. Cylinder wall scored or scuffed. Replace.
5. Worn valves stems. Replace.
6. Defective stem seals. Replace.
7. Worn side rails. Replace.
Engine lacks power. 1. Loosen of valve clearance. Adjust.

2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston ring or cylinder. Replace.
5. Poor seating of valves. Repair or replace.
6. Fouled spark plug. Clean or replace.
7. Worn camshaft. Replace.
8. Spark plug gap incorrect. Adjust or replace.
9. Clogged jets in carburetor. Clean.
10. Float-chamber fuel level out of adjustment. Adjust.
11. Clogged air cleaner element. Clean.
12. Too much enging oil. Drain out excess oil.
13. Defective air intake pipe. Retighten or replace.
Engine overheats. 1. Heavy carbon deposit on piston head. Clean.

2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Repair or clean.
4. Fuel level too low in float chamber. Adjust.
5. Air leak from intake pipe. Retighten or replace.
6. Use of incrrect engine oil. change.
7. Defective oil cooler. Clean or replace.
CARBURETOR
Trouble with 1. Starter jet is clogged. Clean.

starting. 2. Starter pipe is clogged. Clean.
3. Air leaking from a joint between starter body and carburetor. Check starter body and
carburetor for tightness,
adjust and replace gasket.
4. Starter plunger is not operating properly. Check and adjust.
Idling or low-speed 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
trouble. 2. Pilot outlet or bypass is clogged. Check and clean.
3. Starter plunger is not fully closed. Check and clean.
Medium or high 1. Main jet or main air jet is clogged. Check and clean.
speed trouble. 2. Needle jet is clogged. Check and clean.
3. Throttle valve is not operating properly. Check throttle valve for
operation.
4. Filter is clogged. Check and clean.
Overflow and fuel 1. Needle valve is worn or damaged. Replace.

level fluctuations. 2. Spring in needle valve is borken. Replace.
3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.
5. Fuel level is too high or low. Adjust float height.
ELECTRICAL
No sparking or poor 1. Defective ignition coil. Replace.

sparking. 2. Defective spark plug. Replace.
3. Defective CDI unit. Replace.
Spark plug soon 1. Mixture too rich. Adjust carburetor.

become fouled with 2. Idling speed set too high. Adjust carburetor.
carbon. 3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean or replace.
5. Spark plug too cold. Replace by hot type plug.
Spark plug become 1. Worn piston rings. Replace.

fouled too soon. 2. Pistons or cylinder worn. Replace.
3. Excessive clearance of valve stems in valve guides. Replace.
4. Worn stem oil seal. Replace.
Spark plug 1. Spark plug too hot. Replace by cold type plug.
electrodes 2. The engine overheats. Tune up.
overheat or burn. 3. Spark plug loose. Retighten.
4. Mixture too lean. Adjust carburetor.
Generator charge, 1. Lead wires tend to get shorted or open-circuited or loosely connected Repair or retighten.
but charging at terminals.
rate is below the 2. Grounded or open-circuited stator coils of generator. Replace.
specification. 3. Defective regulator/rectifier. Replace.
4. Not enough electrolyte in the battery. Add distilled water between
the level lines.
5. Defective cell plates in the battery. Replace the battery.
Generator 1. Internal short-circuit in the battery. Replace the battery.

overcharges. 2. Resistor element in the regulator/rectifier damaged or defective. Replace.
3. Regulator/rectifier poorly grounded.
Clean and tighten
ground connection.
Unstable 1. Lead wire insulation frayed due to vibration resulting in intermittent Repair or replace
charging. shorting.
2. Generator internally shorted. Replace.
3. Defective regulator/rectifier. Replace.
Starter switch is 1. Battery run down. Recharge or replace.

not effective. 2. Defective switch contacts. Replace.
3. Brushes not seating properly on commutator in starter motor. Repair or replace.
4. Defective starter relay. Replace.
BATTERY
Sulfation acidic 1. Not enough electrolyte. Add distilled water, if the battery
white powdery has not been damaged and
substance or spots sulfation has not advanced
on surfaces of too far, and recharge.
cell plates. 2. Battery case is cracked. Replace the battery.
3. Battery has been left in a run-down condition for a long time. Replace the battery or recharge.
4. Contaminated electrolyte. (Foreign matter has enters the If sulfation has not advanced
battery and become mixed with the electrolyte.) far, try to restore the battery by
replacing the electrolyte,
recharing it fully with the battery
detached from the motorcycle
and then adjusting electrolyte
specific gravity.
Battery runs down 1. The charging method is not correct. Check the generator, regulator
quickly. /rectifier and circuit connections,
and make necessary adjustments
to obtain specified charging
operation.
2. Cell plates have lost much of their active material as a result of Replace the battery, and correct
over-charging. the charging system.
3. A short-circuit condition exists within the battery due to excessive Replace the battery.
accumulation of sediments caused by the high electrolyte specific
gravity.
4. Electrolyte specific gravity is too low. Recharge the battery fully and
adjust electrolyte specific
gravity.
5. Contaminated electrolyte. Replace the electrolyte, recharge
the battery and then adjust
specific gravity.
6. Battery is too old. Replace the battery.
Reversed battery The battery has been connected the wrong way round in the system, so Replace the battery and be
polarity. that it is being charged in the reverse direction. sure to connect the battery
properly.
Battery sulfation 1. Charging rate too low or too high. (When not in use, batteries Replace the battery.
should be recharged at least once a month to avoid sulfation.)
2. Battery electrolyte excessive or insufficient, or its specific gravity too Keep the electrolyte up to the
high or too low. prescribed level, or adjust the
specific gravity by consulting
the battery maker s directions.
3. The battery left unused for too long in cold climate. Replace the battery, if badly
sulfated.
Battery discharges 1. Dirty container top and sides. Clean.

too rapidly. 2. Impurities in the electrolyte or electrolyte specific gravity is too high. Change the electrolyte by
consulting the battery maker s
directions.
CHASSIS
Steering feels too 1. Steering stem nut overtightened. Adjust.

heavy or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Steering 1. Loss of balance between right and left front suspensions. Replace.
oscillation. 2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobbling 1. Distorted wheel rim. Replace.

front wheel. 2. Worn-down wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loosen nut on axle. Retighten.
Front suspension 1. Weakened springs. Replace.

too soft. 2. Not enough fork oil. Refill.
Front suspension 1. Fork oil too viscous. Replace.

too stiff. 2. Too much fork oil. Drain excess oil.
Noisy front 1. Not enough fork oil. Refill.

suspension. 2. Loosen nuts on suspension. Retighten.
Wobbling 1. Distorted wheel rim. Replace.

rear wheel. 2. Worn-down rear wheel bearing. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushing or bearing. Replace.
6. Loosen nut on the rear shock. Retighten.
Rear suspension 1. Weakened springs. Replace.

too soft. 2. Rear suspension adjuster improperly set. Adjust.
Rear suspension 1. Rear suspension adjuster improperly set. Adjust.

too stiff. 2. Worn swing arm bushing or bearing. Replace.
Noisy rear 1. Loosen nuts on suspension. Retighten.

suspension. 2. Worn swing arm bushing or bearing. Replace.
BRAKES
Poor braking 1. Not enough brake fluid in the reservoir. Refill to level mark.
(FRONT and REAR) 2. Air trapped in brake fluid circuit. Bleed air out.
3. Pads worn down. Replace.
4. Too much play on brake lever or pedal. Adjust.
Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace.
power. 2. Worn pads. Replace.
3. Oil adhesion of engaging surface of pads. Clean disk and pads.
4. Worn disk. Replace.
5. Air in hydraulic system. Bleed air.
Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with

sandpaper.
2. Tilted pad. Modify pad fitting.
3. Damaged wheel bearing. Replace.
4. Loosen front-wheel axle or rear-wheel axle. Tighten to specified torque.
5. Worn pads. Replace.
6. Foreign material in brake fluid. Replace brake fluid.
7. Clogged return port of master cylinder. Disassemble and clean
master cylinder.
Excessive brake 1. Air in hydraulic system. Bleed air.

lever stroke. 2. Insufficient brake fluid. Replenish fluid to specified
level ; bleed air.
3. Improper quality of brake fluid. Replace with correct fluid.
Leakage of brake 1. Insufficient tightening of connection joints. Tighten to specified

fluid. torque.
2. Cracked hose. Replace.
3. Worn piston and/or cup. Replace piston and/or cup.
SPECIAL TOOLS
Special tools Part Number Part Name Description Special tools Part Number Part Name Description
09900-20101 09900-21109
Vernier Caliper Torque wrench
Used to conveniently measure various dimensions. Measure torque of tightening.
09900-20201 09900-21304
Micrometer(0~25mm) V-block
Used for precise measurement (00~25mm measure ranges). With using magnetic stand.
09900-20202 09900-22301
Micrometer(25~50mm) Plastigauge
Used for precise measurement (25~50mm measure ranges). Measure clearance of crankshaft thrust.
09900-20203 09900-22401
Micrometer(50~75mm) Small bore gauge
Used for precise measurement (50~75mm measure ranges). Measure inside diameter of conrod small-end.
09900-20508 09900-25002
Cylinder gauge set Pocket tester
Measure inside diameter of cylinder. Measure voltage, electric current, resistance.
09900-20605 09900-26006
Dial calipers Engine tachometer
Meassure width of conrod big-end. Measure rotational frequency of engine.
09900-20606 09900-28107
Dial gauge Electro tester
Meassure oscillation of wheel with using magnetic stand. Inspect ignition coil.
09900-20701 09900-28500
Magnetic stand Battery charger
With using dial gauge. Used to charge the dischared battery.
09900-20806 09910-20115
Thickness gauge Conrod holder
Measure clearance of piston ring. Used to lock the crankshaft.

09910-32812 09913-80112
Crankshaft installer Bearing installer
Used to install the crankshaft in the crankcase. Used to drive bearing in.
09910-34510 09915-63310
Piston pin puller Compression gauge adapter
Use to remove the piston pin. Used with compression gauge.
09913-10760 09915-64510
Fuel level gauge Compression gauge
Measure height of carburetor. Measure cylinder compression.
09913-50121 09915-74510
Oil seal remover Oil pressure gauge
Used to remove the oil seal. Measure oil pressure of 4-stroke engine.
09913-70122 09916-14510
Bearing installer Valve spring compressor
Used to drive bearing in. Used to remove and remounting valve stem.
09913-75520 09916H35C00
Bearing installer Valve spring compressor attachment
Used to drive bearing in. Used with valve spring compressor.
09913-75820 09916HG5100
Bearing installer Valve spring compressor attachment
Used to drive bearing in. Used with valve spring compressor.
09913-75830 09920-13120
Bearing installer Crankcase separater
Used to install rear axle shaft oil seal. Separate to crankcase.
09913-76010 09920-53710
Bearing installer Clutch sleeve hub holder
Used to drive crankshaft bearing in. Used to install or remove clutch sleeve hub nut.
09921-20200 09930-44510
Bearing remover(10mm) Rotor holder
Used to remove oil seal or bearing. Widely used to lock rotary parts such as a flywheel magneto.
09921-20210 09940-10122
Bearing remover(12mm) Clamp wrench
Used to remove oil seal or bearing. A hook wrench to adjust the steering head of motorcycle.
09923-73210 09940-34520
Bearing remover(17mm) T-handle
Used to remove bearing with the rotor remove sliding shaft. Remove and remounting front fork oil cylinder.
09923-74510 09940-34561
Bearing remover(20~35mm) Front fork assembling tool attachment D
Used to remove bearing with the rotor remove sliding shaft. Used with T-handle.
09924-84521 09940-50113
Bearing installer Front fork oil seal installer
Used to drive small bearing in. Install front fork oil seal.
09930-30102 09941-34513
Rotor remove sliding shaft Steering race installer
Used to with bearing remover or rotor remover. Used to install steering outer race.
09930-30162 09941-50111
Rotor remover Wheel bearing remover
Attached to the top of sliding shaft when removing rotor. Used to remove wheel bearing.
09930-30164 09943-74111
Rotor remover Front fork oil level gauge
Attached to the top of sliding shaft when removing rotor. Used to drain the fork oil to the specified level.
09930-40113
Rotor holder
Widely used to lock rotary parts such as a flywheel magneto.

TIGHTENING TORQUE
ENGINE
ITEM N m kg m
Magneto rotor nut 50 ~ 60 5.0 ~ 6.0
Magneto cover bolt 8 ~ 12 0.8 ~ 1.2
Muffler mounting bolt 20 ~ 30 2.0 ~ 3.0
Exhaust pipe nut 18 ~ 28 1.8 ~ 2.8
Starter clutch bolt 15 ~ 20 1.5 ~ 2.0
Cylinder head bolt 7 ~ 11 0.7 ~ 1.1
Cylinder head cover bolt 12 ~ 16 1.2 ~ 1.6
Cylinder head stud bolt 21 ~ 25 2.1 ~ 2.5
Cylinder head base nut 7 ~ 11 0.7 ~ 1.1
Cylinder head base nut 15 ~ 20 1.5 ~ 2.0
Engine sprocket nut 80 ~ 100 8.0 ~ 10.0
Engine oil drain plug 18 ~ 20 1.8 ~ 2.0
Engine mounting bolt 40 ~ 60 4.0 ~ 6.0
Cam chain sprocket bolt 10 ~ 13 1.0 ~ 1.3
Cam chain tensioner bolt 6~8 0.6 ~ 0.8
Cam chain tension adjuster bolt 8 ~ 12 0.8 ~ 1.2
Camshaft sprocket bolt 10 ~ 12 1.0 ~ 1.2
Crankcase bolt 8 ~ 12 0.8 ~ 1.2
Clutch sleeve hub nut 30 ~ 50 3.0 ~ 5.0
Primary drive gear nut 40 ~ 60 4.0 ~ 6.0
Camshaft housing bolt 8 ~ 12 0.8 ~ 1.2
Oil cooler union bolt (M10) 20 ~ 25 2.0 ~ 2.5
Oil cooler union bolt (M12) 20 ~ 25 2.0 ~ 2.5
Spark plug 20 ~ 25 2.0 ~ 2.5
Neutral cam stopper plug 20 ~ 25 2.0 ~ 2.5
CHASSIS
ITEM N m kg m
Rear shock absorber mounting nut (Upper) 40 ~ 60 4.0 ~ 6.0
Rear shock absorber mounting nut (Lower) 40 ~ 60 4.0 ~ 6.0
Rear sprocket nut 20 ~ 30 2.0 ~ 3.0
Rear axle nut 90 ~ 140 9.0 ~ 14.0
Swing arm pivot nut 45 ~ 70 4.5 ~ 7.0
Steering stem nut 80 ~ 100 8.0 ~ 10.0
Steering stem head nut 80 ~ 100 8.0 ~ 10.0
Front and Rear brake disc bolt 18 ~ 28 1.8 ~ 2.8
Front brake master cylinder mounting bolt 5~8 0.5 ~ 0.8
Rear brake master cylinder mounting bolt 18 ~ 28 1.8 ~ 2.8
Front and Rear brake caliper air bleeder valve 6~9 0.6 ~ 0.9
Front and Rear brake caliper mounting bolt 18 ~ 28 1.8 ~ 2.8
Front and Rear brake hose union bolt 20 ~ 25 2.0 ~ 2.5
Front axle bolt 50 ~ 80 5.0 ~ 8.0
Front axle pinch bolt 15 ~ 25 1.5 ~ 2.5
Front fork damper rod bolt 30 ~ 40 3.0 ~ 4.0
Front fork upper clamp bolt 22 ~ 35 2.2 ~ 3.5
Front fork upper bolt 22 ~ 30 2.2 ~ 3.0
Front fork lower clamp bolt 22 ~ 35 2.2 ~ 3.5
Front footrest bolt 22 ~ 35 2.2 ~ 3.5
Handlebar clamp bolt 18 ~ 28 1.8 ~ 2.8
SERVICE DATA
VALVE + GUIDE Unit : mm (in)
ITEM STANDARD LIMIT
Valve diam. IN. 22.0 (0.87)
EX. 19.0 (0.75)
Valve clearance (When cold) IN. 0.1 ~ 0.2 (0.004 ~ 0.008)
EX. 0.2 ~ 0.3 (0.008 ~ 0.012)
Valve guide to valve stem clearance IN. 0.010 ~ 0.037 (0.0004 ~ 0.0015)
EX. 0.030 ~ 0.057 (0.0012 ~ 0.0022)
Valve stem deflection IN. & EX. 0.35 (0.014)
Valve guide I.D. IN. & EX. 4.500 ~ 4.512 (0.1771 ~ 0.1776)
Valve stem O.D. IN. 4.475 ~ 4.490 (0.1762 ~ 0.1768)
EX. 4.455 ~ 4.470 (0.1754 ~ 0.1760)
Valve stem runout IN. & EX. 0.05 (0.002)
Valve head thickness IN. & EX. 0.50 (0.02)
Valve seat width 0.9 ~ 1.1 (0.035 ~ 0.043)
Valve seat angle IN. & EX. 45
Valve head radial runout IN. & EX. 0.03 (0.0012)
Valve spring free length IN. 37.80 (1.488)
EX. 37.80 (1.488)
Valve spring tension 12.1 ~ 13.9kgf (26.7 ~ 30.6 lbs)
IN.
at length 33.7mm (1.33 in)
12.1 ~ 13.9kgf (26.7 ~ 30.6 lbs)
EX.
VALVE + GUIDE Unit : mm (in)

ITEM STANDARD LIMIT
Valve diam. IN. 18.0 (0.71)
EX. 14.5 (0.57)
Valve clearance (When cold) IN. 0.1 ~ 0.2 (0.004 ~ 0.008)
EX. 0.2 ~ 0.3 (0.008 ~ 0.012)
Valve guide to valve stem clearance IN. 0.010 ~ 0.037 (0.0004 ~ 0.0015)
EX. 0.030 ~ 0.057 (0.0012 ~ 0.0022)
Valve stem deflection IN. & EX. 0.35 (0.014)
Valve guide I.D. IN. & EX. 4.000 ~ 4.012 (0.1575 ~ 0.1580)
Valve stem O.D. IN. 3.975 ~ 3.990 (0.1565 ~ 0.1571)
EX. 3.955 ~ 3.970 (0.1557 ~ 0.1563)
Valve stem runout IN. & EX. 0.05 (0.002)
Valve head thickness IN. & EX. 0.50 (0.02)
Valve seat width 0.9 ~ 1.1 (0.035 ~ 0.043)
Valve seat angle IN. & EX. 45
Valve head radial runout IN. & EX. 0.03 (0.0012)
Valve spring free length IN. 37.64 (1.482)
EX. 37.64 (1.482)
Valve spring tension 30 kgf (66.1 lbs)
IN.
30 kgf (66.1 lbs)
EX.
CAMSHAFT + CYLINDER HEAD Unit : mm (in)

ITEM STANDARD LIMIT
Cam height IN. 34.470 ~ 34.510 (1.357 ~ 1.358) 34.170 (1.345)
EX. 34.420 ~ 34.460 (1.355 ~ 1.356) 34.120 (1.343)
Camshaft journal holder I.D. IN. & EX. 35.000 ~ 35.018 (1.378 ~ 1.379)
Cylinder and cylinder head distortion 0.05 (0.002)
Cylinder head cover distortion 0.05 (0.002)
Cam chain pin (Arrow 3 ) 16th pin
CYLINDER + PISTON + PISTON RING Unit : mm (in)

ITEM STANDARD LIMIT
Compression pressure 14~16 kg/cm2 (at 500 rpm) 12 kg/cm2
Piston to cylinder clearance 0.050 ~ 0.060 (0.0020 ~ 0.0024) 0.120 (0.0047)
Cylinder bore 57.000 ~ 57.015 (2.2441 ~ 2.2447) 57.080 (2.2473)
Piston diam. 56.945 ~ 56.960 (2.2419 ~ 2.2425)
(Measure at 15mm (0.6 in) from the skirt end) 56.880 (2.2394)
Cylinder or cylinder head distortion 0.05 (0.002)

Piston ring free end gap 1st 7.2 (0.284) 5.7 (0.224)
2nd 5.8 (0.228) 4.6 (0.181)
Piston ring end gap (Assembly condition) 1st 0.20 ~ 0.32 (0.008 ~ 0.013) 0.5 (0.020)
2nd 0.20 ~ 0.32 (0.008 ~ 0.013) 0.5 (0.020)
Piston ring to groove clearance 1st 0.180 (0.007)
2nd 0.150 (0.006)
Piston ring groove width 1st 1.01 ~ 1.03 (0.040 ~ 0.041)
2nd 1.01 ~ 1.03 (0.040 ~ 0.041)
Oil 2.01 ~ 2.03 (0.079 ~ 0.080)
Piston ring thickness 1st 0.970 ~ 0.990 (0.0382 ~ 0.0390)
2nd 0.970 ~ 0.990 (0.0382 ~ 0.0390)
Piston pin hole bore 15.002 ~ 15.008 (0.5906 ~ 0.5909) 15.030 (0.5917)
Piston pin O.D. 14.994 ~ 15.000 (0.5903 ~ 0.5905) 14.980 (0.5898)
CYLINDER + PISTON + PISTON RING Unit : mm (in)

ITEM STANDARD LIMIT
Compression pressure 11~13 kg/cm2 (at 500 rpm) 10 kg/cm2
Piston to cylinder clearance 0.03 ~ 0.04 (0.0012 ~ 0.0016) 0.1 (0.0040)
Cylinder bore 44.000 ~ 44.015 (1.7323 ~ 1.7329) 44.080 (1.7354)
Piston diam. 43.965 ~ 43.980 (1.7309 ~ 1.7315)
(Measure at 11mm (0.4 in) from the skirt end) 43.890 (1.7280)
Cylinder or cylinder head distortion 0.05 (0.002)

Piston ring free end gap 1st 5.0 (0.197) 4.0 (0.158)
2nd 6.0 (0.236) 4.8 (0.189)
Piston ring end gap (Assembly condition) 1st 0.10 ~ 0.25 (0.004 ~ 0.010) 0.5 (0.020)
2nd 0.25 ~ 0.40 (0.010 ~ 0.016) 0.5 (0.020)
Piston ring to groove clearance 1st 0.180 (0.007)
2nd 0.150 (0.006)
Piston ring groove width 1st 1.01 ~ 1.03 (0.040 ~ 0.041)
2nd 1.01 ~ 1.03 (0.040 ~ 0.041)
Oil 2.01 ~ 2.03 (0.079 ~ 0.080)
Piston ring thickness 1st 0.970 ~ 0.990 (0.0382 ~ 0.0389)
2nd 0.970 ~ 0.990 (0.0382 ~ 0.0389)
Piston pin hole bore 8.9 ~ 9.1 (0.350 ~ 0.358) 13.030 (0.513)
Piston pin O.D. 13.980 (0.550)
CONROD + CRANKSHAFT Unit : mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 15.006 ~ 15.014 (0.5908 ~ 0.5911) 15.040 (0.5921)
Conrod deflection 3.0 (0.12)
Conrod big end side clearance 0.40 ~ 0.85 (0.016 ~ 0.034) 1.0 (0.040)
Conrod big end width 15.95 ~ 16.00 (0.628 ~ 0.630)
Crank web to web width 72 0.1 (2.84 0.004)
Crankshaft runout 0.05 (0.002)
CONROD + CRANKSHAFT Unit : mm (in)

ITEM STANDARD LIMIT
Conrod small end I.D. 13.006 ~ 13.014 (0.5121 ~ 0.5124) 13.040 (0.5134)
Conrod deflection 3.0 (0.12)
Conrod big end side clearance 0.15 ~ 0.40 (0.006 ~ 0.016) 1.0 (0.040)
Conrod big end width 15.95 ~ 16.00 (0.628 ~ 0.630)
Crank web to web width 72 0.1 (2.84 0.004)
Crankshaft runout 0.05 (0.002)
OIL PUMP
ITEM STANDARD NOTE
Oil pressure 2.0 0.5 kg/cm2
(at 65 , 3,000 rpm)
Oil pump reduction ratio 58/19 14/20 = 2.137
OIL PUMP
ITEM STANDARD NOTE
2
Oil pressure 0.9 ~ 1.1 kg/cm
(at 65 , 3,000 rpm)
Oil pump reduction ratio 70/20 14/20 = 2.45
CLUTCH Unit : mm (in)

ITEM STANDARD LIMIT
Clutch cable play 4 (0.16)
Drive plate thickness 2.9 ~ 3.1 (0.114 ~ 0.122) 2.6 (0.102)
Drive plate claw width 11.8 ~ 12.0 (0.465 ~0.472) 11.0 (0.433)
Driven plate distortion 0.1 (0.004)
Clutch spring free length 38.2 (1.50) 36.2 (1.43)
Clutch spring free length 29.5 (1.16)
TRANSMISSION + DRIVE CHAIN Unit : mm (in)

ITEM STANDARD LIMIT
Primary reduction ratio 3.053 (58/19)
Secondary reduction ratio 3.286 (46/14)
Gear ratio 1st 2.462 (32/13)
2nd 1.556 (28/18)
3rd 1.190 (25/21)
4th 0.957 (22/23)
5th 0.840 (21/25)
Shift fork to groove clearance 0.10 ~ 0.30 (0.004 ~ 0.012) 0.5 (0.020)
Shift fork groove width NO.1 & NO.2 5.0 ~ 5.1 (0.197 ~ 0.201)
NO.3 5.0 ~ 5.1 (0.197 ~ 0.201)
Shift fork thickness NO.1 & NO.2 4.8 ~ 4.9 (0.189 ~ 0.193)
NO.3 4.8 ~ 4.9 (0.189 ~ 0.193)
Drive chain Type 520HO
Links 112 LINKS
20-pitch length 317.5 (12.50) 319.4 (12.58)
Drive chain slack 20~30 (0.79 ~ 1.18)
TRANSMISSION + DRIVE CHAIN Unit : mm (in)

ITEM STANDARD LIMIT
Primary reduction ratio 3.000 (70/20)
Secondary reduction ratio 3.714 (52/14)
Gear ratio 1st 2.750 (33/12)
2nd 1.786 (25/14)
3rd 1.350 (27/20)
4th 1.091 (24/22)
5th 0.913 (21/23)
Shift fork to groove clearance 0.10 ~ 0.30 (0.004 ~ 0.012) 0.5 (0.020)
Shift fork groove width NO.1 & NO.2 5.0 ~ 5.1 (0.197 ~ 0.201)
NO.3 5.5 ~ 5.6 (0.217 ~ 0.221)
Shift fork thickness NO.1 & NO.2 4.8 ~ 4.9 (0.189 ~ 0.193)
NO.3 5.3 ~ 5.4 (0.209 ~ 0.213)
Drive chain Type 428SO
Links 136 LINKS
20-pitch length 254.0 (10.00) 256.5 (10.10)
Drive chain slack 20~30 (0.79 ~ 1.18)
CARBURETOR Unit : mm (in)

ITEM SPECIFICATION
Carburetor type MIKUNI BDS26 TYPE(DOUBLE)
Bore size 26
Idle r.p.m. 1,450~1,550 r.p.m.
Float height 17 (0.67)
Throttle cable play 0.5~1.0 (0.02 ~ 0.04)
FRONT REAR
Main jet (M.J.) 92.5 95
Main air jet (M.A.J.) 90 90
Jet needle (J.N.) 2ND 2ND
Needle jet (N.J.) O-3 O-4
Pilot jet (P.J.) 20 20
Throttle valve (TH.V.) 130 130
#1 #2 #3 #4 #1 #2 #3 #4
By-pass (B.P.)
0.9 0.9 0.8 0.8 0.9 0.9 0.8 0.8
Valve seat (V.S.) 1.2 1.2
Starter jet (G.S.) 22.5 22.5
Pilot outlet (P.O.) 0.75 0.75
PV. Stroke (P.V.) STD STD
CARBURETOR Unit : mm (in)

ITEM SPECIFICATION
Carburetor type MIKUNI BDS26 TYPE(DOUBLE)
Bore size 26
Idle r.p.m. 1,450~1,550 r.p.m.
Float height 17 (0.67)
Throttle cable play 0.5~1.0 (0.02 ~ 0.04)
FRONT REAR
Main jet (M.J.) 87.5 90
Main air jet (M.A.J.) 50 50
Jet needle (J.N.) 2ND 2ND
Needle jet (N.J.) O-5 O-4
Pilot jet (P.J.) 15 15
Throttle valve (TH.V.) 130 130
#1 #2 #3 #4 #1 #2 #3 #4
By-pass (B.P.)
0.9 0.9 0.8 0.8 0.9 0.9 0.8 0.8
Valve seat (V.S.) 1.2 1.2
Starter jet (G.S.) 20 20
Pilot outlet (P.O.) 0.75 0.75
PV. Stroke (P.V.) STD STD
ELECTRICAL Unit : mm (in)

ITEM STANDARD NOTE
Ignition timing 15 /2,000rpm ~ 30 /6,000rpm
Type CR8E
Gap 0.7~0.8 (0.028 ~ 0.032)
Spark plug Hot type CR7E
Standard type CR8E
Cold type CR9E
Spark performance Over 8mm (0.32)
Ignition coil resistance Primary 0.19 ~ 0.24
Secondary 5.4 ~ 6.6
Magneto coil resistance Pick-up coil 90 ~ 110 G-L
Charging coil 0.6 ~ 0.9 Y-Y
Magneto no-load voltage 67 ~ 99V/5,000 rpm
Battery standard charging voltage 14 ~ 15V/5,000 rpm
Battery Type STX14A-BS
Capacity 12V 12Ah
Fuse size 15A
WATTAGE Unit : W
ITEM SPECIFICATION
Head lamp HI 60W
LO 55W
Head lamp HI 35W
LO 35W
License lamp 5W
Brake/Tail lamp 21/5W
Turn signal lamp 10W
Speedometer lamp 1.7W 3
Neutral indicator lamp 1.7W
Turn signal indicator lamp (Right & left) 1.7W 2
High beam indicator lamp 1.7W
CAUTION
Do not use except the specified bulb (Wattage).
SUSPENSION Unit : mm (in)

ITEM STANDARD LIMIT
Front fork stroke 120 (4.27)
Front fork spring free length 433.3 (17.1)
Front fork oil type TELLUS #22
Front fork oil level 146 (5.8)
Front fork oil capacity (each leg) 400 2.5cc
Rear wheel travel 110 (4.33)
Swingarm pivot shaft runout 0.6 (0.024)
Rear shock absorber pre-load position 2 / 5 position
Rear shock absorber spring length 179.2 (7.07) 175 (6.89)
SUSPENSION Unit : mm (in)

ITEM STANDARD LIMIT
Front fork stroke 120 (4.72)
Front fork spring free length 361 (14.2) 354 (13.9)
Front fork oil type TELLUS #22
Front fork oil level 155 (6.1)
Front fork oil capacity (each leg) 262cc
Rear wheel travel 110 (4.33)
Swingarm pivot shaft runout 0.6 (0.024)
Rear shock absorber pre-load position 2 / 5 position
Rear shock absorber spring length 179.2 (7.07) 175 (6.89)
TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
SOLO RIDING DUAL RIDING
TIRE PRESSURE
kPa psi kPa psi
FRONT 196 2.00 29.0 196 2.00 29.0
REAR 221 2.25 32.0 245 2.50 36.0
BRAKE+WHEEL Unit : mm (in)

ITEM STANDARD LIMIT
Rear brake pedal height 290 (11.4) [when one person riding from the ground]
Brake disc thickness Front 4.0 (0.16) 3.0 (0.12)
Rear 4.3 (0.17) 3.0 (0.12)
Brake disc runout Front Rear 0.3 (0.012)
Master cylinder bore Front Rear 12.700 ~ 12.743 (0.5000 ~ 0.5017)
Master cylinder piston diam. Front Rear 12.657 ~ 12.684 (0.4983 ~ 0.4994)
Brake caliper cylinder bore Front Rear 25.4 (1.00)
Brake caliper piston diam Front Rear 25.4 (1.00)
Brake fluid type DOT3 or DOT4
Wheel runout Axial 2.0 (0.08)
Radial 2.0 (0.08)
Wheel axle runout Front 0.25 (0.01)
Rear 0.25 (0.01)
Wheel rim size Front J17 MT3.00
Rear J17 MT4.00
Tire tread depth Front 4.6 (0.18) 1.6 (0.06)
Rear 6.3 (0.25) 1.6 (0.06)
FUEL + OIL
ITEM SPECIFICATION NOTE
Fuel type Gasoline used should be graded 85~95 octane or higher.
An unleaded gasoline is recommened.
Fuel tank capacity Including reserve 17
Reserve 3
Engine oil type API Over SG (SAE 10W/30 or 10W/40)
Engine oil capacity Change 1,450
Filter change 1,500
Overhaul 1,800
Engine oil capacity Change 1,450
Filter change 1,500
Overhaul 1,650
WIRE AND CABLE ROUTING
HEAD LAMP RELAY

TURN SIGLAL RELAY FUSE BOX
09407-22402
HARNESS
STARTER RELAY
45280-35000
09407-22402 CABLE COMP. SEAT LOCK
BATTERY PLUS HARNESS
09407-22402
HARNESS
REAR BRAKE S/W
WELDING CLAMP C.D.I UNIT

L/WIRE STARTER MOTOR REGULATOR
BATTERY MINUS
BATTERY MINUS
ENGINE EARTH
ASSEMBLY POINT
Rr. SPARK PLUG CAP
09407-22402
FT. SPARK PLUG CAP HARNESS
DIODE
09407-22402
HANDLE S/W RH
HARNESS
58300HM8102
CABLE ASS Y THROTTLE
09407-14408
HARNESS
HANDLE S/W R.L
HANDLE S/W LH
CLUTCH LEVER S/W
58200HM8101
CABLE ASS Y. 58410HM8102
CABLE COMP. STARTER
CLUTCH
09407-14408
HARNESS
FUSE BOX
09407-14403
HANDLE SWITCH(RH) ASSEMBLY POINT
HANDLE SWITCH(LH)
09407-14408 09407-14408
HANDLE SWITCH(RH) SWITCH, CLUTCH LEVER(LH) HARNESS HARNESS
HEAD LAMP RELAY
09407-14408
09407-14408 TURNSIGNAL RELAY
HARNESS
L/WIRE STEERING LOCK HARNESS
Ft, IGNITION C.D.I UNTT
HANDLE SWITCH R,L L/WIRE FUEL
L/WIRE, SPEEDOMETER CLUTCH LEVER SWITCH GAUGE
DIODE
REGULATOR
Rr. IGNITION COIL STARTER MOTOR RELAY (RH)

WELDING CLAMP
MAGNOTO
NEUTRAL S/W
A OIL COOLER
HOSE LH MAGNETO
WELDING CLAMP NEUTRAL SWITCH
WELDING CLAMP
SIDE STAND SWITCH
HORN
HORN COVER
HORN
09494-06401
DRAIN HOSE
WELDING CLAMP SIDE STAND S/W
WELDING CLAMP
34910HM8101
5948HM8102
CABLE, SPEED
HOSE, FRONT BRAKE
59266HM2901
GUIDE, SPEEDOMETER CABLE
CLUTCH LEVER S/W
HANDLE S/W LH
HANDLE S/W RH
HARNESS 58410HM 8102

CABLE COMP. SPEEDOMETER
59266HM8100
CLAMP, BRAKE HOSE &
SPEEDOMETER CABLE
59480HM8102
HOSE COMP. FRONT
BRAKE
FRONT IGNITION COIL VIEW A

58300HM8102
BATTERY MINUS CABLE ASS Y THROTTLE
58410HM8102
CABLE COMP. STARTER
58200HM8101
CABLE ASS Y CLUTCH
09403H09304
CLUTCH CABLE
L/WIRE, STARTER MOTOR WELDING CLAMP
L/WIRE STARTER MOTOR
REAR BRAKE WELDING CLAMP
BATTERY MINUS
Rr. BARKE S/W OIL COOLER HOSE RH
REAR BRAKE S/W
09404-06401
STARTER MOTOR
09404-06401 09404-06401
L/WIRE STARTER MOTOR L/WIRE STARTER MOTOR
WIRE AND CABLE ROUTING
FUSE BOX
TURN SIGLAL REALY
BATTERY PLUS STARTER RELAY 09407-14408
HARNESS
09407-14408 45280-35000
09407-14408 HARNESS CABLE COMP. SEAT LOCK
HARNESS
REAR BRAKE S/W

WELDING CLAMP
L/WIRE STARTER MOTOR C.D.I UNIT
BATTERY MINUS
FUEL GAUGE REGULATOR

Rr. SPARK PLUG CAP
ENGINE EARTH
BATTERY MINUS
FT. SPARK PLUG CAP
ASSEMBLY POINT
09407-14408
HARNESS
HANDLE S/W RH
DIODE
09407-14408
HARNESS
58300HM8102
09407-14408
HARNESS
HANDLE S/W R,L
HANDLE S/W LH
58410HM8102
58200HM8101
CABLE COMP. STARTER
CABLE ASS Y.
CLUTCH CLUTCH LEVER S/W
09407-14403
HANDLE SWITCH(RH) HANDLE SWITCH(RH)
L/WIRE STEERING LOCK
HANDLE SWITCH(LH)
L/WIRE, SPEEDOMETER
SWITCH, CLUTCH LEVER(LH)

09407-14408
HARNESS
09407-14408
Ft, IGNITION HARNESS FUSE BOX
HANDLE SWITCH R,L TURNSIGNAL RELAY
CLUTCH LEVER SWITCH L/WIRE FUEL 09407-14408
09407-14408 GAUGE HARESS
HARNESS 09407-14408 ASSEMBLY POINT
HARNESS
DIODE C.D.I UNTT
B
5948HM8102 Rr. IGNITION COIL
HOSE, FRONT BRAKE
WELDING CLAMP
MAGNETO REGULATOR
STARTER MOTOR RELAY (RH)
WELDING CLAMP
SIDE STAND SWITCH
NEUTRAL SWITCH
HORN
WELDING CLAMP
MAGNOTO
HORN COVER
NEUTRAL S/W
HORN
WELDING CLAMP
34910HM8101 09494-06401 DRAIN HOSE WELDING CLAMP
CABLE, SPEED
59266HM2901 SIDE STAND S/W
GUIDE, SPEEDOMETER CABLE
CLUTCH LEVER S/W
HANDLE S/W LH
HANDLE S/W RH
HARNESS
58410HM 8102
CABLE COMP. SPEEDOMETER
59266HM8100
CLAMP, BRAKE HOSE &
SPEEDOMTTER CABLE
59480HM8102
HOSE COMP. FRONT
BRAKE
FRONT IGNITION COIL VIEW B

58300HM8102
WELDING CLAMP
BATTERY MINUS
Rr. BARKE S/W
BATTERY MINUS
58410HM8102
CABLE COMP. STARTER
L/WIRE, STARTER MOTOR
58200HM8101
CABLE ASS Y CLUTCH
09403H09304
CLUTCH CABLE
REAR BRAKE
WELDING CLAMP
OIL COOLER HOSE RH
REAR BRAKE S/W
09404-06401
STARTER MOTOR
09404-06401 09404-06401
L/WIRE STARTER MOTOR L/WIRE STARTER MOTOR
SPEEEEDOMETER HANDLE SWITCH RH Ft. IGNITON COIL Rr. IGNITION COIL
FUEL PUMP RELAY FUEL GAUGE
C.D.I UNIT REGULATOR SPARK PLUG SPARK PLUG
Rr. BRAKE S/W TURN SIG. RELAY
FUEL PUMP
WIRING DIAGRAM
HORN
Rr. TURN RH
Ft. TURN RH
LICENSE LAMP
HEAD LAMP
TAIL & STOP
Ft. POSITION
FUSE BOX
Rr. TURN LH
Rr. TURN LH
START RELAY
BATTERY(MF)
ENGINE EARTH
START
SIDE STAND MOTOR
HANDLE SWITCH LH MAGNETO DIODE S/W CLUTCH LEVER S/W
NEUTRAL S/W
IGNITION S/W
WIRE COLOR
B : Black Lg : Light green Y : Yellow RB : Red with Black tracer
Br : Brown O : Orange BG : Black with Green tracer RW : Red with White tracer
G : Green R : Red BW : Black with White tracer WB : White with Black tracer
Gr : Gray Sb : Light blue BR : Black with Red tracer WR : White with Red tracer
L : Blue W : White LW : Blue with White tracer YB : Yellow with Black tracer
Ft. IGNITON COIL Rr. IGNITION COIL
SPEEEEDOMETER SPARK PLUG SPARK PLUG
HANDLE SWITCH RH
FUEL GAUGE Rr. BRAKE S/W C.D.I UNIT REGULATOR TURN SIG. RELAY
HORN WIRING DIAGRAM
Rr. TURN RH
Ft. TURN RH
LICENSE LAMP
HEAD LAMP
TAIL & STOP
POSITION LAMP
FUSE BOX
Rr. TURN LH
Rr. TURN LH
START RELAY
BATTERY(MF)
ENGINE EARTH
START MOTOR
SIDE STAND
HANDLE SWITCH LH S/W
MAGNETO NEUTRAL S/W
IGNITION S/W CLUTCH LEVER S/W
DIODE
WIRE COLOR
B : Black Lg : Light green Y : Yellow RB : Red with Black tracer
Br : Brown O : Orange BG : Black with Green tracer RW : Red with White tracer
G : Green R : Red BW : Black with White tracer WB : White with Black tracer
Gr : Gray Sb : Light blue BR : Black with Red tracer WR : White with Red tracer
L : Blue W : White LW : Blue with White tracer YB : Yellow with Black tracer
TAPPET SHIM SELECTION CHART (IN.)
SHIM No. 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
MEASURING SHIM THICKNESS
TAPPET AT PRESENT
(mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
CLEARANCE (mm)
0.00-0.04 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.10-0.20 Specified clearance - Adjustment unnecessary
0.21-0.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.26-0.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.31-0.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.36-0.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.61-0.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
HOW TO USE THE CHART
1. Measure the tappet clearance.(When cold)
0.71-0.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
2. Measure the shim thickness at present.
0.76-0.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 3. Look for meeting space in that horizontal line
0.81-0.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 for thickness and vertical line for clearance.
0.86-0.90 1.95 2.00 2.05 2.10 2.15 2.20
(EXAMPLE)
0.91-0.95 2.00 2.05 2.10 2.15 2.20 When the tappet clearance is 0.23mm and the
0.96-1.00 2.05 2.10 2.15 2.20 shim thickness at present is 1.70mm, the shim
1.01-1.05 2.10 2.15 2.20 thickness should be used 1.80mm.
1.06-1.10 2.15 2.20
1.11-1.15 2.20 HYOSUNG MOTORS & MACHINERY INC.
TAPPET SHIM SELECTION CHART (EX.)
SHIM No. 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
MEASURING SHIM THICKNESS

TAPPET AT PRESENT 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
(mm)
CLEARANCE (mm)
0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
0.10-0.14 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.15-0.19 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.20-0.30 Specified clearance - Adjustment unnecessary
0.31-0.35 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.36-0.40 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.61-0.65 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 HOW TO USE THE CHART
0.76-0.80 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 1. Measure the tappet clearance.(When cold)
0.81-0.85 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2. Measure the shim thickness at present.
3. Look for meeting space in that horizontal line
0.86-0.90 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
for thickness and vertical line for clearance.
0.91-0.95 1.90 1.95 2.00 2.05 2.10 2.15 2.20
(EXAMPLE)
0.96-1.00 1.95 2.00 2.05 2.10 2.15 2.20
When the tappet clearance is 0.33mm and the
1.01-1.05 2.00 2.05 2.10 2.15 2.20
shim thickness at present is 1.70mm, the shim
1.06-1.10 2.05 2.10 2.15 2.20 thickness should be used 1.80mm.
1.11-1.15 2.10 2.15 2.20
1.16-1.20 2.15 2.20
1.21-1.25 2.20 HYOSUNG MOTORS & MACHINERY INC.
Prepared by

Overseas Technical Department
1st Ed. NOV. 2002.
Manual No. 99000-94710

Printed in Korea

Hyosung GT125 & GT250 Workshop Manual

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HYOSUNG MOTORS & MACHINERY INC.

This manual contains an introductory description on

HYOSUNG MOTORS & MACHINERY INC.

COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2002.

Example: Front wheel

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply oil. Use engine oil unless otherwise

Apply SUPER GREASE A . Measure in voltage range.

Apply SUPER GREASE C . Measure in resistance range.

Apply SILICONE GREASE. Measure in current range.

Apply MOLY PASTE. Use special tool.

Apply BOND 1215 .

INFORMATION LABELS 1-1

GENERAL PRECAUTIONS 1-1

FUEL AND OIL RECOMMENDATIONS 1-4

BREAK-IN PROCEDURES 1-5

EXTERIOR ILLUSTRATION 1-6

WARNING / CAUTION / NOTE

SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

FUEL AND OIL RECOMMENDATION

If an SAE 10W/30 or 10W/40 motor oil is not available,

Use a premium quality 4-stroke motor oil to ensure

FRONT FORK OIL

Initial 800km Less than 1/2 throttle

DIMENSIONS AND DRY MASS

Overall length 2,080 mm (81.9 in)

Type Four-stroke, DOHC, air-cooled and oil-cooled

Clutch Wet multi-plate type

Front suspension Telescopic type

Ignition type CDI type

Fuel tank 17.0

PERIODIC MAINTENANCE SCHEDULE 2- 1 2

EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS 2- 5

DRIVE CHAIN 2-11

COMPRESSION PRESSURE 2-19

OIL PRESSURE 2-20

PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE CHART

Clutch lever holder Front brake lever holder

The valve clearance specification is different for

Rotate the magneto rotor to set the front cylinder s

To inspect the front cylinder s valve clearance, insert

Valve clearance (when cold)

Thickness gauge : 09900-20806

If the clearance is out of specification, first remove the

Select the tappet that agree with tappet clearance

Adjust valve timing, install the camshaft housing and the

Rotate the magneto rotor to set the rear cylinder s

Inspect the rear cylinder s valve clearance with the

Disconnect the spark plug caps.

TYPE SPARK PLUG SPECIFICATION

Remove the carbon deposite with wire or pin and adjust

Thickness gauge : 09900-20806

Check to see the worn or burnt condition of the elec-

EXHAUSE PIPE NUTS AND MUFFLER

Tighten the exhaust pipe nuts , and muffler mount-

Exhaust pipe nut