Daelim B-Bone 125cc Service Manual 27MB

SM57-0902-01E
Contents
To ensure safety and optimal operating conditions of the

vehicle, carry out regular inspections according to the
maintenance schedule(Section 2).
Sections 1 through 2 provide information on overall
vehicle; section 3, assembly and disassembly procedures
for external components, and section 4 describes
maintenance procedure for the engine, frame and
electrical systems.
To facilitate use of this manual, each page starts with
disassembly and system diagrams, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide.
Engine
This manual explains how to maintain procedure for the

SN125 manufactured by DAELIM MOTOR CO., LTD.
General
How to use this manual
Electrical
Frame
Contents of this manual and specifications are subject

to change without prior notice for improvement of
vehicle quality.
No part of this publication may be reproduced without
written permission of DAELIM Motor Co.,Ltd.,
Service Information
Inspections / Adjustments
External Parts
Lubrication System
EMS(Engine Management System)
Fuel System
Engine Removal / Installation
LH, Crank Case Cover

Continuously Variable
Transmission
A.C Generator / Starter Clutch
Cylinder Head / Valves
10
Cylinder Head / Piston
11
Transmission / Crank Shaft

Crank Case
12
Front Wheel / Front Fork

/ Steering
13
Rear Wheel / Suspension /

Rear Swing Arm
14
Brake System
15
Charging System
16
Ignition System
17
Starter System
18
Lights / Switches / Horn
19
Wiring diagram(Euro2,Euro3)
20
SERVICE INFORMATION
1. SERVICE INFORMATION
SERIAL NUMBER LOCATION 1-1
1-2
SPECIFICATIONS
1-4
TORQUE VALUES
1-5
STANDARD TORQUE VALUES
1-5
SYMBOLS/ABBREVIATIONS
WIRING DIAGRAM
GENERAL SAFETY
SERVICE RULES
CAUTION WHEN WIRING
1-6
1-10
1-10
1-14
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
FRAME SERIAL NUMBER LOCATION
1-1
SERVICE INFORMATION
1,910mm
750mm
1,090mm
1,360mm
755mm
126mm
130kg
277kg
60
2.00
2.25
7.1 (6.8 )
1.2
25
90mm
80
90/70
stroke SOHC
1.0
1.05
13.8
ATDC
"( )" MARKED CONTENTS APPLY TO EURO 2 ONLY
1-2
380
SERVICE INFORMATION
ITEM
SPECIFICATIONS
TYPE / VENTURI BORE

MODEL MARK
CHOKE TYPE
MAIN JET
PILOT SCREW INITIAL SETTING
FLOAT LEVEL
IDLE SPEED
CV type ( vacuum ) / '24.2 mm

CVK
Auto-bystarter
# 95
2
17 mm
1.700100 rpm
DRIVE TRAIN
CLUTCH TYPE
PRIMARY REDUCTION
SECONDARY REDUCTION
Automatic Transmission
3.000
2.786
ELECTRICAL
SYSTEM
IGNITION SYSTEM
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT ( HIGH / LOW )
POSITION LIGHT
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEAM PILOT
WINKER PILOT
METER LIGHTS
LICENSE LAMP
ECU (C.D.I)
Closed type (MF) 12V 10AH
CR8EH -9 (NGK)
0.8 - 0.9 mm
15A, 30A (15A)
Starter motor
12V 55W / 12V 55W
12V 5W
12V 10W4
12V 21 / 5W
LED
LED
LED
12V 5W
(CARBURETOR)
( )MARKED CONTENTS APPLY TO EURO2 ONLY
1-3
SERVICE INFORMATION
1-4
SERVICE INFORMATION
1-5
SERVICE INFORMATION
1-6
SERVICE INFORMATION
1-7
SERVICE INFORMATION
1-8
SERVICE INFORMATION
1-9
SERVICE INFORMATION
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other workers action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or
recommended parts.
2. Before maintenance, remove deposit or dust from the

chasis.
3. Store the parts of each system discriminatively to install

each part in the right place.
4. After removing gasket, O-ring, piston pin clip and cotter

pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
1-10
SERVICE INFORMATION
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.
6. Check necessary place and measure necessary data

during installation. When installing, return to the state
before removing.
7. Align the bolts to uniform the tightening points before

tightening them when you dont know the bolt length.
8. Bolts, nuts and pieces must be tightened from the bigger

diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
9. Check to see if the rubber part is worn out when

removing it and replace it if necessary. Some rubber part
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
10. Recommended grease must be applied to or filled in

the specified place.
11. Maintenance needed to use the specialized tools must

performed with the right tool.
12. Never reuse the ball bearing removed with the ball
applied pressure when removing press-fitted the
bearing.
1-11
SERVICE INFORMATION
13. Check the smooth rotation of inner or outer race of the
ball bearing by rotating it manually.
Replace the ball bearing having excessive axial/
longitudinal hanging.
Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball
bearing)
Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
14. Pay attention to installation direction in case of the

single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way
that the face marked with manufacturer and size
should direct to the outer axle.
SINGLE-SEALED TYPE DOUBLE-SEALED TYPE
OPEN TYPE
15. When blowing the ball bearing with compressed air

after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.
MANUFACTURERS NAME, BEARING No.
16. Install the snap ring so that chamfered side directs to

the load-applied side. After installation, check the
proper installation by rotating the snap ring.
SNAP RING
CHAMFERED EDGE
17. Check each part for proper tightening and operation

after installation.
18. The brake fluid and coolant can damage the painted
plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
19. Install the oil seal so that the manufacturer marked

surface directs outer surface.(direction not covered
with oil)
Pay attention not to bend or damage the lip
Apply the grease to the lip
20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.
CAVITY
MANUFACTURERS NAME
CLIP
FITTING
1-12
SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine
interior from the infiltration of dust.
22. Install the gasket mounted in the contact surface of

each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively.

Transformed or damaged cable may cause malfunction
or damage.
24. Install the boots with the installing groove by inserting

the boots into the groove.
BOOTS
1-13
SERVICE INFORMATION
CAUTION WHEN WIRING

Each cord must be connected depending on its color.
When connecting different cord, attach color tube
around the connector. Connect the coupler to the
connector with same color and same pin number.
Identify the two-colored cord by main color first and
then striped color .
BLACK TUBE
WHITE
TUBE
When measuring voltage or resistance of the cord

terminal using tester, contact the tester plug behind of
the coupler. Pay attention not to open the cord terminal
and contact the tester plug from the front of the coupler
in case of water-proof coupler.
RED STRIPE
TESTER PLUG
WHITE
COUPLER.
WHITE
RED STRIPE
BLACK CORD
Recheck the condition of contact, securing and

continuity of each part after maintenance.
When connecting the battery, the plus terminal must be
connected first.
After connecting the terminal, apply the grease to the
terminal.
WHITE / RED CORD
When disconnecting the battery, the minus terminal

must be disconnected first.
Make sure that the tool such as spanner do not contact
with the frame.
Connect covers to the terminal after maintenance.
If the fuse is short-circuited, find out the cause and

repair. Replace with the fuse having the specified
capacity.
If there is rust in the terminal, remove the rust with sand

paper prior to connecting.
VALIDATION
OF CAPACITY!
1-14
REMOVE
THE
RUST!
SERVICE INFORMATION
Turn off the main switch before connecting/disconnecting.
Release the lock to disconnect the lock of the coupler.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
When disconnecting the coupler, disconnect it while

holding the coupler body. Pull while holding the wire
harness cord and do not remove the coupler connection.
Insert the lock of the coupler until the lock is fully

secured.
Release the lock by inserting the coupler slightly and

then narrowing connection to remove the coupler.
Pay attention not to damage the vinyl cover of the

coupler.
Check to see if there is bended terminal and secure it to

avoid disconnecting.
If the wire harness coating is damaged, repair by

winding vinyl tape or replace it.
Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.
1-15
SERVICE INFORMATION
Insert the connector until the vinyl cover is fully inserted
into the terminal.
The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.
DRAINING HOLE
When removing T-start, broaden the groove of T-start

using the wiring driver and release the torque.
Connect the harness and the hose to T-start and then
insert until the groove is locked.
When removing T-start from the frame, replace it with
the new one.
WIRING DRIVER
GROOVE SIDE
Wire band must be secured firmly in the specified

location of the frame. In case of aluminium band, secure
the wire harness to the coated part.
Secure the wire harness firmly using the clamp.
In case of the weld clamp, do not clamp in the welded

part.
When clamping the wire harness, make sure that the

harness is not contacted with the shaft or rotating part.
When clamping the wire, pay attention not to contact

with hot part.
The wire harness must be routed without contacting

with the end of the lamp or any sharp edge.
The wire harness must be routed without contacting
with the end of the bolt or the piece.
1-16
SERVICE INFORMATION
In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape.
The wire must not hang down or be pulled excessively.
NOT TO
PULL!
If necessary, lock the wire harness properly.
When mounting parts, make sure that the wire harness

is not pressed by the parts.
Do not twist the wire harness.
Wire the wire harness not to be pulled or expanded

when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
Prior to using the tester, please read the manual carefully and understand the contents.
When testing the resistance of the tester, the zero
adjustment must be performed before testing.
Do not drop or throw the parts especially semiconductor

contained parts because these parts may be damaged by
the impact of the drop.
Is this
measurement range or
configuration in accord
with the manual?
1-17
MEMO
INSPECTIONS/ADJUSTMENTS
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1
MAINTENANCE SCHEDULE 2-3
FUEL LINE 2-4
THROTTLE GRIP OPERATION 2-4
AIR CLEANER 2-5
SPARK PLUG 2-5
VALVE CLEARANCE 2-6
CYLINDER COMPRESSION
RESSURE 2-6
CARBURETOR IDLE SPEED 2-7
TRANSMISSION OIL 2-7
ENGINE OIL 2-7

DRIVE BELT 2-7
BRAKE FLUID 2-8
BRAKE PAD 2-8
BRAKE SYSTEM 2-8
SIDE STAND 2-9
SUSPENSION 2-9
BOLTS, NUTS, FASTENERS 2-10
WHEELS/TIRES 2-10
STEERING STEM 2-10
LUBRICATION POINTS 2-11
2-1
2-2
2-3
FUEL
FUEL
TUBE
FUELTUBE
TUBE
FUEL
PUMP
FUEL
FUELPUMP
PUMP
FUEL
PUMP
THROTTLE
THROTTLEGRIP
GRIP
THROTTLE
GRIP
FREE
FREE
PLAY
FREEPLAY
PLAY
THROTTLE
THROTTLE
CABLE
THROTTLECABLE
CABLE
LOCK
NUT
LOCK
LOCKNUT
NUT
CARBURETOR
CARBURETOR
CARBURETOR
ADJUST
NUT
ADJUST
ADJUSTNUT
NUT
THROTTLECABLE
CABLE
THROTTLE
CABLE
THROTTLE
RUBBER
RUBBER
RUBBER
RUBBER
LOCK
LOCK
NUT
LOCK NUT
NUT
2-4
ADJUST
NUT
ADJUST
ADJUSTNUT
NUT
ADJUST
NUT
AIR
AIR
CLENER
AIRCLENER
CLENER
AIR
AIR
CLEANER
ELEMENT
AIRCLEANER
CLEANERELEMENT
ELEMENT
Check the element, if it is dirty or damaged replace it.
The air cleaner element made of dry process paper

filter.
Do not clean by compressed air blowing.
CHECK GAP,
DEPOSITS
0.8 ~ 0.9mm
Remove the spark plug maintenance cover.
CHECK WASHER
FOR DAMAGE
CHECK FOR
CRACKS
SPECIAL
BOLT
SPECIAL
SPECIALBOLT
BOLT
SPECIAL
BOLT
CYLINDER
CYLINDER
HEAD
COVER
CYLINDERHEAD
HEADCOVER
COVER
Hand-tighten the spark plug before using a wrench to

tighten to the specified torque.
SPARK
SPARK
PLUG
CAP
SPARKPLUG
PLUGCAP
CAP
2-5
TIMINCT
TIMINCT HOlLE
HOlLE CAP
CAP
TIMINCT
HOlLE
CAP
COOLING
COOLING
FAN
COOLING FAN
FAN
- Floor panel ass'y.

Loosen the 4 cylinder head bolts.
fan cover.
Remove the shroud B grommet of the timit hoile cap
on the RH. shroud.
ADJUST
WRENCH
ADJUST WRENCH
WRENCH
ADJUST
ADJUST
WRENCH
FEELER
FEELER
GAUGE
FEELER GAUGE
GAUGE
TAPPET
TAPPET
ADJUST
SCREW
TAPPET ADJUST
ADJUST SCREW
SCREW
SPARK
PLUG
CAP
SPARK
SPARK PLUG
PLUG CAP
CAP
CYLINDER
HEAD
CYLINDER
CYLINDER HEAD
HEAD
spark plug maintenance.
COMPRESSION
GAUGE
COMPRESSION
COMPRESSION GAUGE
GAUGE
COMPRESSION
GAUGE
CYLINDER
HEAD
CYLINDER
CYLINDER HEAD
HEAD
CYLINDER
2-6
PILOT
PILOT
SCREW
PILOTSCREW
SCREW
CARBURATOR IDLE SPEED

Erect the motorcycle on the mainstand.
Remove the rear fender, center cover.
Verify all engine adjustments satisfy specifications.
Make adjustment, If necessary.
Heat the engine to make accurate idling inspection and
adjustment.
Turn the throttle stop screw and make adjustments to
prescribed idling speed.
100RPM
IDLE SPEED : 1,700
THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW
Do not over adjustment the pilot screw. it could be

effect to starting. (refer to page 6-9)
TRANSMISSION OIL
INSPECTOIN
Remove the LH. crank case. (-> 8-2)
Remove the bolt and check the oil on oil check hole.
If the oil level is low(80W/90), add the oil.
Install oil check bolt.
OIL
CHECK
HOLE
OIL
OILCHECK
CHECKHOLE
HOLE
OIL
CHECK
HOLE
Make sure that the oil sealing washer is good

condition.
Erect the motorcycle on the main stand.
ENGINE OIL
OIL
OIL
SIGHT
GLASS
OILSIGHT
SIGHTGLASS
GLASS
INSPECTOIN
Start the engine and let it be warm fully.
Stop the engine. check the oil level line of the LH.
crank case cover oil sight glass.
It is good if the oil surface is between the lower level
line and upper that of the sight glass. If the oil level is
near the lower level line or below that, full to the
upper level line with the recommended oil.
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER
DRAIN
DRAIN
PLUG
BOLT
DRAINPLUG
PLUGBOLT
BOLT
DRIVE
FACE
DRIVE
DRIVEFACE
FACE
TAPPET
ADJUSTING
HOLE
CAP
TAPPET
TAPPETADJUSTING
ADJUSTINGHOLE
HOLECAP
CAP
TAPPET
ADJUSTING
HOLE
CAP
DRIVE
BELT
DRIVE
DRIVEBELT
BELT
DRIVE
BELT
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
Erect the motorcycle on the main stand.
DRIVE BELT
Remove the LH. crankcase cover.
Check the drive belt for wear or damage.
Check schedule maintenance period, replace the new
drive belt if possible.
2-7
BRAKE FLUID
MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER
Check the oil level inside the front brake reservoir.

If the oil level is near the lower limit line, remove
the reservoir diaphrag mand fill DOT3 and DOT 4
brake fluid to the top limit line.
If the brake fluid reaches the lower limit line, check
the entire brake system for leaks.
CHECK
CHECK
GLASS
CHECKGLASS
GLASS
If the brake pad is worn severely brake fluid level

can be down.
BRAKE PAD
BRAKE PAD REPLACEMENT
ROD MARK
ROD MARK
BRAKE PAD
BRAKE PAD
DUBLE
DUBLE
BRAKE
HOSE
DUBLE BRAKE
BRAKE HOSE
HOSE
REAR
REAR
BRAKE
HOSE
REAR BRAKE
BRAKE HOSE
HOSE
Check the brake pads for wear.

If the rod mark on the pad reaches the brake
disc, replace the pads.
BRAKE SYSTEM
Check the front brake hose for cracks or damage.
If any leaks are found,replace immediately
FRONT
FRONT
CALLIPER
FRONT CALLIPER
CALLIPER
REAR
CALIPER
REAR
REAR CALIPER
CALIPER
REAR
CALIPER
FRONT
FRONT
BRAKE
HOSE
FRONT BRAKE
BRAKE HOSE
HOSE
BRAKE LEVER FREE PLAY
BRAKE
BRAKE
LEVER
BRAKE LEVER
LEVER
Check the free play after pulling the lever.

FREE
PLAY
FREE
FREEPLAY
PLAY
FREE
PLAY
2-8
FRONT:10~20mm
REAR:10~20mm
GREASE
GREASE
GREASE
SIDE
SIDE
STAND
SIDE STAND
STAND
SIDE
SIDE STAND
STAND SWITCH
SWITCH
SIDE
STAND
SWITCH
SIDE
SIDE
STAND
SIDE STAND
STAND
2-9
STANDARD PRESSURE
TIRE
TIRE
PRESSURE
GANGE
GAUGE
TIREPRESSURE
PRESSUREGANGE
GANGE
ITEM
FRONT WHEEL REAR WHEEL
DRIVER ONLY
2.00(29
2.00(29 psi)
1.78 psi)
DRIVER AND A PASSENGER
2.25(32
2.25(32 psi)
2.29 psi)
STEERING STEM
2-10
LUBRICATION POINTS
Use general grease unless specified here.
Apply oil or grease to the other sliding surfaces not shown here.
CONTROL CABLE LUBRICATION

Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning.
Change it when the cable lengthened.
RR. BRAKE LEVER PIVOT
THROTTLE GRIP
STEERING HEAD BEARING
WHEEL BEARING / SPEDOMETER GEAR

MAIN / SIDE STAND PIVOT
WHEEL BEARING
2-11
MEMO
EXTERNAL PARTS
SEAT SUPPORT PIPE 3-6
3-2
INNER BOX 3-3
FRONT COVER 3-3
FRONT FENDER3-4
FRONT UNDER COVER 3-4
SEAT3-5
REAR FENDER 3-5
REAR UPPER COVER 3-5
REAR UNDER COVER 3-5
CENTER COVER 3-6
MAINTENANCE PROCEDURE
3-7
FLOOR SIDE COVER 3-7
FLOOR PANEL 3-7
UNDER COVER 3-8
REAR WHEEL MUDGUARD 3-8
SPEEDOMETER 3-8
MUFFLER 3-9
TRUSS PIPE
3-1
EXTERNAL PARTS
MAINTENANCE PROCEDURE
NAME OF FRAME COVERS
This chart shows arrows connected in the order of disassembling covers.
3-2
INNER BOX
SEAT
CENTER COVER
UNDER COVER
FR. COVER
RR. FENDER
TRUSS PIPE
RR. WHEEL MUDGUARD
FR. FENDER
RR. UPPER COVER
FLOOR SIDE COVER
FR. WHEEL
RR. UNDER COVER
BATTERY COVER
FR. UNDER COVER
SEAT SUPPORT PIPE
FLOOR PANEL
EXTERNAL PARTS
FRONT
FRONT
COVER
FRONT COVER
COVER
INNER
INNER
BOX
INNER BOX
BOX
INNER BOX
REMOVAL / ASSEMBLY
Loosen the 6 tapping screws securing the
front side cover
FRONT
FRONT
SIDE
COVER
FRONT SIDE
SIDE COVER
COVER
TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
Release the lock by turning the cap securing the

main key remove the cap.
Loosen the tapping screw securing inner box.
Remove the inner box.
Install in the reverse order of removal.
INNER
BOX
INNER
INNER BOX
BOX
INNER
TAPPING
TAPPING
SCREW
TAPPING SCREW
SCREW
HEAD
LIGHT
HEAD
HEAD LIGHT
LIGHT
HEAD
FRONT COVER
REMOVAL/ASSEMBLY
Loosen the 2 washer screw securing the
headlight case. Remove the headlight.
WASHER
WASHER
SCREW
WASHER SCREW
SCREW
Remove the speedometer cable, headlight

cable coupler (left and right)
HEAD
HEAD
LIGHT
CABLE
HEAD LIGHT
LIGHT CABLE
CABLE
Loosen the flange bolt securing the headlight

case.
Remove the case.
3-3
EXTERNAL PARTS
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
Remove the speedometer cable and

speedometer.
Loosen the 6 tapping screw securing the front
side cover.
SPEEDOMETER
CABLE
SPEEDOMETER
SPEEDOMETER CABLE
CABLE
Loosen the 3 special screw securing the front

cover and remove the front cover.
Install in the reverse order of removal
SPECIAL
SPECIAL
SPECIAL
SPECIAL
SCREW
SCREW
SCREW
SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL
FRONT
FRONT
FENDER
FRONT FENDER
FENDER
FRONT FENDER
REMOVAL/ASSEMBLY
Loosen the 4 special screws (R/L).
Remove the wire grommet.
Remove the front fender.
TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
FRONT UNDER COVER

REMOVAL/ASSEMBLY
Loosen the 4 tapping screws (R/L) securing
the front of the floor panel.
Loosen the 2 flange bolts securing the front
under cover.
Loosen the 4 washer screws (R/L) securing
front of the floor side cover.
TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
FRONT
UNDER
COVER
FRONT
FRONT UNDER
UNDER COVER
COVER
FRONT
3-4
FLOOR
FLOOR
SIDE
COVER
FLOOR SIDE
SIDE COVER
COVER
EXTERNAL PARTS
Remove the front under cover.
SEAT REMOVAL/ASSEMBLY
Release the seat lock at the back of seat.
Loosen the 2 flange nuts and remove the seat.
SEAT
SEAT
SEAT
REAR FENDER
REMOVAL/ASSEMBLY
SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL
Loosen the 2 special bolts.

Loosen the 2 washer bolts and remove the rear
fender.
Remove the tail light cable.
WASHER
WASHER
BOLT
WASHER BOLT
BOLT
REAR
FENDER
REAR
REAR FENDER
FENDER
REAR
REAR UPPER
UPPER COVER
COVER
REAR
REAR
UPPER
COVER
REAR UPPER COVER

REMOVAL/ASSEMBLY
Pull the behind of the rear upper cover to
remove it.
3-5
EXTERNAL PARTS
REAR UNDER COVER

REMOVAL/ASSEMBLY
SPECIAL
SPECIAL
SCREW
SPECIAL SCREW
SCREW
Loosen the 4 special screw (R/L) securing the

rear under cover.
Remove it by opening the rear under cover.
REAR
UNDER
COVER
REAR
REAR UNDER
UNDER COVER
COVER
REAR
SEAT
SEAT
SUPPORT
SEAT SUPPORT
SUPPORT
SEAT
SEAT
SEAT
UPPER
UPPER
COVER
HANDLE
HANDLE COVER
SEAT SUPPORT PIPE

REMOVAL/ASSEMBLY
Remove the rear upper cover.
Remove the rear fender.
the bar end cap B.
BAR
END
CAP
B
BAR
BAR END
END CAP
CAP B
B
Loosen the 4 flange bolts securing the seat

support.
Loosen the cap bolt securing the truss pipe and
remove the support pipe.
FLANGE
BOLT
FLANGE
FLANGE BOLT
BOLT
FLANGE
CAP
BOLT
CAP
CAP BOLT
BOLT
CAP
BOLT
TAPPING
SCREW
TAPPING
TAPPING SCREW
SCREW
TAPPING
FLANGE
BOLT
FLANGE
FLANGE BOLT
BOLT
CENTER COVER
REMOVAL/ASSEMBLY
Remove the rear upper and rear fender.
Remove the seat support pipe.
Loosen the 2 tapping screws and 2 flange bolts.
Remove the center cover.
CENTER
CENTER
COVER
CENTER COVER
COVER
3-6
EXTERNAL PARTS
TRUSS PIPE
REMOVAL/ASSEMBLY
Remove the bar end cap B.
Loosen the flange bolt.
Loosen the 4 cap bolts.
Remove the truss pipe.
FLOOR SIDE COVER

REMOVAL/ASSEMBLY
Loosen the 6 special screws LH., RH. in floor
side cover and loosen the 4 tapping screws
RH., LH.
Remove the floor side cover (R/L).
TAPPING
TAPPING
SCREW
TAPPING SCREW
SCREW
TAPPING
FLOOR
SIDE
COVER
SPECIAL
SCREW
FLOOR SIDE
SIDE COVER
COVER
SPECIAL
SPECIAL SCREW
SCREW FLOOR
SPECIAL
SCREW
FLOOR
SIDE
COVER
FLOOR PANEL
REMOVAL/ASSEMBLY
BATTERY
COVER
BATTERY
BATTERY COVER
COVER
Remove the rear fender and upper cover.

Remove the support pipe.
Remove the truss pipe.
CENTER
COVER
CENTER
CENTER COVER
COVER
CENTER
FLOOR
PANEL
FLOOR
FLOOR PANEL
PANEL
FLOOR
FUEL
FUEL
CAP
NECK
FUEL CAP
CAP NECK
NECK
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT

Remove the batery and loosen the flange bolt
securing under.
Remove the fuel cap neck.
3-7
EXTERNAL PARTS
Remove the floor side cover.
Loosen the tapping screw securing the floor panel
and remove the floor panel.
UNDER
UNDER
COVER
UNDER COVER
COVER
UNDER COVER
REMOVAL/ASSEMBLY
Remove the floor side cover.
Loosen the special screw (R/L) and remove
the under cover.
SPECIAL
SCREW
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL
WASHER
WASHER BOLT
BOLT
WASHER
BOLT
REAR WHEEL MUD GUARD

REMOVAL/ASSEMBLY
Loosen the air cleaner and 3 washer bolts
securing mud guard.
Remove the rear wheel mud guard.
REAR
REAR
WHEEL
MUD
GUARD
REAR WHEEL
WHEEL MUD
MUD GUARD
GUARD
SPEEDO METER
REMOVAL/ASSEMBLY
Remove the headlight, speedometer coupler
and cable.
Remove the speedometer cable.
SPEEDOMETER
SPEEDOMETER
CABLE
SPEEDOMETER CABLE
CABLE
3-8
EXTERNAL PARTS
Loosen the 2 flange bolts securing the pilot
box.
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
Remove the speedometer cable.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
MUFFLER
REMOVAL/ASSEMBLY
Loosen the washer bolt securing the brake hose
clamp.
Loosen the 3 hex cap nut securing Ex. Pipe
comp.
Loosen the 2 flange bolt securing the muffler
comp.
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
HEX
CAP
HEX
HEX CAP
CAP
Never performing the maintenance of the muffler

right after stopping the vehicle because the muffler
is extremely hot.
FLANGE
NUT
FLANGE
FLANGE NUT
NUT
FLANGE
NUT
Remove the Ex. muffler comp.
EX. PIPE
Loosen the 2 flange nuts securing the cylinder
comp.
Pull the Ex. pipe comp downward to remove it.
Replace the packing when assemblying the muffler
and Ex. pipe comp.
3-9
MEMO
LUBRICATION SYSTEM
4-1
4-2
4-3
4-3
4-4
4-4
4-7
4-8
4-1
LUBRICATION SYSTEM
Inclusion of water.
Low or no oil pressure
Close oil valve relief.
Clogged oil strainer.
Worn and faulty oil pump.
Internal oil leaks.
Inadequate oil viscosity.
Shout of oil quantity.
Oil pump drivegear or sprocket it is not right.
4-2
LUBRICATION SYSTEM
OIL
OIL
SIGHT
GLASS
OILSIGHT
SIGHTGLASS
GLASS
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
MIDDLE
MIDDLE
MIDDIE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER
Loosen the oil drain plug bolt and drain engine oil.
Tighten the oil drain plug bolt.
TORQUE VALVE : 1.4kgf m
OIL
OIL
DRAIN
PLUG
BOLT
OILDRAIN
DRAINPLUG
PLUGBOLT
BOLT
OIL
FILTER
SCREEN
SPRING
OIL
OILFILTER
FILTERSCREEN
SCREENSPRING
SPRING
OIL
FILTER
SCREEN
SPRING
TAPPER
TAPPER
ADJUST
HOLE
CAP
TAPPERADJUST
ADJUSTHOLE
HOLECAP
CAP
OILCOLLAR
COLLAR
OIL
OIL
COLLAR
OIL
FILTER
SCREEN
OIL
OIL FILTER
FILTER SCREEN
SCREEN
TAPPER
TAPPER
ADJUST
HOLE
CAP
TAPPERADJUST
ADJUSTHOLE
HOLECAP
CAP
ENGINE
OIL
REFUELING
ENGINE
ENGINEOIL
OILREFUELING
REFUELING
ENGINE
OIL
REFUELING
4-3
LUBRICATION SYSTEM
FLANGE
FLANGE
BOLTS
FLANGEBOLTS
BOLTS
OIL
FILTER
COVER
OIL
OILFILTER
FILTERCOVER
COVER
OIL
OIL
FILTER
ELEMENT
OILFILTER
FILTERELEMENT
ELEMENT
OIL
SEAL
OIL
OIL SEAL
SEAL
REDUCTION
GEAR
REDUCTION
REDUCTIONGEAR
GEAR
REDUCTION
GEAR
START
START
DRIVEN
GEAR
STARTDRIVEN
DRIVENGEAR
GEAR
OIL
OIL
PUMP
OILPUMP
PUMP
FLAT
FLAT
SCEWS
FLATSCEWS
SCEWS
OIL
OIL
PUMP
OILPUMP
PUMP
4-4
LUBRICATION SYSTEM
PLATE
PLATE
PLATE
PLATE
DRIVEN
DRIVEN
GEAR
DRIVENGEAR
GEAR
OUTER
ROTOR
OUTER
OUTER ROTOR
ROTOR
BODY
BODY
BODY
OIL
OIL
PUMP
SHAFT
OILPUMP
PUMPSHAFT
SHAFT
OIL PUMP DISASSEMBLY

Loosen the screw securing the oil pump plate.
Remove the oil pump body and the oil pump plate.
Clean the oil pump body, inner and outer rotors with
fresh cleaning oil.
INNER
INNER
ROTOR
INNERROTOR
ROTOR
PUMP
PUMP
BODY
PUMPBODY
BODY
FEELER GAUGE
GAUGE
FEELER
FEELER
GAUGE
4-5
LUBRICATION SYSTEM
OUTER
OUTER
ROTOR
OUTERROTOR
ROTOR
INNERROTOR
ROTOR
INNER
ROTOR
INNER
PUMPBODY
BODY
PUMP
PUMP
BODY
OIL
OIL
PUMP
SHAFT
OILPUMP
PUMPSHAFT
SHAFT
OILPUMP
OILPUMP
SHAFT
OILPUMPSHAFT
SHAFT
ROLLER
ROLLER
ROLLER
U
U
NUT
UNUT
NUT
DRIVEN
DRIVEN
GEAR
DRIVENGEAR
GEAR
OIL
OIL
PUMP
OILPUMP
PUMP
(
(
4-6
9-6)
9-5)
( 9-4)
( 9-2)
( 9-2)
( 14-6)
( 15-8)
3-9)
LUBRICATION SYSTEM
OIL
OIL
BOLT
OILBOLT
BOLT
OIL
OIL
RADIATOR
OILRADIATOR
RADIATOR
RADIATOR
RADIATOR
COVER
RADIATORCOVER
COVER
RADIATOR
RADIATOR
RUBBER
RADIATORRUBBER
RUBBER
RADIATOR COLLAR
COLLAR
RADIATOR
RADIATOR
COLLAR
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
4-7
LUBRICATION SYSTEM
RADIATOR
RADIATOR
RADIATOR
RADIATOR
OIL
OIL
CHECK
BOLT
OILCHECK
CHECKBOLT
BOLT
( 8-2)
AC
AC
GENERATOR
CAP
ACGENERATOR
GENERATORCAP
CAP
4-8
8-2)
5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS
5-2
2. THE COMPONENT PARTS OF THE EMS
5-3
3.TERMINAL ARRANGEMENT OF THE ECU
5-4
4. WIRING DIAGRAM OF THE ECU
5-4
5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp)
5-5
- Self diagnostic function
5-5
- Fail safe function
5-6
- How to check the fault code
5-7
- How to show the fault code
5-8
- How to read the fault code
5-8
- Fault code table
5-9
- How to remove the fault code
5-10
- EMS trouble shooting
5-10
6. ECU (Electronic Control Unit)
5-11
7. THROTTLE BODY
5-12
8. INJECTOR
5-16
9. MAPAT (Manifold Air pressure Sensor temperature sensor)
5-18
10. TPS (Throttle Position Sensor)
5-22
11. ETS (Engine Temperature Sensor)
5-25
12. ISA (Idle Speed Actuator)
5-28
13. O2(Oxygen) SENSOR
5-31
14. MIL
5-34
15. CKP (Crank Position sensor)
5-35
16. FUEL PUMP
5-39
17. HOW TO USE THE SCAN WHEN THE ECU IS INITIALIZED
5-42
18. HOW TO USE THE SCAN WHEN THE ISA PWM ADJUSTING
5-44
19. HOW TO USE SCAN WHEN THE IGNITION TIMING IS CHECK
5-45
20. HOW TO USE SCAN WHEN THE ENGINE REVOLUTION IS CHECKING
5-46
5-1
1. CAUTION WHEN REPAIRING THE EMS PARTS.

If the fuse is short-circuited, findout the cause and repair.
Replace with the fuse having the specified capacity.
Do not use the electlic wires or others instead of the fuse.
Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop.
Do not touch the ECU terminal, because it may be damaged by the static.
The ignition key off when assembly and disassembly of the ECU coupler.
otherwise, it might be damage to ECU.
Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts
While engine operating, do not disassembly the battery terminal.

otherwise, it might cause damaged the EMS parts.
Use the specitied voltmeter and resistance meter.
5-2
2. THE COMPONENT PARTS OF THE EMS

EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.
1) INTAKE SYSTEM
As a system which controls and measures air to be necessary for combustion in engine, the intake system
is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air
cleaner and ISA(Idle Speed Actuator), etc.
In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means
that idle speed control system is installed in order to control small of quantity of air being necessary for
combustion.
2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to
injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division
pipe and injector.
The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter.
Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of
intake system.
Injector sprays fuel into the intake system by injection signals of ECU.
3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to
control proper spark time in cylinder, high-voltage system, and so forth.
4) CONTROL SYSTEM
Various sensors to move electric signals converted by checking the current engine status
Input interface which works various processes like regulating voltage levels, removal of noise, A/D
conversion, amplifying of inputted signals from above sensors.
Micro-computer which decides output value through various calculating, arithmetic and logic
processing.
Output interface to amplify the above output signals.
Actuator being mechanically worked by receiving the amplified output signals.
(Intake pressure sensor+Intake

temperature)
5-3
3. TERMINAL ARRANGEMENT OF THE ECU
Remarks
ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected.
4. WIRING DIAGRAM OF THE ECU
5-4
5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)

SELF-DIAGNOSTIC FUNCTION
The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation
normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL
(malfunction indicator lamp). It gives the rider that malfunction has occurred in the system.
However, the ECU takes fail-safe function, it enables to drive only temporary when that happen.
Normally, the MIL illuminates for 3 seconds, when the main key is turned on.
SPEEDOMETER
ODOMETER
DIRECTION
INDICATOR LAMP
HIGH BEAM
INDICATOR
MALFUNCTION INDICATOR LAMP
FUEL GAUGE
when the ignition key ON.
MIL
OFF
Able to engine start

Starting and driving are temporary
ON
Unable
Unable to engine start
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs
fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON
MIL on continuously, when the engine operating
Blink
MIL blinks, when the main key is turn on (engine is stop)
5-5

FAIL-SAFE FUNCTION
If the ECU checks something wrong , the vehicle can be driven by its fail safe function.
However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation
can be impossible.
MIL
on
INTAKE
INTAKE
: MIL on/off
: MIL on
If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.
intake
intake
INTAKE
INTAKE
The value of intake pressure is fixed as the

pressure just before when the intake pressure
sensor is out of order.
The value of intake temperature is fixed as a
temperature just before when the intake
pressure sensor is out of order.
! CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.
5-6

HOW TO CHECK THE FAULT CODE
There are two methods of checking the fault codes.
1) Use the MIL in the speedometer.
2) The diagnostic tool.
First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic
methods for each part)
Second) The diagnostic tool (refer to scan users manual.)
Turn off the ignition key
Disassemble the rh.side cover
The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.
(The coupler to check the malfunction of vehicle is placed in the rh.side cover)
Turn on the ignition key
Press the power button of diagnostic tool
Checks according to diagnostic procedure of diagnostic tool.
Coupler to check the malfunction diagnosis

Wire color to check the malfunction diagnosis
-P/W : PINK/WHITE
-P/Y : PINK/YELLOW
-B : BLACK
-G : GREEN
The diagnostic Tool.

The wireharness to check the ECU
This wireharness is connected with the ECU and main wireharness
It has two couplers to check the terminals.
First coupler) ECU no.1~20
Second coupler) ECU no.21~40
Arrangement of ECU PIN
First coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connected
Second coupler) ECU no.36,38 were not connected
The wireharness to check the ECU
5-7

HOW TO SHOW THE FAULT CODE
There are two methods to show the Fault codes.
First, the methods to show in engine operation
In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the
light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code,
stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be
verified.(refer to the fault code table)
Second,the ways of indication only turn on the ignition key.
When only ignition key is on and if the defect of each part brings out, the MIL keeps showing
the Fault code of defect part repeatedly in order to give defect information to driver.
! CAUTION
If the MILon when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started
HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS.
Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed.
E.g. ) The Fault code of ISA
ON
OFF
1.5 sec
3 sec
1 flashing cycle : 0.5 sec
If many problems will happened in the EMS parts at the same time only one fault code is displayed by the
priority, however, the ECU is remembers all the fault codes.
After revise the code, remove the memorized fault code by the method of warm up.(5-10)
(Refer to remove the fault codes)
When the vehicle is checked using the diagnosis tool.
- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.
5-8

FAULT CODES TABLE
MIL INDICATION
(The number of blinks)
Fault
code no.
Priority
order
00
No failure
21
Injection valve failure(IV)
22
Idle speed actuator failure (ISA)
23
Electrical fuel pump failure (EFP)
12
Intake Manifold absolute pressure signal

failure (IMP)
13
Throttle position signal failure (TPS)
24
O2 sensor heater output failure (LSH)
14
Lambda signal failure (VLS)
15
Engine temperature signal failure (TENG)
16
Breathing air temperature signal failure

(TBA)
28
11
Malfunction indicate lamp failure (MIL)
Description
5-9

HOW TO REMOVE THE FAULT CODE
Remove the fault codes in two ways;
First) Full warm up
1. Starting the engine.
- The MIL blinks continuously because the ECU memorized the fault code yet.
2. Full warm up the engine (keep idling five minutes)
3. Turn off the ignition key after full warm up the engine
4. Turn on the ignition key again, and check whether the fault code is disappeared or not.
After full warm up, it is possible to check the fault code is removed with the ignition key on/off.
If many problems happened in the EMS parts at the same time, only one defect code will is displayed
by the priority order.
Even thought repair a fault and remove the memorized fault code, another fault code blinks.
at this time, revise the fault and remove the memorized fault code by the warm up.
Second) Malfunction diagnosis tool
(refer to the scan users manual)
EMS TROUBLE SHOOTING

Inspection before diagnosis
Inspection the following before malfunction diagnosis.
Quantity of engine oil and leakage
Quantity of fuel and leakage
Blocked of air cleaner
Condition of battery
Free play of throttle cable
Cutting of fuse
Leakage of emission gas
Connection of each coupler
5-10

SEAT
SEAT
SUPPORT
PIPE
SEAT SUPPORT
SUPPORT PIPE
PIPE
CENTER
CENTER
COVER
CENTER COVER
COVER
6. ECU
(ELECTRONIC CONTROL UNIT)
REMOVE
! CAUTION
Before disassemble, the key is off.
Remove the ECU coupler.
Loosen the 4 flange bolts and remove the

ECU.
FLANGE
FLANGE
BOLT
FLANGE BOLT
BOLT
ECU
ECU
ECU
ASSEMBLY
Assembly is the reverse order of removal.
! CAUTION
Be sure to assemble the ECU ground wire.

(The color is green)
5-11
7. THROTTLE BODY
CENTER
CENTER
COVER
CENTER COVER
COVER

Loosen the screw securing air cleaner connecting

tube band.
Remove the throttle body and air cleaner.
SCREW
SCREW
SCREW
Remove the gasoline in fuel tube.

Disconnect fuel tube securing inject cap.
Disconnect injector, MAPAT, throttle sensor, ISA
coupler.
Disconnect throttle cable.
Loosen the 2 flange bolts securing insulator and
remove the throttle body assy.
Remove the each component parts securing

throttle body and check.
! NOTE
Do not disconnect both the throttle adjust screw

and adjust nut.
5-12
DISCONNECT THE THROTTLE BODY

Disconnect fuel tank and air cleaner.
Remove the gasoline in fuel tube.
Disconnect fuel tube securing injector cap.
Disconnect TPS, ISA, MAPAT, injector coupler.
Disconnect throttle cable.
! CAUTION
THROTTLE
THROTTLE
BODY
THROTTLE BODY
BODY
INSULATOR
INSULATOR
INSULATOR
INSULATOR
THROTTLE
BODY
THROTTLE
THROTTLE BODY
BODY
THROTTLE
BODY
ISA
ISA
ISA
ISA
Do not disconnect both the throttle adjust screw

and adjust nut.
REMOVE
Loosen the throttle body 2 bolts securing the
insulator.
Disconnect the TPS (Throttle position sensor).
Disconnect the ISA(Idle speed actuator).
Disconnect the MAPAT.
TPS
TPS
TPS
! CAUTION
Do not disconnect the throttle valve.

MAPAT SENSOR
SENSOR
MAPAT
MAPAT
SENSOR
CHECKING THE THROTTLE BODY

Checking the TPS.
Checking the ISA.
Checking the MAPAT.
MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
ISA
ISA
ISA
TPS
TPS
TPS
TPS
Checking the throttle shaft.

Checking the valve.
Install the O-ring on the throttle body.
THROTLE
THROTLE
SHAFT
THROTLE SHAFT
SHAFT
THROTTLE
THROTTLE VALVE
VALVE
THROTTLE
VALVE
5-13

DISASSEMBLE THE INSULATOR
Disconnect injector cap bolt.
Disconnect injector and injector cap at the
same time from the insulator.
Disconnect injector and injector cap.
CHECKING THE INSULATOR

INJECTOR
INJECTOR
CAP
INJECTOR CAP
CAP
INJECTOR
INJECTOR
INJECTOR
INJECTOR
Check the O-ring.

Check the insulator inside.
Check the insulator cap inside.
ASSEMBLY OF THE INSULATOR

Assemble is the reverse order of removal.
Assemble the O-ring to insulator.
Install the insulator to the throttle body.
Torque : 1.0 kgf m
Remove the injector and check.
ASSEMBLY OF THE THROTTLE BODY

Assemble the O-ring to the insulator.
! CAUTION
Replace the o-ring with new one.
Assemble the insulator to the throttle body.

Torque : 1.0 kgf m
INSTALLATION OF INSULATOR AND

THROTTLE BODY
Installation of insulator and throttle body in the
reverse order of removal.
Check the o-ring when the insulator assembly.
Assemble the insulator gasket.
! CAUTION
Replace the gasket with new one.
Install the assembled insulator and throttle

body to the cylinder head.
Torque : 1.2 kgf m
5-14

ADJUSTMENT OF THROTTLE CABLE
Assemble the throttle cable.
Adjust the free play of throttle grip.
INSPECTION OF SENSOR AND

ACTUATOR
Connect each sensor and the actuator coupler.
Check the ISA.
Check the TPS.
Check the MAPAT sensor.
! CAUTION
Be sure to the valve of TPS is whether the

standard valve after it became assembly.
Check the MAPAT sensor.
ADJUSTMENT OF IDLE SPEED

ACTUATOR (ISA)
A vehicle is assembled in the state which
engine operation is possible.
Loosen the maintenance cover and the adjustscrew is makes possible to adjust.
The coupler to check the malfunction of
vehicle is connected to the coupler of
diagnostic tool.
Turn on the ignition key.
Press the power-button of diagnostic tool.
The vehicle is warms up enough to adjust the
idling speed.
! CAUTION
The ECU is always initilized, before the engine

is starting.
The vehicle is warms up enough to adjust the

idling speed.
ENGINE TEMPERATURE : OVER 100

IDLE SPEED ACTUATOR : APROXIMATELY 20%
ISA
ISA
ISA
ISA
5-15
8. INJECTOR
REMOVE
INJECTOR
CAP
INJECTOR
INJECTOR CAP
CAP
INJECTOR
CAP
INJECTOR
INJECTOR
INJECTOR
INJECTOR
Turn off the ignition key.

Disconnect the injector coupler.
! CAUTION
Before disassemble, the key is off.
Loosen the injector cap bolt.
FLANGE BOLT
BOLT
FLANGE
FLANGE
BOLT
INJECTOR
INJECTOR
INJECTOR
Disconnect the injector.

!
NOTICE
Be sure to check the engine is cooling

because a little gasoline remains, It could be
still hot.
Be sure to inject the gasoline, after remove
the coupler from the ignition coil. It could be
damaged for the fire, sparked on the spark
plug.
ASSEMBLY
5-16

CHECKING METHODS BY FAULT CODES
Checking of the Injector circuit
The fault code is displayed by MIL
Checking Circuit
ECU
INJECTOR
40 : INJECTOR control
39 : FUEL PUMP control
FUEL PUMP RELAY
Coupler terminal is based on wire harness.

Checking Procedure
1) Turn off the ignition key.
2) Check to see if the injector coupler has come loose or the wire is peeling off.
If there is no problem, measured the resistance of injector.
3)Disassemble the injector coupler and measure the resistance between injector terminals.
The resistance of injector : 14.50.7[ ], 20
Remarks : measuring unit for resistance : resistance R [ ]
4)If there is no problem, check the continuity between each terminal and ground.
The resistance between each terminal and ground : [ ]
If resistance value is not normal, replace injector with the new one.
5)If the resistance is normal, turns on the ignition key
- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.
6) Measure between the voltage of coupler.
Measuring terminal : BLACK/RED electric wire ~ ground
Measuring voltage : battery voltage 1.0[V]over
Remarks : Measuring unit of voltage : voltage [V]
7) If the measured voltage is normal,
Check the Blue/Yellow electric wire to see if they have been broken or have short-circuited
or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)
If there is no problem in the electric wires, ECU is broken
Replace the ECU with new one, it rechecks
8) If the measured voltage is not normal,
Check the Black/Red electric wire to see if they have been broken or have short-circuited.
Check the fuel pump relay.
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-17
MAPAT
SENSOR
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
TPS
TPS
TPS
9. MAPAT (Mainfold Air pressure sensor

Temperature sensor)
Located on the left-side of the throttle body.
! CAUTION
Before disassembly, the key is off.
REMOVE
MAPAT
MAPAT
SENSOR
MAPAT SENSOR
SENSOR TPS
TPS
TPS
Disconnect the MAPAT circuit sensor coupler.

Loosen the 2 MAPAT circuit sensor screws.
Disconnect the MAPAT sensor.
ASSEMBLY
5-18

Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))s circuit
Fault code number is displayed by MIL
The Fault code of intake pressure sensor
The Fault code of intake temperature sensor
Checking circuit
MAPAT
ECU
3 : Intake
sensorpressure
ground
3 : pressure
Inhalation
26 : sensor
5V voltage
GROUND
27 : 26
IMP: 5V voltage
28 : TBA
27 : IMP 28 : TBA
Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input voltage of MAPATs coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
If voltage value is not normal,
Check to see if the ECU coupler is loose or if there is a bad contact.
Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited
Remark : refer to (5-20) if the intake pressure sensor is broken
refer to (5-20) if the intake temperature sensor is broken
5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-19

Checking of the intake pressure sensor
1) If voltage value is normal, turn off the ignition key.
Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler
2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler.
Refer to how to assemble or disassemble the ECU ( 5-11 )
3) Turn on the ignition key. Start engine and operate idle.
4) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor.
Measuring terminal : ECU No. 27(P/L:PINK/BLUE)
~ ECU No.3(P/G : PINK/GREEN)
Measuring voltage : 0.1[V] ~ 4.8[V]
Remarks : Measuring unit of voltage : Voltage [V]
The voltage of air pressure;
20[kPa]: 0.719 ~ 0.859[V]
107[kPa]: 4.154 ~ 4.294[V]
WIRE
WIRE
HARNESS
WIRE HARNESS
HARNESS

Check the P electric wire, P/G electric wire,
P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with the new one and it rechecks.
If measuring voltage is normal,
P/L electric wire to see if they have been broken or have
short- circuited if there is a bad contact.
badness of terminal No. 3, No. 26, No.27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.
5-20

Checking of the intake temperature sensor
1) If voltage value is normal, turn off ignition key.
2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.
Resistance of intake pressure sensor : 2000100[], 251
Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)
Remarks : Measuring value for resistance : Resistance[ ]
The Voltage of air pressure;
24 ~ 26[ ] : 1800~2200[ ]
99 ~ 101[ ] : 161~206[ ]
3) If measuring resistance is not normal,
Replace the MAPAT sensor with new one and it rechecks.
If the measured voltage is normal,
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No. 27 of ECU coupler.
Replace the ECU with the new one, it rechecks.
4) Turn on the ignition key. Start the engine and idling.
5) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor
- Measuring terminal: ECU No.28(TBA)
~ ECU No.3(IMP GROUND)
- Measuring voltage: 0.1[V] ~ 4.9[V]
Remarks : Measuring unit of voltage : Voltage [V]
P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with new one and it rechecks.
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No.28 of ECU coupler.
Replace ECU with the new one, it rechecks.
7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-21
10. TPS(Throttle position Sensor)

Located on the left side of throttle body.
! CAUTION
TPS
TPS
TPS
REMOVE
Disconnect the TPS coupler.
Loosen 2 TPS screws.
MAPAT
MAPAT SENSOR
SENSOR
MAPAT
SENSOR
Disconnect the TPS.
TPS
TPS
TPS
ASSEMBLY
5-22

CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM
Checking circuit
TPS
ECU
4 : SENSOR GROUND
18 : 5V SUPPLY VOLTAGE
19 : TPS
The coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the IGNITION KEY.
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPSs coupler.
If voltage value is not normal,
Check to see if the ECU coupler is loose if there is bad contact.
Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been
broken or have short- circuited.
5) If the value of voltage is normal, turn off the ignition key.
5-23

Checking Procedure
6) Check continuty between the Sensor Ground Terminal of TPS and Earth.
The continuty TPS : 0[ ],201
Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH
Remarks : Measuring unit for resistance : Resistance R [ ]
7) If not problem, measure the resistance of TPS.
By turning round throttle grip, measure the resistance.
The resistance of TPS
If the throttle is totally closed : 0.9~1.6[k ],201
If the throttle is totally opened : 2.3~2.6[k ],201
Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Remarks : Measuring value of resistance : Resistance[k ]
8) If resistance and the continuty are not abnormal.
Adjust correctly the position of TPS
Replace the TPS with the new one and re-check.
9) If resistance and continuty are normal, connect the TPS coupler.
10) Turn on the ignition key.
11) Measure the TPS voltage of wire-harness to check the ECU.
Rotate the throttle lever, measure the voltage
Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE)
Output voltage of TPS
-If the throttle is totally closed : 4.0~5.5[V]
-If the throttle is totally opened : 0.1~0.6 [V]
Remarks : Measuring unit for voltage : Voltage [V]
12) If the measured voltage is abnormal,
Replace the TPS with the new one, and re-check.
Check the GR/B electric wire, GR/L electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, and recheck.
13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-24

RH. SHROUD
SHROUD
RH.
RH.
SHROUD
11. ETS(Engine Temperature Sensor)

Situated at the back of the cylinder head.
Remove the RH. shroud.
! CAUTION
REMOVE
Disconnect the ETS coupler.
Disconnect the ETS.
ASSEMBLY
ETS
ETS
ETS
5-25

1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)
CHECKING CIRCUIT
ETS
ECU
4 : SENSOR GROUND
5V SUPPLY VOLTAGE
20 : ETS
Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key .
2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input 5 voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
Measure the terminal voltage of ETSs coupler.
Remarks : Measuring unit for voltage : voltage [V]
If the voltage value is not normal,
Check to see if the ECU coupler is loose if there is bad contact.
Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS :1.6[k ]~10.6[k ],20 ~80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance R [k ]
5-26

6-1) If the measured value is not normal,
Replace the ETS with the new one, recheck.
If the measured value is normal,
Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if
the ECU coupler is a bad contact ( No.4, No. 20.)
Replace ECU with the new one, recheck.
6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
Checking Procedure
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to ETS disassembly)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperatures change and testers value.
Characters of ETS
Temperature
Resistance value
20
10.6[k ]~14.4[k ]
80
1.35[k ]~1.65[k ]
110
0.57[k ]~0.69[k ]
Measuring unit of resistance : Resistance R [k ]

If the value of resistance is high or out of the standard value, replace the ETS with the new one.
! CAUTION
1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.
3) Install
Tighten the ETS to the specified torque.
ETS torque : 3.0[kgf m]
5-27

ISA
ISA
ISA
INJECTOR
INJECTOR
INJECTOR
12. ISA(Idle Speed Actuator)

Located on the throttle body.
! CAUTION
REMOVE
Disconnect the ISA coupler.
ISA COUPLER
COUPLER
ISA
ISA
COUPLER
Loosen 2 ISA screws.

ISA
ISA
SCREW
ISA SCREW
SCREW
Remove the ISA.
ASSEMBLY
5-28

1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.
Showing of defects codes by MIL
CHECKING CIRCUIT
ECU
ISA
FUEL PUMP RELAY
Coupler terminal is based on the side of the wire-harness
CHECK PROCEDURE
1) Turn off ignition key .
2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ],20
remarks : Measuring unit of resistance : Resistance R[ ]
ISA
ISA
ISA
ISA
4) If there is not problem, check about the level of electricity flow between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : [ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-28 )
remarks : Measuring unit for resistance : Resistance R[ ]
5-29

CHECK PROCEDURE
5) If the measured resistance and continuty is abnormal.
Replace ISA with the new one, and recheck.
6) If resistance and continuty is normal, connect the coupler of ISA.
7) Turn on ignition key
8) Measure ISA voltage of wire-harness to check ECU.
Measuring terminal : B/R electric wire ~ EARTH
Output voltage of ISA : Battery Voltage [V]
Remarks : Voltage measuring unit : Voltage [V]
Check the B/R electric wire, L/G electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, recheck.
If the measured voltage is abnormal,
Check the B/R electric wire, L/G electric wire, W/B electric wire to see if they have been
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code.
5-30
13. O2(Oxygen) SENSOR

REMOVE
O2
O2 SENSOR
SENSOR COUPLER
COUPLER
O2
SENSOR
COUPLER
Located on the exhaust pipe.

Disconnect the RH. floor side cover.
Disconnect the O2 sensor coupler.
! CAUTION
O2
SENSOR
O2
O2 SENSOR
SENSOR
O2
SENSOR
Remove the O2 sensor on the muffler.
Check the O2 sensor.

! CAUTION
Take precaution not to impact on the O2 sensor.
ASSEMBLY
O2
O2
SENSOR
O2 SENSOR
SENSOR
5-31

1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT
Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.
CHECKING CIRCUIT
OXYGEN SENSOR
ECU
Lamda
2 : LAMBDA SENSOR GROUND

12 : OXYGEN SENSOR SIGNAL
34 :: OXYGEN
34
OXYGENSENSOR
SENSORHEATER
GROUND
Coupler terminal is based on the side of Wire-Harness.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

1) Turn off the ignition key.
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key
4) Measure input voltage of oxygen(O2)sensor coupler
Input voltage : Battery voltage[V]
Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler
(B/BR : BLACK/BROWN) ~ EARTH
Remarks : Measuring unit of Voltage : Voltage[V]
5-32

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER
If the voltage value is abnormal,
Check to see if the ECU coupler is loose or if there is bad contact.
Check the B/B electric wire, G/W electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.
Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22
Measuring terminal (side of wire-harness) :
oxygen(O2)3 terminal of sensor coupler
Remarks : Measuring unit of Resistance : Resistance R[ ]
6) If the measured resistance is abnormal,
Replace the oxygen(O2)sensor with new one and recheck it.
If the measured resistance is normal,
Check the B/B electric wire, G/W electric wire to see if they have been
If the electric wire is no problem, the ECU is broken.
Replace the ECU with new one, and recheck it.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) The wire harness to check the ECU is connected to the ECU with a ECU coupler
Refer to the ECU assembly/disassembly (5-4)
4) Turn on the ignition key
5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.
Measuring terminal:
(V :VIOLET) ~ (V/B:VIOLET/BLACK)
Output voltage of oxygen(O2) sensor : 0.1~0.8[V]
Remark : measuring unit of voltage : voltage[V]
Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf m]
Check the V electric wire,
V/B electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal
No. 2, No. 12 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and recheck it.
Check the V electric wire, V/B electric wire, W/B electric wire to see if they have been
6) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)
5-33
14.CHECKING OF MIL
CHECKING CIRCUIT
ECU
24 : MALFUNCTION INDICATOR LAMP OUTPUT
MALFUNCTION INDICATOR LAMP(MIL)
CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
3) Turn on the ignition key.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the lamp.
But If the lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : (B) electric wire ~ (G)electric wire => Output voltage: battery voltage
Measuring terminal : (B/Y)electric wire ~ (G)electric wire => output voltage: 9V~15V
Remarks : measuring unit of voltage : voltage[V]
Check the R/Y electric wire, B electric wire, G electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.
Check the B/Y electric wire, B electric wire, G electric wire to see if they have been
6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code.
5-34
15. CKP(Crank Position Sensor)

REMOVE
Remove the ACG coupler.
Remove the CKP coupler.
CKP is located inside the RH. crank case
cover.
! CAUTION
RH. SHROUD
SHROUD COMP
COMP
RH.
RH.
SHROUD
COMP
CRANK
CRANK
POSITION
SENSOR
CRANK POSITION
POSITION SENSOR
SENSOR

Remove the cooling fan.
Remove the fly wheel.
Remove the 3 screws securing ACG stator.

Remove the 2 screws securing CKP.
Check the ACG stator and position sensor.

Take precaution not to use the stator comp (18
terminal) like the carburetor type stator.
5-35

Check the fly wheel.
Fly wheel for the EMS system have 10 spots
on the fly wheel protrusion. It is different with
carburetor type.
Check the mark or contamination on the
protrusion.
! CAUTION
When replace the fly wheel, check the 10 spots

of protrusion part.
ASSEMBLY
CHECKING OF CKP(Crank Position

Sensor)
MEASUREMENT RESISTANCE
Remove the seat.
Remove the LH. side cover.
Disconnect the ACG coupler and (L/G)
connector.
Measure the resistance between G and L.
STANDARD : 80~150(20)
MEASUREMENT PVA
Disconnect the ACG (L/G) connector.
Connect the (+)cord of PVA tester to the green
terminal or ground wire.
Connect the (-)cord of PVA tester to the blue
terminal.
Crank the engine with the starter motor and
measure the peak voltage of crank position
sensor coil.
HIGHEST VOLTAGE : 1.5V Over.
TOOL : PVA Multy tester.
5-36
CHECK THE CIRCUIT OF CKP

CHECKING CIRCUIT
GREEN
BLUE
RED
BLUE
ECU PIN NUMBER

ECU
30 : CRANK
SIGNAL-A
30 :
_ A
22 :
_ B
22 : CRANK
SIGNAL-B
22
30
CHECK PROCEDURE
1) Turn ON ignition key.
2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.
When start up the ENGINE SINK ON change OFF to ON, its okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance.
- measuring resistance : 80 ~ 150[]
5-37

4) Check if crank signal A,B wires is breaks or not.
Remove the ECU, connect wire harness for inspection to wire harness of vehicle.
Check the wiring of crank signal A
- Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[]
Red
CKP_B
1
CKP_A
2
Check the wiring of crank signal B

- Measure terminal : No. 22 pin of wire harness for inspection - Blue wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[]
Blue
CKP_B
1
CKP_A
2
5) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)
5-38
16. FUEL PUMP
FUEL
FILLER
CAP
FUEL
FUEL FILLER
FILLER CAP
CAP
FUEL
FILLER
CAP
REMOVE
Fuel pump is located inside the fuel tank.
Remove the fuel filler cap.
Remove the floor panel.
! CAUTION
Make sure that the key is off before assembly.
Remove the fuel hose.

Remove the fuel pump coupler.
FUEL
FUEL
TUBE
FUEL TUBE
TUBE
FUEL
PUMP
COUPLER
FUEL
FUEL PUMP
PUMP COUPLER
COUPLER
FUEL
PUMP
COUPLER
Loosen the 4 fuel pump setting place screws.

FUEL
FUEL
PUMP
SETTING
PLACE
FUEL PUMP
PUMP SETTING
SETTING PLACE
PLACE
SCREW
SCREW
SCREW
Remove the fuel pump.
5-39
FUEL PUMP
The terminal arrangement of the fuel pump

(The following color chart is the internal color of the fuel pump)
CONNECTOR WIRING
5-40
LOCATION
FUNCTION
COLOR
FUEL UNIT
YELLOW
FUEL UNIT2
GREEN
PUMP (+)
RED
GROUND
BLACK

Check the fuel pump.
Measure the resistance between terminals.
The FLOAT position
Terminals resistance []
F : 140.5[mm]
40 5[]
1/2 : 83.5[mm]
220 5[]
E : 28.5[mm]
400 3[]
The float position is based on tank bottom plate.

Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)
wire of fuel unit terminal
Remark : measuring unit of resistance : resistance[]
If the measured resistance value is out of standard at float position, replace the fuel unit.
CHECK THE BLOW PRESSURE OF FUEL PUMP

- Blow pressure : 3.0 Bar
- After remove fuel tube from the injector, turn the ignition key ON/OFF 3
times, when the fuel come out about 100cc over, its Okay.
If under 100cc, check the fuel pump. Replace it if necessary.
(Be sure to the resistance of battery is over 12.6V)
ASSEMBLY
5-41
17.HOW TO USE THE SCAN WHEN

ECU IS INITIALIZED
The coupler to check the malfunction of vehicle
is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnostic tool.
Press the enter button in the initial screen.
Press the enter in the vehicle diagnosis screen.
Press the enter button on the resetting ECU values.
If the enter-key is press than the ECU will reset.
Press the rest button on the following screen.
5-42

Press the enter button when it is ready
When the ECU was initialized. turn off the lgnition

key and then turn on the ignition key.
5-43

THE ISA PWM IS ADJUSTING
The coupler to check the malfunction of vehicle
is connected to the coupler of diagnostic tool.
Turn the lgnition key on.
Press the power button of the diagnosis tool.
Press the enter button on the initial screen.
Press the button at the vehicle diagnostic screen.
Press the enter button on the current data.
By looking the displayed figure on the ISA PWM,

adjust the throttle adjust screw.
5-44

THE IGNITION TIMING IS CHECKING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the enter button on the vehicle diagnosis screen.
To check the ignition angle
5-45

ENGINE REVOLUTION IS CHECKING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the enter button on the vehicle diagnosis screen.
Check the engine rpm on the engine speed
5-46
MEMO
MEMO
FUEL SYSTEM
6. FUEL SYSTEM
TROUBLESHOOTING 6-2
FUEL TANK 6-3
CARBURETOR 6-3
FLOAT CHAMBER/FLOAT/JET6-5
CARBURETOR INSULATOR 6-8
PILOT SCREW ADJUSTMENT 6-9
FUEL PUMP6-11
SERVICE INFORMATION
GENERAL SAFETY
!
WARNING
Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore,
the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas.
Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly
ventilated area.
!
CAUTION
Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions.
Pay particular attention to the position of O-ring. Replace with new ones when disassembled.
If it is desired to store a vehicle for a period longer than 1 month, drain gasoline out of the carburetor float chamber.
Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits, and idling may
become unstable.
SPECIFICATIONS
FUEL TANK CAPACITY : 7.2
RESERVE FUEL CAPACITY : 1.2
CARBURETOR SPECIFICATIONS
ITEM
VENTURI BORE
SETTING SERIES MARK
SPECIFCATUIONS
CV TYPE/ 24.2mm
CVK 166 (A)
MAIN JET No.
#95
FLOAT LEVEL
17mm
PILOT SCREW INITIAL OPENING
IDLING SPEED
THROTTLE GRIP FREE PLAY
1,700 100rpm
2-6mm
TOOL
FLOAT LEVEL GAUGE
6-1
FUEL SYSTEM
TROUBLESHOOTING
The vehicle does not start.
Air/Fuel mixture is extremely rich.
No gasoline in fuel tank.

Fuel is not coming out of carburetor.
Too much fuel is flowing into cylinder.
Air cleaner is blocked.
No spark emitted from spark plug.
Float valve is damaged.

Oil level is too high.
Air jet is blocked.
Auto bystarter is damaged.
Idle is unstable and engine turns off after starting.

Faulty idle adjustment.
Excessively lean or rich mixture.
Suction system is experiencing secondary intake of air.
Clogged fuel system.
Auto bystarter is damaged.
Ignition system is damaged.
Using low quality gasoline.
Air screw is adjusted improperly.
Carburetor is blocked.
Compression pressure is low.
Air/Fuel mixture is extremely lean

Fuel jet is blocked.
Bad ventilation of air in tank cap.
Fuel strainer screen is blocked.
Fuel tank is bent, creased or blocked.
Float valve is damaged.
Oil level is low.
Suction system is receiving secondary suction of air.
Fuel pump is incorrect flow of oil.
6-2
Back firing
Mixture is too lean.
Mis-firing occurs when driving at high speeds.

Insufficient power and high fuel consumption.
FUEL SYSTEM
CRADLE
PIPE
CRADLE
CRADLEPIPE
PIPE
CRADLE
PIPE
CENTER
COVER
CENTER
CENTERCOVER
COVER
CENTER
COVER
FLOOR
FLOOR
PANEL
FLOORPANEL
PANEL
FUEL TANK
REMOVAL
!
WARNING
Gasoline is extremely flammable. Avoid fire during

work, and pay particular attention to electric sparks.
Furthermore, the evaporated (gasified) gasoline is highly
explosive. Work in a well-ventilated areas.
TRUSS
TRUSS
PIPE
COMP
TRUSSPIPE
PIPECOMP
COMP
SEATSUPPORT
SUPPORTPIPE
PIPE
SEAT
SUPPORT
PIPE
SEAT
FUELCAP
CAP
FUEL
CAP
FUEL
FLOOR
FLOOR
PANEL
FLOORPANEL
PANEL
SPECIAL
SPECIAL SCREW
SCREW
SPECIAL
SCREW
Release the seat lock by turning the main switch key to

open the seat.
Remove the following parts.
- Rear fender.
- Seat support pipe.
- Center cover.
- Truss pipe.
- Battery.
- Floor panel.
Remove the fuel unit wiry coupler.
Remove the fuel strainer tube.
Remove the flange nut.
Remove the fuel tank.
Install in the revers order removal.
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
FUEL
UNIT
FUEL
FUELUNIT
UNIT
FUEL
UNIT
CAUTION
After removing the fuel tank be sure to close

the fuel tank cap.
(Gasoline is extremely flemmable)
FUEL
TANK
FUEL
FUELTANK
TANK
FUEL
TANK
FUEL
STRAINER
TUBE
FUEL
FUELSTRAINER
STRAINERTUBE
TUBE
FUEL
STRAINER
TUBE
CARBURETOR
AIR
AIR
CLEANER
CONNECTING
BAND
AIRCLEANER
CLEANERCONNECTING
CONNECTINGBAND
BAND
REMOVAL
- Rear fender.
- Center cover.
- Air cleaner connecting tube band.
CARBURETOR
CARBURETOR
CARBURETOR
INSULATOR
INSULATOR
INSULATOR
6-3
FUEL SYSTEM
THROTTLE
CABLE
LOCK
NUT
THROTTLE
THROTTLECABLE
CABLELOCK
LOCKNUT
NUT
THROTTLE
TOP
TOP
SET
TOPSET
SET
Loosen the throttle cable lock nut and remove the

throttle cable from the carburetor.
Remove the fuel tube.
Remove the auto bystarter wiring.
Loosen the screw on the carburetor insulation band.
Remove the carburetor.
REMOVAL
Loosen the special pan screw on the carburetor top set.
Remove the top set.
SPECIAL
PAN
SCREW
SPECIAL
SPECIAL PAN
PAN SCREW
SCREW
COMPRESSION
COMPRESSION SPRING
SPRING
Remove the top set cover.

Remove the compression spring, vacuum piston comp.
Remove the spring seat, jet needle.

VACUUM
PISTON
COMP
VACUUM
VACUUMPISTON
PISTONCOMP
COMP
VACUUM
VALVE
PLATE
SET
VALVE
VALVEPLATE
PLATESET
SET
VALVE
6-4
FUEL SYSTEM
VACUUM
VACUUM
PISTON
VACUUMPISTON
PISTON
JET
JET
NEEDLE
JETNEEDLE
NEEDLE
INSPECTION
Check the needlejet for wear and replace if necessary.
Check the vacuum piston for damage and replace if
necessary.
Check the diaphragm for damage pin holes, wrinkles
and bends and replace if necessary.
!
NOTE
Check the diaphragm adequately for crack in

the wrinkle area and bend area.
VALVE
VALVE
PLATE
SET
VALVEPLATE
PLATESET
SET
FLOAT CHAMBER / FLOAT /

JET
DISASSEMBLY
Loosen the 4 screws securing float chamber set.
PAN
PAN
PAN
SCREW
SCREW
SCREW
SCREW
FLOAT
CHAMBER
SET
FLOAT
FLOATCHAMBER
CHAMBERSET
SET
FLOAT
CHAMBER
SET
FLOAT
VALVE
SET
FLOAT
FLOATVALVE
VALVESET
SET
FLOAT
VALVE
SET
ARM
ARM
PIN
ARMPIN
PIN
FLOAT
FLOAT
COMP
FLOATCOMP
COMP
Remove the float pin, float and float valve

!
CAUTION
Do not damage the jets. because it made of

soft material and also do not use the wire
when cleaning the air and fuel passage.
Otherwise it will damage to the carburetor
body, eventually it will be effect the engine.
Namely, it is cause of bad condition of engine.
FLOAT
FLOAT VALVE
VALVE SET
SET
FLOAT
VALVE
SET
MAIN
MAIN JET
JET
MAIN
JET
SLOW
JET
SLOW
SLOWJET
JET
SLOW
Check the float valve and valve seat for scores,

scratches, clogging and damage replace if necessary.
Check the float valve operation.
6-5
FUEL SYSTEM
Remove the main jet, needle jet holder, needle jet, slow
jet, screw set, diaphragm comp, compression spring.
CARBURETOR BODY
NOTE
Turn in the pilot jet and record the number of

turns it takes before it seats lightly.
Do not force the pilot screw against its seat;
The seat will be damaged.
Clean the jet and hole of carburetor body with blow the
compressed air.
TOP SET
FLOAT
VALVE SET
COMPRESSION SPRING
FLOAT COMP
AUTO BYSTARTER SET
NEDDLE JET COMP
SCREW SET
VACUUM PISTON COMP

FLOAT CHAMBER SET
DIAPHRAGM COMP
NEEDLE JET HOLDER

MAIN JET #95
6-6
SLOW JET
FUEL SYSTEM
ASSEMBLY
SCREW
SCREW
SET
SCREWSET
SET
Install the needle jet, needle jet holder, main jet and
slow jet.
Tighten the pilot jet until it seat lightly, then turn it out
as much as number recorded during removal.
Install the pilot jet rubber.
Install the float valve set, float comp, float pin.

Measure the float level with the float valve gauge.
FLOAT LEVEL : 13 mm
TOOL : FLOAT COMP LEVEL GAUGE
Install the float chamber set.

Install the stay plate set and 4 pan screws.
!
FLOAT
FLOAT
CHAMBER
SET
FLOATCHAMBER
CHAMBERSET
SET
NOTE
Be sure to replace the float chamber body O-ring

with the new one.
Install the valve plate set, compression spring in the

vacuum piston comp.
TOP
SET
TOP
TOPSET
SET
NOTE
Install the jet needle aligned with the grooves.

Install the diaphragm cover with its cutout aligned with
the cover.
Place the top set on the spring.
Tighten the 2 special pan screws.
6-7
FUEL SYSTEM
NOTE
Be careful not to pinch the diaphragm, and to

keep the spring straight.
COMPRESS
STRAIGHT
Install the drain tube and air-hose.
THROTTLE
CABLE
THROTTLE
THROTTLECABLE
CABLE
THROTTLE
CABLE
CABURETOR INSTALLATION
Install the carburetor to the carburetor insulator.
Tighten the carburetor insulator band screw.
Install the fuel tube to the carburetor.
Intall the wiring coupler of the auto bystarter.
Install the throttle cable to the carburetor.
Intall the air cleaner.
Install the center cover.
NOTE
After adjusting the carburetor, check the

throttle grip free play.
AIRCLEANER
CLEANERCONNECTING
CONNECTINGTUBE
TUBEBAND
BAND
AIR
CLEANER
CONNECTING
TUBE
BAND
AIR
CABURETOR INSULATOR
REMOVAL
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
Remove
- Center cover.
- Air cleaner.
- Carburetor.
Remmove the fuel pump negative pressure tube.
Loosen the carburetor insulator 2 setting nuts.
Remove the carburetor insulator.
Remove the carburetor insulator band.
Install the reverse order of removal.
INSULATOR
INSULATOR
INSULATOR
INSULATOR
6-8
FUEL SYSTEM
O-RING
O-RING
O-RING
INSPECTION
Check the carburetor insulator O-ring for wear or
damage.
PILOT SCREW ADJUSTMENT

THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
THROTTLE
STOP
SCREW
PILOT
PILOT
SCREW
PILOTSCREW
SCREW
USING THE EMISSION ANALYZER (CO,HC)

Open the seat and remove the center cover.
Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM
MUFFLER
MUFFLER
MUFFLER
EMISSION
ANALYZER
EMISSION
EMISSIONANALYZER
ANALYZER
EMISSION
ANALYZER
NOTE
Before adjustment the pilot screw, check the

following items.
- Fuel system electrical system for troubling.
- Do not force the pilot screw against its seat ;
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
- Emission analyzer for correction.
Exhaust gas contains poisonous substance.
Do not adjusting for a long period of time in a
closed, or poorly ventilated area.
Extend the hose (60Cm) at the tail pipe, and insert the
probe of the emission analyzer to the tail pipe, and
adjust the pilot screw with a , the Co to became
3~4%.
Adjust by the throttle stop screw, repeat steps and
until accord the idle rpm (1,800rpm) and the Co
(3~4%).
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW
6-9
FUEL SYSTEM
When idling, check to see if the rotation is smoothly
and to return is nomal.
Install the center cover.
ACCELERATION
ACCELERATION
ACCELERATION
PILOT
SCREW
PILOT
PILOTSCREW
SCREW
PILOT
SCREW
THROTTLE
STOP
SCREW
THROTTLE
THROTTLESTOP
STOPSCREW
SCREW
THROTTLE
STOP
SCREW
CAUTION
If the engine cannot be adjusted by turning the

pilot screw within a turn, check for other
engine problems.
EMISSION ANALYZER IS NOT EXIST

Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM
ACCELERATION
ACCELERATION
ACCELERATION
PILOT
PILOT
SCREW
PILOTSCREW
SCREW
6-10
THROTTLE
THROTTLE
STOP
SCREW
THROTTLESTOP
STOPSCREW
SCREW
NOTE
Before adjustment the pilot screw, check the

following items.
- Fuel system electrical system for troubling.
- Do not force the pilot screw against its seat ;
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
When idling, check to see if the rotation is smoothly
and to return is normal.
Turn the throttle stop screw until the 1,000RPM, and
check the stopping of engine.
If the engine is stop, adjust the pilot screw with a ,
and repeat step and .
FUEL SYSTEM
!
ACCELERATION
ACCELERATION
ACCELERATION
ACCELERATION
CAUTION
If the engine cannot be adjusted by turning the

pilot screw within a turn, check for other
engine problems.
After the final test of the starting and driving, readjust
if necessary.
FUEL PUMP
REMOVE
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
- Center cover.
- Inlet, outlet, vacuum tube.
- 2 bolts securing the fuel pump.
- Fuel pump.
FUEL
FUELPUMP
PUMP
FUEL
PUMP
FUEL
FUEL
PUMP
FUELPUMP
PUMP
DISASSEMBLY
Loosen the 4 screws securing the fuel pump.

Check the diaphragm A and B of fuel pump for
damage.
6-11
FUEL SYSTEM
Check the gaskets.
Check the suction valve, outlet valve and relief valve

for damage and crack.
FUEL
PUMP
FUEL
FUELPUMP
PUMP
FUEL
PUMP
!
NOTE
After install the fuel pump, check the blowing

quantity of fuel in the outlet tube.
6-12
ENGINE REMOVAL/INSTALLATION
7. ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL/INSTALLATION7-2
SERVICE INFORMATION
GENERAL SAFETY
NOTE
Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness.
Attach tape to the frame to protect it during the engine removal or installation.
The following works can be carried out without removing the engine from the vehicle body.
-TRANSMISSION (SECTION 12)
-STARTING CLUTCH (SECTION 9)
-OIL PUMP (SECTION 4)
-A.C. GENERATOR (SECTION 9)
-START MOTOR (SECTION 18)
-CONTINUOUSLY VARIABLE TRANSMISSION (SECTION 8)
-CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 10,11)
-EX. MUFFLER (SECTION 3)
-CARBURETOR (SECTION 6)
-REAR SWING ARM (SECTION 14)
Items to be worked after removing engine.
-CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING
Engine oil capacity : 1.1 - When disassembled.
TORQUE VALUES :
ENGINE HANGER BOLT (FRONT) : 2.7fm
(REAR) : 3.5fm
7-1
ENGINE REMOVAL
Drain the engine oil.
Release the seat lock by turning the main switch key to
open the seat.
- Rear under cover.
- Air cleaner (2-5)
- Carburetor (6-3)
Disconnect the ACG coupler and connector wiring
connected to the ACG, disconnect the starter motor
wiring cable.
Disconnect the high-tension cord from the engine.
Remove the bleeder tube from the cylider hesd cover.
DRAIN
DRAINPLUG
PLUGBOLT
BOLT
DRAIN
PLUG
BOLT
BRAKE
BRAKE
HOSE
BRAKEHOSE
HOSE
MUDGUARD
MUDGUARD
MUDGUARD
MUDGUARD
MUFFLER
MUFFLER
MUFFLER
MUFFLER
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
REAR
REAR
WHEEL
REARWHEEL
WHEEL
RADIATER
HOSE
RADIATER
RADIATERHOSE
HOSE
RADIATER
HOSE
7-2
Remove
- Muffler
- Rear brake caliper
- Swing arm
- Rear wheel mudguard
Loosen the U nut.

Remove the rear wheel.

Remove the RH. radiater hose.
Loosen the rear cushion under bolt.
REAR
CUSHION
REAR
REARCUSHION
CUSHION
REAR
CUSHION
REAR
REAR
CUSHION
UNDER
BOLT
REARCUSHION
CUSHIONUNDER
UNDERBOLT
BOLT
SECONDARY
SECONDARY
SECONDARY
SECONDARY
AIR
FILTER
AIR
AIRFILTER
FILTER
AIR
FILTER
Remove the SAI tube from the secondary air filter

assembly.
Loosen the 10mm U nut from the engine hanger.
Lifting the frame back side and remove the flange bolt
securing engine hanger and disassemble the frame and
engine.
ISA
ISA
TUBE
ISATUBE
TUBE
ENGINE INSTALLATION
!
ENGINE
ENGINE
HANGER
PLATE
ENGINEHANGER
HANGERPLATE
PLATE
NOTE
Take precautions not to damage wiring and

cable.
Take precautions not to damage the thread part
of bolts.
Arrange the cable tube and wring in the right
positions.
TORQUE :
ENGINE HANGER NUT (FRONT) : 4.5fm
(REAR) : 4.5fm
Check the following after the engine is installed.

- Engine oil
- Electric systems
7-3
LH.CRANKCASECOVER/CONTINUOUSLYVARIABLETRANSMISSION
LH. CRANK CASE COVER
8-0
LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION
8. LH. CRANKCASE
/CONTINUOUSLY VARIABLE TRANSMISSION
SERVICE INFORMATION8-1
TROUBLESHOOTING 8-1
LH. CRANK CASE COVER 8-2
DRIVE BELT 8-3
MOVABLE DRIVE FACE8-5

CLUTCH/DRIVEN PULLEY ASSEMBLY8-8
DRIVEN FACE INSPECTION 8-10
DRIVE PULLEY INSTALLATION8-13
SERVICE INFORMATION
GENERAL SAFETY
Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil
contact.
Do not operate starter motor while the LH. crank case front cover is removed.
!
NOTE
Take precautions not ot apply the grease oil to the movable drive face or weight roller.
SPECIFICATIONS
ITEM
STANDARD
SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER
24.000-24.013mm
24.05mm
DRIVE FACE BOSS OUTER DIAMETER
23.980-23.993mm
23.96mm
DRIVE BELT WIDTH
22mm
20.5mm
WEIGHT ROLLER OUTER DIAMETER
19.95-20.02mm
19.50mm
CLUTCH OUTER AND INNER DIAMETER
125.0-125.2mm
125.5mm
DRIVEN FACE SPRING PLAY
140mm
135mm
DRIVEN FACE OUTER DIAMETER
33.965-33.985mm
33.785mm
DRIVEN FACE INNER DIAMETER
34.000-34.025mm
34.060mm
TROUBLESHOOTING
Engine starts but motorcycle does not work.
Drive belt worn.
Ramp plate damaged.
Clutch shoe worn or damaged.
Movable driven face spring cut.
Vehicle unable to run at the maximum speed,

or lack of output
Drive belt worn.
Defective movable driven face spring.
Weight roller worn.
Pulley face contaminated.
Engine stops, or the vehicle runs suddenly,

after starting.
Clutch shoe spring cut.
8-1
LH. CRANKCASE COVER
B-STAY
B-STAY
B-STAY
B-STAY
DISASSEMBLY
AIR
AIR
CLEANER
AIRCLEANER
CLEANER
Remove the air cleaner and flange bolt securing B stay.

Remove the flange bolts securing LH. crankcase.
LH.
CRANK
CASE
COVER
LH.
LH.CRANK
CRANKCASE
CASECOVER
COVER
LH.
COVER
GASKET
LH.
LH.COVER
COVERGASKET
GASKET
LH.
DRIVE
FACE
DRIVE
DRIVEFACE
FACE
DRIVE

Remove the gasket and dowel pin.
INSTALLATION
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
Install the new gasket and dowel pin after removing the
gasket of the crankcase surface.
!
NOTE
Tighten the bolts diagonally with specified

tightening torque.
Be sure to replace a new gasket and dowel pin.
Install the LH. crankcase cover.

Install the air cleaner and B stay and tighten the flange
bolt.
8-2
DRIVE
FACE
HOLDER
DRIVE
DRIVEFACE
FACEHOLDER
HOLDER
DRIVE
FACE
HOLDER
DRIVE
FACE
DRIVE
DRIVEFACE
FACE
DRIVE
FACE
DRIVE BELT
REMOVAL
Loosen the drive face setting flange nut 12mm using
the drive face holder and remove the drive face.
TOOL : DRIVE FACE HOLDER
Loosen the clutch outer setting nut using the universal

holder.
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
TOOL : UNIVERSAL HOLDER
Enlarge the driven pulley belt groove with the drive

belt in place as photo.
DRIVE BELT
CAUTION
Squeeze the drive belt into the pulley groove as

shown so that it slackens enough to remove the
driven pulley from the drive shaft.
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
DRIVEN
PULLEY
DRIVEN
DRIVENPULLEY
PULLEY
DRIVEN
PULLEY
Remove the driven pulley sub assembly with the drive

belt in place.
Remove the drive belt from the driven pulley sub assy.
8-3

DRIVE BELT INSPECTION
Check the drive belt for cracks, pry separation and
wear, replace as necessary.
Measure the width of the drive belt as shown.
COG
WIDTH
SERVICE LIMIT : 20.5mm

!
NOTE
Use only a genuine DAELIM replacement drive belt.

Do not get oil or grease on the drive belt or pulley
faces. Clean off any grease or oil before reinstalling.
DRIVE BELT INSTALLATION

DRIVEN PULLEY SUB ASSY
Turn the pulley clockwise and spread the face apart

while installing the drive belt and install the drive belt
to the driven pulley assy.
Install the driven pulley sub assy on the drive belt.

Install the drive belt to the movable drive face apart.
DRIVE
DRIVE
BELT
DRIVEBELT
BELT
DRIVEN
PULLEY
DRIVEN
DRIVEN PULLEY
PULLEY
Temporarity install the driven pulley and flange nut.

Hold the clutch outer using the universal holder and
tighten the flange nut with the specified torque.
NOTE
Do not rotate the movable drive face to became

the original position until the driven pulley to
be installed completely to the drive shaft.
8-4
FLANGE
NUT
FLANGE
FLANGENUT
NUT
Install the drive face to the LH. crank shaft.

Install the rear axel collar and temporaily install the
flange nut.
Tighten the flange nut to the specified torque using the
drive face holder.
m
TORQUE VALVE : 7.0~8.0kgf
m
UNIVERSAL HOLDER
CAUTION
When installing the drive face match it when

the LH. crank shaft serration accurately.
MOVABLE DRIVE FACE

MOVABLE
MOVABLE
DRIVE
FACE
MOVABLEDRIVE
DRIVEFACE
FACE
REMOVAL
Remove the LH. crank case cover.
Hold the drive face holder on drive face.
Remove the drive face nut, rear axel collar, drive face.
DRIVEFACE
FACEBOSS
BOSS
DRIVE
DRIVE
FACE
BOSS

Remove the movable drive face and drive face boss.
Remove the ramp plate, weight rollers and oil seal

from movable drive face.
SLIDE
SLIDE
PIECE
SLIDEPIECE
PIECE
FACE
FACE
BOSS
FACEBOSS
BOSS
RAMP
RAMP
PLATE
RAMPPLATE
PLATE
MOVABLEDRY
DRY WEIGHT
MOVABLE
MOVABLE
DRY
WEIGHT ROLLER
ROLLER
WEIGHT
ROLLER
FACE COMP
COMP
FACE
FACE
COMP
8-5

MOVABLE DRIVE FACE INSPECTION
WEIGHT ROLLER
Check the rollers for wear or damage.

Measure the O.D. of each roller.
Measure the abnormal wear.
SERVICE LIMIT : LESS THAN 2.0mm
Check the drive face boss for wear or damage and

replace as necessary.
Measure the O.D. of the drive face boss. Replace the
boss if the service limit is exceeded.
MOVABLE DRIVE FACE
BOSS

Measure the I.D. of the drive face . Replace it if the
service limit is exceeded.
Movable drive face inner diameter.
RAMP
PLATE
RAMP
RAMPPLATE
PLATE
GREASE
GREASE
GREASE
MOVABLE DRIVE FACE INSTALLATION

Install the weight roller on the movable drive face.
Apply the inside of the movable drive face with the
specified amount of grease.
SPECIFIED GREASE : ALVANIA EP2
GREASE APPLICATION : 0.5~1.5 g
Install the movable drive face boss.
OIL
SEAL
OIL
OIL SEAL
SEAL
!
WEIGHT
ROLLER
WEIGHT
WEIGHT ROLLER
ROLLER
MOVABLE
DRIVE
FACE
MOVABLE
MOVABLEDRIVE
DRIVEFACE
FACE
MOVABLE
DRIVE
FACE
8-6
NOTE
Do not get the grease on the drive face. Remove

any misplaced grease with a degreasing agent.
Use only the specified grease in the specified amount.
Install the movable drive face boss and movable drive
face to the LH. crank shaft.

Install the drive belt into the movable drive face.
MOVABLE
DRIVE
FACE
MOVABLE
MOVABLE DRIVE
DRIVE FACE
FACE
Install the drive face in to the LH. crank shaft, and

install the rear axcel collar.
DRIVE
DRIVE
FACE
DRIVEFACE
FACE
REAR
AXCEL
COLLAR
REAR
REARAXCEL
AXCELCOLLAR
COLLAR
REAR
Tighten the flange nut into the drive face.

FLANGENUT
NUT
FLANGE
FLANGE
NUT
Tighten the nut to the specified torque using the drive

face holder.
m
!
NOTE
Tighten the drive face nut to the specified

torque.
8-7
DRIVEN PULLEY
REMOVAL
Remove the drive face.
Hold the clutch outer using the universal holder and
remove the 12mm flange nut, then remove the driven
pulley.
UNIVERSAL HOLDER
Remove the driven pulley sub assembly from the drive

shaft.
Remove the drive belt.
DRIVEN
DRIVEN
PULLEY
DRIVENPULLEY
PULLEY
DISASSEMBLY
LOCK NUT WRENCH
Remove the special nut.
LOCK NUT
TOOL : CLUTCH SPRING NUT

LOCK NUT WRENCH
CLUTCH SPRING COMPRESSOR
DRIVEN
FACE
COMP
DRIVEN
DRIVENFACE
FACECOMP
COMP
DRIVEN
DRIVEN
DRIVEN
FACE
SPRING
DRIVENFACE
FACESPRING
SPRING
SPRINGGUIDE
GUIDE
SPRING
GUIDE
SPRING
DRIVE
PLATE
DRIVE
DRIVEPLATE
PLATE
DRIVE
PLATE
8-8
Remove the drive plate, driven face spring and driven

face spring guide.

Remove the seal collar from the driven pulley.
SEAL COLLAR
MOVABLE DRIVEN FACE
GUIDE ROLLER PIN

GUIDE PIN
Remove the guide pins and guide pin rollers and the
movable driven face.
Remove the O-ring from movable driven face.
GUIDE ROLLER
DRIVEN FACE
GUIDE PIN
Remove the oil seal from the movable driven face.

MOVABLE DRIVEN FACE
OIL SEAL
O-RING
GUIDE PIN
OIL SEAL
Remove the movable driven face.
O-RING
8-9

DRIVEN PULLEY INSPECTION
DRIVEN FACE BEARING INSPECTION
Check the each parts.
Check the driven face needle bearing(inner) for
damage or excessive play and replace as necessary.
Turn the inner race of the ball bearing with your finger.
Check that the bearing turns smoothly and quietly, and
that the bearing outer race fits securely.
Replace the bearing (8-11).
INNER NEEDLE BEARING
OUTER BALL BEARING
MOVABLE DRIVEN FACE SPRING INSPECTION

MOVABLE DRIVEN FACE SPRING
Measure the free length of the driven pulley spring and

replace if the service limit is exceeded.
SERVICE LIMIT : 135mm
TOOL : VERNIER CALIPER
FREE
LENGTH
CLUTCH OUTER
Measure the I.D. at shoe contact surface of the clutch
outer. Replace the outer if the service limit is exceeded.
VERNIER
CALIPER
CLUTCH OUTER
CLUTCH SHOE INSPECTION

Check the clutch shoe for wear or damage.
Measure the thickness of each shoe.
CLUTCH SHOE
8-10

Check the following;
- Movable driven face for damage or excessive wear.
- Guide pin groove for damage or deformation.
Replace damaged or worn parts as necessary.
Measure the I.D. of the movable driven face; replace if
the service limit is exceeded.
GUIDE GROOVE
MOVABLE DRIVEN FACE
Check the driven face for damage or excessive wear;

replace as necessary.
Measure the O.D. of the driven face; replace if the
service limit is exceeded.
DRIVE FACE
DRIVEN FACE BEARING REPLACEMENT

Remove the inner bearing.
Remove the snap ring then drive out the outer bearing
toward the inner bearing side.
Drive a new outer bearing into place with the sealed
end toward the outside. Install the snap ring securely.
Apply the specified amount of specified grease as
shown.
OUTER BEARING
GREASE APPLICATION : 9.0~9.5 g
INNER BEARING
SNAP RING
INNER REARING
Install in a new inner bearing.

SEALED SIDE
SPECIFIED
GREASE
SNAP RING
INNER NEEDLE
BEARING
TOOLS : BEARING DRIVEN ATTACHMENT

DRIVE PILOT
!
NOTE
Install the cir-clip fimly to the groove.

Install the inner-bearing using a hydraulic press.
OUTER BEARING
8-11

DRIVEN FACE / MOVABLE DRIVEN FACE
OIL SEAL
Install new oil seal and O-ring on the movable driven

pulley face.
O-RING
MOVABLE DRIVEN FACE
GUIDE ROLLER PIN

GUIDE PIN
Install the movable face on the driven pulley face.

Install the guide rollers and guide pins.
GUIDE ROLLER
GUIDE PIN
DRIVEN FACE
Install the seal collar.

SEAL COLLAR
LOCK NUT WRENCH
DRIVEN PULLEY SUB ASSY

Install the spring guide, driven face, drive plate assy.
Compress the assembly by turning the tool handle until
the special nut can be installed.
Clamp the clutch spring compressor in a vise and
tighten the lock nut to the specified torque using the
lock nut wrench.
m
TORQUE VALVE : 5.5kgf
Remove the spring compressor.
CLUTCH SPRING COMPRESSOR
8-12
TOOL : CLUTCH SPRING COMPRESSOR

LOCK NUT WRENCH

CLUTCH/DRIVEN PULLEY INSTALLATION
Turning the driven pulley assy rightside, extend the
belt assemble groove maximum.
Install the drive belt into driven pulley sub assy, install
the drive shaft.
Install the drive belt into movable drive face..

DRIVEN
PULLEY
DRIVEN
DRIVEN
PULLEY
DRIVEN
PULLEY
fifi
fifi
PULLEY
fifi
fifi
fifi
fifi
DRIVE
DRIVE BELT
BELT
DRIVE
BELT
DRIVE
DRIVE
FACE
DRIVEFACE
FACE
Install the drive face, rear axcel collar drive pulley nut.
Tighten to the specified torque using drive face holder.
m
DRIVEN
DRIVEN PULLEY
PULLEY
DRIVEN
PULLEY
Install the clutch onter into driven pulley sub assy and
flange nut.
Hold the clutch outer using drive universal holder,
install the flange nut to the specified torque.
m
TORQUE VALVE : 5.5kgf
Install the LH. crank case cover, and tighten the flange
bolt.
8-13
A.C GENERATOR / STARTER CLUTCH
STARTER
COMP
@
FLY
WHEEL
@
COOLING
FAN
9-0
SAIsai@@
LID VALVE
9
9
9
9
9
9
9
16.
9-1
SHROUD
RH.
RH.
SHROUD
RH.SHROUD
SHROUD
SAI
TUBE
SAI
SAITUBE
TUBE
SAI
TUBE
REMOVAL
- RR. Inner
- SAI Tube
- RH. / LH. Pillion step holder
- Muffler comp
SETTING
SETTING
SCREW
SETTINGSCREW
SCREW
Loosen the RH. shroud 4 flange bolts and 4 tapping

screws.
Loosen the LH. shroud setting screw.
Remove the LH. shroud.
LH.
SHROUD
LH.
LH.SHROUD
SHROUD
LH.
SHROUD
SAI
SAI
TUBE
SAITUBE
TUBE
A.C GENERATOR
REMOVAL
Loosen the rear cushion under cover.
Loosen the 3 bolts securing RH. shroud.
Remove the SAI.
Remove the shroud.
SAI
SAI
REED
VALVE
SAIREED
REEDVALVE
VALVE
COOLING
COOLING
FAN
COOLINGFAN
FAN
Loosen the 3 cooling fan bolts.

Remove the A.C.G. wiring from the A.C.G. wiring
setting clamp securing the engine and frame.
FLYWHEEL
FLYWHEEL
COMP
FLYWHEELCOMP
COMP
9-2
FLYWHEEL
FLYWHEEL
FLYWHEEL
DRIVE
DRIVE
FACE
DRIVEFACE
FACE
Install the universal holder on the flywheel.

If the universal holder connot be used, remove the LH.
crankcase cover at the left side of the crankshaft, and
hold the drive face with the drive face holer.
Loosen the flange nut securing the fly wheel, and

remove the flywheel using the A.C.G rotor puller.
! CAUTION
A.C.G
A.C.G
ROTOR
PULLER
A.C.GROTOR
ROTORPULLER
PULLER
Insert the puller shaft and remove the flywheel

after inserting the A.C.G rotor puller and
securing it with spanner.
The flywheel may easily removed if you rotate
the puller while tapping the puller shaft with
metal hammer.
Always use a holder and a puller to remove the
flywheel. Do not try to remove the flywheel by
hammering directly on it. The crankshaft or
components could be damaged.
After removing the flywheel, check the
woodruff key for damage and wear.
A.C.GCOUPLER
COUPLER
A.C.G
A.C.G
COUPLER
STARTER
COMP
STARTER
STARTERCOMP
COMP
STARTER
Disconnect the A.C.G wire coupler.

TOOL : A.C.G ROTOR PULLER
UNIVERSAL HOLDER
DRIVE FACE HOLDER
Loosen the fan screw securing the starter comp and

remove the starter comp on the RH.crankcase cover.
RH.
CRANK
CASE
COVER
RH.
RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.
9-3

A.C GENERATOR INSTALLTION
STARTER
STARTER
COMP
STARTERCOMP
COMP
SAI
TUBE
SAI
SAITUBE
TUBE
SAI
Install the stator to the RH. Crankcase cover.

Clean the tapered portion of the crankshaft.
Clean the inside part of the flywheel.
Check the woodruff key, install the flywheel by
aligning the groove with the woodruff key.
Temporarily install the flywheel nut, hold the flywheel

with the universal holder, or remove the LH. crankcase
cover and tighten the flywheel nut with the specified
torque.
TORQUE VALVE : 5.0~6.0kgf m
Hold the drive face with drive face holder and install
the cooling fan.
TORQUE : 0.8~1.2kgf m
Install the RH. Shroud.
Connect the A.C.G wiring coupler and connector to the
wire harness, and install the wiring with the clamp.
Install rear under cover.
Install the muffler.
SAI
REED
VALVE
SAI
SAIREED
REEDVALVE
VALVE
SAI
COOLING
COOLING
FAN
COOLINGFAN
FAN
SAI
PIPE
SAI
SAI PIPE
PIPE
RH. CRANKCASE COVER
RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.
RH.
CRANK
CASE
COVER
9-4

- Rear under cover.
- Ex. Muffler.
- Rear swing arm.
- RH shroud.
- Cooling fan.
- A.C.G starter comp.
- SAI reed valve.
Loosen the flange bolt securing the RH. Crankcase
cover.
Remove the RH crankcase cover.

Remove the RH. Crankcase cover gasket and dowelpin.
REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR
STARTINGCLUTCH
CLUTCH
STARTING
CLUTCH
STARTING
GASKET
GASKET
GASKET
DOWEL
DOWEL
PIN
DOWELPIN
PIN
OIL
PUMP
OIL
OILPUMP
PUMP
OIL
PUMP
OIL
OIL
SEAL
OILSEAL
SEAL
RH.
CRANK
CASE
COVER
RH.
RH.CRANK
CRANKCASE
CASECOVER
COVER
RH.
CRANK
CASE
COVER
REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR
SHAFT
SHAFT
SHAFT
STARTER
REDUCTION
GEAR
STARTER
STARTERREDUCTION
REDUCTIONGEAR
GEAR
STARTER
REDUCTION
GEAR
9-5

STARTER REDUCTION GEAR
INSTALLATION
REDUCTION
REDUCTION
GEAR
REDUCTIONGEAR
GEAR
Install the starter reduction gear and shaft.

Remove the gasket residues from the RH. Crankcase.
GASKET
GASKET
GASKET
GASKET
DOWELPIN
PIN
DOWEL
DOWEL
PIN
Install a new gasket and dowel pin.

Tighten the RH. Crankcase cover with flang bolts.
Install the following parts.
- A.C.Generator
- Cooling fan
- RH. Shroud
- Rear swing arm
- Rear caliper
- EX. Muffler
- Rear under cover
- Pillion step holder
STARTER CLUTCH
REMOVAL
- Rear under cover
- EX. Muffler
- Rear swing arm
- RH. Crankcase cover
RHCRANK
CRANKCASE
CASECOVER
COVER
RH
RH
CRANK
CASE
COVER
Loosen the starter clutch lock nut with a special socket.

STARTING
STARTING
CLUTCH
STARTINGCLUTCH
CLUTCH
SPECIAL
SOCKET
SPECIAL
SPECIALSOCKET
SOCKET
SPECIAL
SOCKET
9-6

TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER

Remove the thrust washer.
Remove the starter driven gear and starter clutch.
THRUST
THRUST WASHER
WASHER
THRUST
WASHER
LOCK
LOCK
NUT
LOCKNUT
NUT
OIL
OIL
PUMP
DRIVE
GEAR
OILPUMP
PUMPDRIVE
DRIVEGEAR
GEAR
Check the starter driven gear and starter clutch for

proper operation.
Remove the starter clutch.
OIL
OIL
PUMP
OILPUMP
PUMP
STARTER CLUTCH INSPECTION

NEEDLE
NEEDLE
BEARING
NEEDLEBEARING
BEARING
Check the starting clutch assembly for proper

operation.
Remove the starter driven gear, needle bearing and
starter oneway clutch set from the starter clutch
assembly.
STARTER
ONEWAY
CLUTCH
SET
STARTER
STARTERONEWAY
ONEWAYCLUTCH
CLUTCHSET
SET
STARTER
ONEWAY
CLUTCH
SET
STARTER
STARTER
DRIVEN
DRIVEN
GEAR
GEAR
STARTER DRIVEN GEAR
Check the starter driven gear for wear or damage.

Measure the inner diameter of the starter driven gear.
AAA
SERVICE LIMT : A : 32.10 mm

B : 39.53 mm
BB
BB
9-7
STARTER
STARTER
ONEWAY
CLUTCH
SET
STARTERONEWAY
ONEWAYCLUTCH
CLUTCHSET
SET
THRUST
WASHER
THRUST
THRUST WASHER
WASHER
LOCK
LOCK
NUT
LOCKNUT
NUT
Hold the drive face with the drive face holder.

Tighten the lock nut with specified torque.
TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER
SPECIAL
SPECIAL
SOCKET
SPECIALSOCKET
SOCKET
Install the following parts.

- RH. Crankcase cover
- A.C Generator
- Cooling fan
- RH. Shroud
- Rear swing arm
- Rear caliper
- EX. Muffler
- Rear under cover
- Pillion step holder
RH.
RH. CRANK
CRANK CASE
CASE COVER
COVER
RH.
CRANK
CASE
COVER
9-8
MEMO
CYLINDER HEAD / VALVES
FLANGE NUT
IN VALVE ROCKER ARM
CAM SHAFT HORDER

EX. VALVE ROCKER ARM
CAM SHAFT COMP
EX. VALVE
INLET VALVE
CARBURETOR INSULATOR
CYLINDER HEAD COMP

SAI PIPE
CYLINDER HEAD GASKET
10-0
10. CYLINDER HEAD / VALVES

TROUBLESHOOTING 10-2
CAMSHAFT 10-3
CYLINDER HEAD 10-5
VALVE SPRINGS 10-6
VALVES 10-6
VALVE GUIDES 10-7
VALVE SEATS 10-8
CYLINDER HEAD ASSEMBLY10-12
CAMSHAFT ASSEMBLY10-13
SERVICE INFORMATION
GENERAL SAFETY
The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed
from the frame to maintain the cylinder head.
The oil of camshaft oil is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder
head.
SPECIFICATIONS
Unit : mm
ITEM
ROCKER ARM
CAMSHAFT
STANDARD VALUE
ROCKER ARM INNER DIAMETER
12.016 - 12.034
12.060
ROCKER ARM SHAFT OUTER DIAMETER
11.982 - 12.000
11.950
IN
33.835 - 33.995
33.625
EX
33.984 - 34.144
-
33.765
-
IN
37.21
36.90
EX
37.21
36.90
IN
4.972 - 4.984
4.920
EX
4.952 - 4.964
4.900
VALVE GUIDE INNER DIAMETER
IN,EX
5.000 - 5.012
5.030
CLEARANCE BETWEEN
STEM AND GUIDE
IN
0.016 - 0.040
0.090
EX
0.036 - 0.060
0.120
0.8 - 1.0
1.4
CAM HEIGHT
CYLINDER HEAD WARPAGE

VALVE SPRING FREE LENGTH
VALVE
VALVE GUIDE
SERVICE LIMIT
VALVE STEM OUTER DIAMETER
VALVE SEAT WIDTH
TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT
SPARK PLUG
CAMSHAFT HOLDER 8mm NUT
CAM CHAIN TENSIONER MOUNTING BOLT
CAM CHAIN TENSIONER SEALING SCREW
CYLINDER HEAD COVER BOLT
CYLINDER HEAD BOLT
TAPPET ADJUST NUT
1.0 kgfm
1.2 kgfm
2.0 kgfm
1.2 kgfm
0.4 kgfm
0.9kgfm
1.1 kgfm
0.8 kgfm
10-1
10

TOOLS
VALVE GUIDE REAMER
VALVE GUIDE DRIVER
VALVE SPRING COMPRESSOR
VALVE SEAT CUTTER
SEAT CUTTER IN 37(21.5mm)
EX 37(18.5mm)
IN 45(22.0mm)
EX 45(22.0mm)
IN 55(20.0mm)
EX 55(20.0mm)
TROUBLESHOOTING
Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,
or by tracing noises to the top-end with a sounding rod or stethoscope.
Low comperssion
Rough idle
Valves
-Incorrect valve adjustment (see section 3)
-Burned or bent valves
-Incorrect valve timing
-Broken valve spring
-Uneven valve seating
Low cylinder compression
Cylinder head
-Leaking or damage head gasket
-Warped or cracked cylinder head
Cylinder, piston (see section 11)
Excessive white smoke

Worn valve guide or valve stem
Damaged valve stem seal
Worn or damaged piston ring
10-2
Compression too high

Excessive carbon build-up on piston or combustion
chamber
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Worn rocker arm and / or shaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
Damaged cylinder head gasket
Incorrect spark plug installation
CAMSHAFT
REMOVAL
SPECIALBOLTS
BOLTS
SPECIAL
SPECIAL
BOLTS
CYLINDERHEAD
HEADCOVER
COVER
CYLINDER
HEAD
COVER
CYLINDER

- Rear fender
- Seat support pipe
- Center cover
- Truss pipe
- Floor panel
Loosen the special bolt securing the cylinder head
cover and remove the cover.
Turn the crankshaft to the left, and align theTmark

of the flywheel with the index mark of the RH.
crankcase cover.
Verify that the piston is located at the top dead center.
(Make all camshaft lobes face downward.)
If all camshaft lobes face upward, rotate the crankshaft
to the left for 1 turn (360
), and align theT mark
with the index mark once again.
T-MARK
T-MARK
T-MARK
Loosen the pan screw of the cam chain, remove the

tensioner flange bolts and tensioner lifter.
FAN
SCREW
FAN
FANSCREW
SCREW
FAN
TENSIONER
TENSIONER
LIFT
TENSIONERLIFT
LIFT
Loosen the 4 camshaft holder 8mm nuts.

Remove the camshaft holder from the cylinder head.
FLANGENUT
FLANGENUT
FLANGENUT
CAM
SHAFT
HOLDER
CAM
CAMSHAFT
SHAFTHOLDER
HOLDER
CAM
SHAFT
HOLDER
10-3
Remove the cam chain from the camshaft.
! NOTE
Take precautions not to allow the cam chain to drop

into the crankcase.
Remove the camshaft.

CAM
CAM
SHAFT
CAMSHAFT
SHAFT
Insert the 6mm bolt into the rocker arm shaft, and
pulling bolts to remove the rocker arm shaft.
Remove the rocker arm.
Remove the other side rocker arm shaft and rocker arm
in the same sequence.
ROCKER
ARM
SHAFT
ROCKER
ROCKERARM
ARMSHAFT
SHAFT
CAMSHAFT INSPECTION
Check the rocker arm and rocker arm shaft for wear or
damage.
Measure the inner diameter of the rocker arm.
SERVICE LIMIT : 12.060 mm
INNER
INNER
DIAMETER
INNERDIAMETER
DIAMETER
Measure the outer diameter of the rocker arm shaft.

OUTER
DIAMETER
OUTER
OUTERDIAMETER
DIAMETER
OUTER
DIAMETER
MICRO
MICROMETER
METER
MICRO
METER
Check the cam lobes of the camshaft for wear or

damage.
Measure the height of the cam lobe.
SERVICE LIMIT : IN : 33.625 mm
EX: 33.765 mm
CAM
SHAFT
CAM
CAMSHAFT
SHAFT
CAM
SHAFT
10-4
Manually turn the camshaft bearing outer race, and

check if it turns smoothly.
Check the bearing for wear or damage.
! CAUTION
Be sure to check the valve clearance.
CAMSHAFT
BEARING
CAMSHAFT
CAMSHAFTBEARING
BEARING
CYLINDER HEAD
CYLINDER
CYLINDER
HEAD
CYLINDERHEAD
HEAD
FLANGE
FLANGE
FLANGE
BOLTS
BOLTS
BOLTS

- Rear fender
- Seat support pipe
- Center cover
- Truss pipe
- Floor panel
- RH. LH. shroud
- Cylinder head cover
- Cam shaft
- EX. Pipe
- Cylinder head
Remove the cylinder head gasket, dowel pin and
camchain guide from the cylinder.
CYLINDER
CYLINDER
HEAD
GASKET
CYLINDERHEAD
HEADGASKET
GASKET
CAMCHAIN
CAMCHAIN
CAMCHAIN
CAMCHAIN
CYLINDERHEAD
HEAD
CYLINDER
CYLINDER
HEAD
DISASSEMBLY
SPARK
PLUG
SPARK
SPARKPLUG
PLUG
SPARK
PLUG
Remove the carburetor insulator.

Remove the spark plug from the cylinder head.
10-5
Remove the valve spring, valve cotter, retainer, spring

and valve. Using the valve spring compressor.
TOOL : VALVE SPRING COMPRESSOR
! NOTE
To prevent the loss of tension, do not compress the

valve spring more than necessary.
Mark the disassembled parts so that they can be
reassembled into the original position later.
VALVE
SPRING
VALVE
VALVESPRING
SPRING
VALVE
SPRING
COMPRESSOR
VALVE
VALVESPRING
SPRINGCOMPRESSOR
COMPRESSOR
CYLINDER HEAD INSPECTION

Remove the carbon deposits from the inside of the
combustions chamber.
! NOTE
Take precautions not to damage the cylinder head

gasket attachment.
Check the spark plug assembling hole and the valve
seat for cracks.
Using a square and a feeler gauge, check the cylinder
head distortion.
FEELER
FEELERGAUGE
GAUGE
FEELER
GAUGE
VALVE SPRINGS
VALVESPRING
SPRING
VALVE
VALVE
SPRING
Measure the free length of the inner and outer valve

springs.
! NOTE
Replace the valve spring with new one if the length of

any one is less than the service limit.
VALVE
VALVE
VALVE
VALVES
Inspect each valve for bending, burning, scratches or
abnormal wear.
Insert the valves in their original positions in the
cylinder head.
Check that each valve moves up and down smothly,
without binding.
Measure and record the valve stem outer diameter in
three places along the valve guide sliding area.
EX: 4.900 mm
Replace the valve with a new one if the service limit is

exceeded.
10-6
VALVE
GUIDE
REAMER
VALVE
VALVEGUIDE
GUIDEREAMER
REAMER
VALVE
GUIDE
REAMER
VALVE GUIDES
INSPECTION
Insert the valve guide reamer from the combustion
chamber side and ream the guide to remove any carbon
build-up before measuring the guide.
! NOTE
Take care not to tilt or lean the reamer in the guide

while reaming.
Rotate the reamer clockwise, never counterclockwise
when inserting and removing.
VALVE
VALVE
GUIDE
VALVEGUIDE
GUIDE
TOOL : VALVE GUIDE REAMER
Measure and record each valve guide inner diameter.

Measure the guide-to-stem clearance with a dial

indicator while rocking the stem in the direction of
normal thrust.
EX: 0.120 mm
Measure the inner diameter of the new valve guide. If

the clearance is not within the service limit, replace the
valve.
VALVE
VALVE
GUIDE
DRIVER
VALVEGUIDE
GUIDEDRIVER
DRIVER
REPLACEMENT
Heat the cylinder head to 130
C - 140
C (275
F - 290
F).
Support the cylinder head and drive the old guides out
of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER
! NOTE
Avoid damaging the head when driving the valve

giude out.
! CAUTION
Do not heat the cylinder head beyond 150

C (300
F).
Use temperature indicator sticks, available from
welding supply stores, to be sure the cylinder head is
heated to the proper temperature.
Using a torch to heat the cylinder head may cause
warping.
Wear insulated gloves to avoid burns when handling
the heated cylinder head.
Refinish the valve seats whenever the valve guides are
replaced to prevent uneven seating.
10-7
VALVE
GUIDE
VALVE
VALVEGUIDE
GUIDE
VALVE
GUIDE
Apply oil to a new O-ring and install it onto a new

valve guide.
Drive the new guide in from the camshaft side of the
cylinder head while the cylinder head is still heated.
When reaming new valve guides, insert the valve guide

reamer from the combustion chamber side.
! NOTE
Take care not to tilt or lean the reamer in the guide

while reaming.
Otherwise, the valve is installed slanted, that causes oil
leaks from the stem seal and improper valve seat
contact and results in the valve seat refacing not able
to be performed.
Use cutting oil on the reamer during this operation.
Rotate the reamer clockwise, never counterclockwise
when inserting and removing.
Reface the valve seats and clean the cylinder head

thoroughly to remove any metal particles.
VALVE SEATS
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to each valve
face.
VALVE
VALVE
VALVE
10-8
VALVE
VALVE
SEAT
VALVESEAT
SEAT
Remove the valve and inspect the valve seat face.

The valve seat contact should be within the specified
width and evenly all around the circumference.
If the valve seat width is not within specification,
reface the valve seat.
! NOTE
Valve faces and stem tips cannot be ground. If a valve

face or stem tip is rough, worn unevenly, or contacts
the seat improperly, the valve must be replaced.
Measure the valve seat width.STANDARD VALUE : 0.8
-1.0 mm
VALVE SEAT REFACING

Reface the worn valve seat by using valve seat cutters
and grinders.
45
! NOTE
55
Follow the refacer manufactuers operating instructions.

Reface the valve seat whenever the valve guide has been
replaced.
Be careful not to grind the seat more than necessary.
37
Using a 45 degree cutter, remove any roughness or

irregularities from the seat.
ROUGHNESS
Using a 37 degree cutter, remove of the existing

valve seat material.
37
10-9
Using a 55 degree cutter, remove the bottom of the

old seat.
55
Using a 45 degree cutter, cut the seat to the proper

width.
SEAT WIDTH
45
If the contact area is too high on the valve, the seat

must be lowered using a 37 degree flat cutter.
Refinish the seat to specifications, using a 45 degree
finish cutter.
CONTACT TOO HIGH
37
If the contact area is too low on the valve, the seat must
be raised using a 55 degree inner cutter.
Refinish the seat to specifications, using a 45 degree
finish cutter.
CONTACT TOO LOW
55
10-10
After cutting the valve seat, apply lapping compound to

the valve face, and insert the valve with a valve guide
reamer.
! NOTE
Do not excessively press and turn the valve to set it as it

may cause damage. Gently strike and set the valve.
The seat surface may become worn on one side if the

valve is set in the same position. Turn the valve slightly
when setting it.
Take precautions not to allow compound to get into the
clearance between the stem and guide while the valve is
being set.
CYLINDER
CYLINDER
CYLINDER
STEM
SEAL
STEM
STEMSEAL
SEAL
IN/EX VALVE ASSEMBLY
VALVE
VALVE
VALVE
SPRING
SPRING
SPRING
RETAINER
RETAINER
RETAINER
RETAINER
COTTER
COTTER
COTTER
Install the valve spring and new stem seals.

Lubricate each valve stem with molybdenum disulfide
grease and insert the valve into the valve guide.
Check the valve moves up and down smoothly.
For valve spring with varying pitch, install the valve

springs with the narrow pitch end facing down.
NARROW PITCH
Install the spring retainers.

Compress the valve springs with the valve spring
compressor and install the valve cotters.
! CAUTION
Compressing the valve spring more than necessary

when installing the valve cotters may cause loss of
valve spring tension.
TOOL : VALVE SPRING COMPRESSOR
VALVE
SPRING
COMPRESSOR
VALVE
VALVESPRING
SPRINGCOMPRESSOR
COMPRESSOR
VALVE
SPRING
COMPRESSOR
10-11
Tap the valve stems gently with a soft hammer to

firmly seat the cotters.
! CAUTION
Take necessary precautions not to damage the valve.
VALVE
VALVE
SPRING
VALVESPRING
SPRING
CYLINDER
CYLINDER
HEAD
CYLINDERHEAD
HEAD
Apply engine oil to the new O-ring, and assemble it to

the carburetor insulator groove.
Tighten the carburetor insulator with mounting bolts.
Install the cam chain tensioner, and assemble pilot.
TORQUE : 1.0 kgf m
Install the spark plug.

TORQUE : 1.2 kgf m
CYLINDER
CYLINDER
CYLINDER
GASKET
GASKET
GASKET
CYLINDER HEAD ASSEMBLY

Clean any gasket material from the cylinder mating surface.
Install the cam chain guide to the cylinder.
Install the dowel pins and new gasket.
DOWEL
PIN
DOWEL
DOWEL PIN
PIN
CAM
CAM
CHAIN
CAMCHAIN
CHAIN
CYLINDER
HEAD
CYLINDER
CYLINDERHEAD
HEAD
CYLINDER
10-12
Install the cylinder head.
CAMSHAFT ASSEMBLY
EX.
VALVE
ROCKER
ARM
EX.
EX.VALVE
VALVEROCKER
ROCKERARM
ARM
EX.
VALVE
ROCKER
ARM
IN.
IN.
VALVE
ROCKER
ARM
IN.VALVE
VALVEROCKER
ROCKERARM
ARM
Apply engine oil to the rocker arm shaft, and assemble

the rocker arm to the camshaft holder.
EX.
ROCKER
ARM
SHAFT
IN.
ROCKER
ARM
SHAFT
EX.
IN.
EX.ROCKER
ROCKERARM
ARMSHAFT
SHAFT
IN.ROCKER
ROCKERARM
ARMSHAFT
SHAFT
EX.
ROCKER
ARM
SHAFT
CAM
SHAFT
HOLDER
CAM
SHAFT
HOLDER
CAM SHAFT HOLDER
CAM
CAM SHAFT
SHAFT HOLDER
HOLDER
CAM
SHAFT
HOLDER
CAM
SHAFT
CAM
CAMSHAFT
SHAFT
CAM
CAM
CHAIN
CAMCHAIN
CHAIN
Tighten the rocker arm shaft with 6mm bolts, and align
the bolt hole of the camshaft holder with the fitting side
of the rocker arm shaft.
Check the camshaft assembly for abnormal condition,

and place it on the cylinder head.
Put the cam chain and cam sprocket on the cam
sprocket.
Slowly rotate the crankshaft counterclockwise, and

align theTmark of the flywheel with the index mark
of the RH. crank case cover.
! CAUTION
Take precautions not to allow the cam chain to come

T-MARK
T-MARK
T-MARK
T-MARK
off the camshaft timing gear while turning the

camshaft.
10-13
Apply engine oil to the camshaft, and install it on the

cylinder head with the cam thread facing downward.
Assemble the cam chain and cam sprocket after
matching the cam sprocket timing mark in parallel with
the top of the cylinder head.
CAM
CAM
SHAFT
CAMSHAFT
SHAFT
TIMING
MARK
TIMING
TIMINGMARK
MARK
CAM
CAM
SHAFT
HOLDER
CAMSHAFT
SHAFTHOLDER
HOLDER
Install the dowl pins on the cylinder head.

Install the cam shaft holder.
! CAUTION
The hole of the camshaft holder and the fitting section

of the rocker arm shaft fit section must be in alignment.
Of IN and EX, the shorter rocker arm should be

installed on the IN side.
Install the cam cover plate.

Apply engine oil to the threaded part; install the
camshaft holder nut and bolts, and tighten them driving
with 2 - 3 times.
TORQUE VALUE : 2.0 kgf m
Remove the pan screws and seals from the cam chain
tensioner lifter.
Rotate the tensioner shaft clockwise with a small
driver, and insert the shaft into the body completely.
! CAUTION
If the cam chain tensioner lifter is dropped, the shaft

will advance by the spring force.
10-14
HARDCLIP
HARDCLIP
HARDCLIP
TENSIONER
TENSIONER
LIFTER
TENSIONERLIFTER
LIFTER
Fix the tensioner shaft with a hard clip.

Assemble a new gasket to the tensioner lifter, and
install the tensioner lifter on the cylinder.
Tighten the tensioner mounting bolts.
Remove the tensioner shaft clip from the tensioner

lifter. Assemble the O-ring and pan screws to the
tensioner lifter.
FAN
FAN
SCREW
FANSCREW
SCREW
Fill clean engine oil into the operating parts of the

cylinder head.
Adjust the valve clearance.
VALVE CLEARANCE : INHALE 0.12 0.02mm
EXHALE 0.12 0.02mm
FEELER
GAUGE
FEELER
FEELERGAUGE
GAUGE
FEELER
GAUGE
Remove oil from the cylinder head cover grooves, and

accurately assemble the gasket to the cover.
Install the cylinder head cover.
Tighten the cylinder head cover bolts.
Install the carburetor insulator..

SPARK
SPARK
PLUG
CAP
SPARKPLUG
PLUGCAP
CAP
10-15
CYLINDER / PISTON
CYLINDER
TOP RING
SECOND RING
OIL RING
CYLINDER GASKET
PISTON
11-0
CYLINDER / PISTON
11. CYLINDER / PISTON

CYLINDER 11-2
PISTON / PISTON RING 11-3

CYLINDER INSTALLATION 11-6
SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
Take care not to damage the cylinder wall and piston.
Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
Unit : mm
ITEM
STANDARD VALUE
SERVICE LIMIT
INNER DIAMETER
56.000 - 56.010 mm
56.100 mm
TAPER
0.050 mm
OUT-OF-ROUND
0.005 mm
HEAD CONTACT WARPAGE
0.020 mm
PISTON SKIRT OUTER DIAMETER
55.925 - 55.945 mm
55.825 mm
PISTON PIN HOLE INNER DIAMETER
15.002 - 15.008 mm
15.040 mm
PISTON PIN OUTER DIAMETER
14.994 - 15.000 mm
14.960 mm
PISTON-TO-PISTON PIN CLEARANCE
0.002 - 0.014 mm
0.020 mm
TOP
0.040 - 0.067 mm
0.110 mm
SECOND
0.025 - 0.052 mm
0.080 mm
TOP / SECOND
0.10 - 0.25 mm
0.50 mm
OIL RING (SIDE RAIL)
0.20 - 0.70 mm
1.10 mm
CYLINDER-TO-PISTON CLEARANCE
0.055 - 0.090 mm
0.200 mm
CONNECTING ROD SMALL END INNER DIAMETER
15.010 - 15.028 mm
15.060 mm
GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN
0.010 - 0.034 mm
0.040 mm
CYLINDER
PISTON,
PISTON PIN,
PISTON RING
PISTON RING-TOGROOVE CLEARANCE

PISTON RING
JOINT GAP
TROUBLESHOOTING
Comperssion too low
Overheating
Worn piston
Worn, damaged piston ring
Worn cylinder
Excessive carbon build-up on top of piston
Abnormal noise
Excessive smoke
Worn cylinder, piston or piston rings
Improper installation of piston ring
Scored or scratched piston or cylinder wall
Worn cylinder and piston

Worn connecting rod small end bearing or piston pin
Damaged piston ring
Excessive carbon build-up on top of piston
11-1
11
CYLINDER / PISTON
CYLINDER
CYLINDER
CYLINDER
CYLINDER
REMOVAL
Remove EX. pipe.
Remove the cylinder head cover.
Remove the cam shaft.
Remove cylinder head.
Remove the cam chain guide from the cylinder.
Remove cylinder
CAM
CAM
CHAIN
GUIDE
CAMCHAIN
CHAINGUIDE
GUIDE
Remove the gasket and dowel pin. Carefully remove

any adhering gasket material from the cylinder / head
mating surface. Do not scratch the surface.
! NOTE
Take care not to damage the cylinder mating surface.

CYLINDER
GASKET
CYLINDER
CYLINDERGASKET
GASKET
PISTON
PISTON
PISTON
PISTON
WEAR INSPECTION
CYLINDER
GAUGE
CYLINDER GAUGE
Inspect the cylinder wall for scratches and wear.

Measure and record the cylinder inner diameter at three
levels in both an X and Y axis.
Take the maximum reading to determine the cylinder
wear.
Measure the piston outer diameter.

Calculate the piston-to-cylinder clearance. Take the
maximum reading to determine the clearance.
TOP
TOP
MIDDLE
MIDDLE
BOTTOM
BOTTOM
11-2
Calculate the cylinder for out-of-round at three levels in

an X and Y axis. Take the maximum reading to
determine the out-of-round.
Calculate the cylinder for taper at three levels in an X
and Y axis. Take the maximum reading to determine
the taper.
If any of the cylinder measurements exceed the service
limits, replace the cylinder.
SERVICE LIMIT : OUT-OF-ROUND : 0.005 mm
TAPER : 0.05 mm
CYLINDER / PISTON
WARPAGE INSPECTION
Check the cylinder for warpage by placing a straight
edge and feeler gauge across the stud holes. Replace
the cylinder if the service limit is exceeded.
! NOTE
Any clearance between the cylinder and head due to

damage or warpage will result in compression leaks
and reduced performance.
FEELER
FEELER
GAUGE
FEELERGAUGE
GAUGE
PISTON
PISTON
PISTON
PISTON
PISTON / PISTON RING

REMOVAL
! NOTE
Place a clean shop towel over the crankcase to prevent

the possibility of the clip falling into the crankcase.
PISTON
PISTON
PIN
CLIP
PISTONPIN
PINCLIP
CLIP
Remove the piston pin clip using a pair of pliers.

Press the piston pin out of the piston.
! NOTE
Do not damage or scratch the piston.

Do not apply side force to the connecting rod.
Do not let the clip fall into the crankcase.
INSPECTION
Clean carbon deposits from the piston.
Inspect the piston rings for movement by pressing the
rings. The rings should be able to move in its groove
without catching.
Spread each piston ring and remove it by lifting it up at
a point just opposite the gap.
! NOTE
Do not damage to the piston by piston ring when

PISTON
RING
PISTON RING
removing.
Measure the clearance between the piston ring and
piston grooves.
SERVICE LIMIT : TOP : 0.110 mm
SECOND : 0.080 mm
OIL RING : 0.280 mm
Inspect the piston for wear or damage.
11-3
CYLINDER / PISTON
11-4
CYLINDER / PISTON
MARK
R
TOP RING
SECOND RING
SIDE RAIL
OIL
SPACER
20mm
RING
SIDE RAIL
PISTON
TOP RING
SECOND RING
CRANK
SHAFT
CONNECTING
ROD
CRANK
CRANKSHAFT
SHAFTCONNECTING
CONNECTINGROD
ROD
CRANK
11-5
CYLINDER / PISTON
CYLINDER
CYLINDER
GASKET
CYLINDERGASKET
GASKET
PISTON
PISTON
PISTON
DOWEL
DOWEL
PIN
DOWELPIN
PIN
PIN
PIN
CLIP
PINCLIP
CLIP
CYLINDER
CYLINDER
CYLINDER
( 10-12)
( 10-13)
( 10-5)
( 3-9)
( 7-3)
11-6
MEMO
TRANSMISSION/CRANKSHAFT/CRANK CASE
12-0
TRANSMISSION/CRANKSHAFT/CRANKCASE
12
12-1
12-2
12-3
12-6
12-7
12-8
12-9
12-10
( SECTION 4-4)
( SECTION 7)
( SECTION 10 AND 11)
( SECTION 9)
( SECTION 8)
( SECTION 8)
( SECTION 12)
12
12-1
TORQUE VALUE
CRANK CASE BOLT 1.0kg-m
TOOLS
-UNIVERSAL BEARING PULLER
-BEARING REMOVER SET
-REMOVER ASSEMBLY
-REMOVER SHAFT
-REMOVER HEAD
-SLIDING WEIGHT
-ASSEMBLY SHAFT
TROUBLESHOOTING
Engine Noise
Connecting rod big and small ends loose.
Crank pin bearing loose.
Engine started but unable to move out

Transmission damage.
Transmission seized.
Noise during operation

Gear worn, overheated, or cranked.
Bearing worn.
Oil leaks
Excessive oil level.
Oil seal worn or damaged.
12-2
8-2
8
3-9
14-6
15-8
14-3
TRANSMISSION
COVER
TRANSMISSION
TRANSMISSIONCOVER
COVER
TRANSMISSION
COVER
COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER
SPECIAL
SPECIAL
BOLT
SPECIALBOLT
BOLT
FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT
DRIVESHAFT
SHAFT
DRIVE
DRIVE
SHAFT
TRANSMISSION
COVER
TRANSMISSION
TRANSMISSIONCOVER
COVER
TRANSMISSION
COVER
OIL
SEAL
OIL
OILSEAL
SEAL
OIL
SEAL
12-3
FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT
COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER
DRIVE SHAFT
FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT
COUNTER
COUNTER
SHAFT
COUNTERSHAFT
SHAFT
12-4
NEEDLE
NEEDLE
BEARING
NEEDLEBEARING
BEARING
BALL
BEARING
BALL
BALL BEARING
BEARING
OUTER
OUTER
DRIVER
OUTERDRIVER
DRIVER
OUTER
OUTER
HANDLE
OUTERHANDLE
HANDLE
DRIVER
DRIVER
PILOT
DRIVERPILOT
PILOT
CRANK
ASSEMBLY
COLLAR
CRANK
CRANKASSEMBLY
ASSEMBLYCOLLAR
COLLAR
CRANK
Install the bearing to the case with special tools.
CRANK
ASSEMBLY
SHAFT
CRANK
CRANKASSEMBLY
ASSEMBLYSHAFT
SHAFT
CRANK
TOOL : DRIVE HANDLE A

OUTER DRIVER
DRIVER PILOT
FINAL
FINAL SHAFT
SHAFT
FINAL
SHAFT
COUNTER
SHAFT
COUNTER
COUNTERSHAFT
SHAFT
COUNTER
SHAFT
12-5
Replace the new oil seal on the transmission

cover.
Insrall the transmission cover.
MISSIONCOVER
COVER
MISSION
MISSION
COVER
ENGINE
ENGINE
ENGINE
ENGINE
Loosen the 8 RH./LH. crankcase setting bolt.

Remove the transmission bleeder tube.
Remove the RH./LH. radiator hose from the RH.
crankcase.
FLANGE
FLANGE
BOLTS
FLANGEBOLTS
BOLTS
12-6
RH.
RH.
CRANK
CASE
RH.CRANK
CRANKCASE
CASE
LH.
LH.
CRANK
CASE
LH.CRANK
CRANKCASE
CASE
CRANK
CRANK
SHAFT
CRANKSHAFT
SHAFT
GASKET
GASKET
GASKET
GASKET
DOWEL
DOWEL
PIN
DOWELPIN
PIN
CRANK
CRANK
BEARING
CRANKBEARING
BEARING
RH.
RH.
CRANK
CASE
RH.CRANK
CRANKCASE
CASE
UNIVERSAL REARING PULLER
12-7
DIAL GAUGE
MEASURING POINT
FILLER GAUGE
DIAL GAUGE
Y
X
OIL
OIL SEAL
SEAL
LH.
CRANK
CASE
LH.
LH.CRANK
CRANKCASE
CASE
LH.
BEARING
BEARING
BEARING
OIL
OIL SEAL
SEAL
OIL
SEAL
12-8
BEARING
BEARING
REMOVER
SET
BEARINGREMOVER
REMOVERSET
SET
DRIVER
DRIVER
HANDLE
DRIVERHANDLE
HANDLEAAA
OUTER
DRIVER
OUTER
OUTERDRIVER
DRIVER
OUTER
DRIVERPILOT
PILOT
DRIVER
DRIVER
PILOT
DRIVER
DRIVER
HANDLE
DRIVERHANDLE
HANDLEAAA
TOOL : CRANK SHAFT ASSEMBLER
CRANK
SHAFT
ASSEMBLY
CRANK
CRANKSHAFT
SHAFTASSEMBLY
ASSEMBLY
CRANK
12-9
DOWEL
DOWEL
PIN
DOWELPIN
PIN
CRANK
CRANK
SHAFT
CRANKSHAFT
SHAFT
LH.
LH.
CRANKCASE
LH.CRANKCASE
CRANKCASE
Install the crankcase.

Install the engine on the frame. (
12-10
7-3)
MEMO
FRONT WHEEL/FRONT FORK/STEERING
STEERING HANDLE
STEERING STEM
FRONT FORK
FRONT DISK
FRONT WHEEL
FRONT TIRE
13-0
13. FRONT WHEEL/FRONT FORK/STEERING

STEERING HANDLE 13-3
FRONT WHEEL 13-4
FRONT WHEEL BEARING 13-5
SPEEDOMETER GEAR13-6
FRONT WHEEL INSTALLATION13-7
FRONT FORK 13-7
STEERING STEM 13-12
SERVICE INFORMATION
GENERAL SAFETY
!
CAUTION
Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged.
Place a jack underneath the engine to support the 2-wheeled vehicle.
SPECIFICATIONS
ITEM
STANDARD VALUE (mm)
SERVICE LIMIT (mm)
0.2
RADICAL
2.0
AXIAL
2.0
AXLE SHAFIT DEFLECTION

FRONT WHEEL RIM DEFLECTION
FRONT CUSHION SPRING FREE LENGTH
266.3
13
TORQUE VALUES
STEERING STEM LOCK NUT
STEERING TOP CONE RACE
FRONT CUSHION BOLT
FRONT AXLE NUT
BRAKE CALIPER BOLT
7.84~11.76 fm
0.49~1.27 fm
1.98~2.45 fm
4.41~4.9 fm
2.45~3.43 fm
13-1
TROUBLESHOOTING
Hard steering
Steering top cornice too tight.
Damaged steering stem steel ball.
Faulty steering ball race, cone race.
Insufficient tire pressure.
Tire is worn.
Steers to one side or does not track straight

Bent front fork.
Bent front axle.
Bent frame.
Tire is worn or modification.
Worn wheel bearing.
Front wheel wobbling

Bent rim.
Faulty wheel bearing.
Hard to rotate the wheel.

Faulty wheel bearing.
Soft suspension
Weak fork spring.
Front cushion noise

Loose front fork fasteners.
13-2
STEERING HANDLE
MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER
MASTER
CYLINDER
REMOVAL
Loosen the bolts securing the front and rear break
master cylinder.
MASTERCYLINDER
CYLINDER
MASTER
MASTER
CYLINDER
HOLDER
HOLDER
HOLDER
HOLDER
INNER
BOX
INNER
INNERBOX
BOX
LH.HANDLE
HANDLEGRIP
GRIP
LH.
HANDLE
GRIP
LH.
RH.
HANDLE
GRIP
RH.
RH.HANDLE
HANDLEGRIP
GRIP
Disconnect the throttle cable from the throttle grip.
Remove the handle grip from the handlebar.

HANDLE
HANDLE
GRIP
HANDLEGRIP
GRIP
HEX
SOCKET
BOLTS
HEX
HEXSOCKET
SOCKETBOLTS
BOLTS
HEX
SOCKET
BOLTS
Remove the cap on the handle upper holder.

Loosen the hexbolt securing handle bar and remove the
steering handle comp.
HANDLE
HANDLE UPPER
UPPER HOLDER
HOLDER
HANDLE
UPPER
HOLDER
13-3
STEERING
HANDLE
STEERING
STEERINGHANDLE
HANDLE
STEERING
INSTALLATION
Align the line of the steering handle to the handle under
holder.
Install the handle upper holder using the hexbolt, to the
specified torgue.
TORQUE : 3.92 - 4.9fm
HANDLE
HANDLE
UNDER
HOLDER
HANDLEUNDER
UNDERHOLDER
HOLDER
NOTE
Adjust the throttle grip free play to the

specified range of 2-6mm.
HANDLE
HANDLE UPPER
UPPER HOLDER
HOLDER
HANDLE
UPPER
HOLDER
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
FRONT
FRONT
CALIPER
FRONTCALIPER
CALIPER
FRONT WHEEL
REMOVAL
Jack the motorcycle front wheel off the ground.
Loosen the flange bolt securing the front caliper to
remove the caliper.
Loosen the axle nut, speedometer cable setting screw
and remove the wheel.
DIAL
GAUGE
DIAL
DIALGAUGE
GAUGE
DIAL
GAUGE
FRONT
AXLE
FRONT
FRONTAXLE
AXLE
INSPECTION
AXLE RUNOUT
Set the axle in V blocks and measure the runout using a
dial gauge.
The actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT : 0.2mm replace if over
13-4
ROTATION
ROTATION
ROTATION
BEARING
BEARING
REMOVER
HEAD
BEARINGREMOVER
REMOVERHEAD
HEAD
DRIVER
HANDLE
DRIVER
DRIVERHANDLE
HANDLEAAA
DRIVER
13-5
SPEEDOMETER GEAR
GEAR
GEAR
WASHER
GEARWASHER
WASHER
INSPECTION
Remove the speedometer gear from the speedometer
gear box.
Apply grease to the speedometer gear unit and install.
SPEEDOMETER
GEAR
BOX
SPEEDOMETER
SPEEDOMETERGEAR
GEARBOX
BOX
SPEEDOMETER
GEAR
BOX
SPEEDOMETER
GEAR
SPEEDOMETER
SPEEDOMETERGEAR
GEAR
SPEEDOMETER
GEAR
ASSEMBLY
DUST
SEAL
DUST
DUSTSEAL
SEAL
DUST
SEAL
Apply grease to left side dust seal rim.

Install the left side dust seal.
Install the brake disk.
Install disk bolts.
TORQUE VALUE : 4.0 ~4.5 kgfm
BEARING
BEARING
BEARING
Install the front wheel side collar.
FRONT
FRONT
WHEEL
SIDE
COLLAR
FRONTWHEEL
WHEELSIDE
SIDECOLLAR
COLLAR
Install the speedometer gear unit by aligning its

retaining pawl with the hub cutout.
GEARBOX
BOXRETAINER
RETAINER
GEAR
GEAR
BOX
RETAINER
13-6
Apply grease to the dust seal rim.

Install the dust seal, and align the tangs of the
speedometer gear retainer with the gear groove to
assemble the speedometer gear box.
GEAR
BOX
RETAINER
GEAR
GEARBOX
BOXRETAINER
RETAINER
GEAR
BOX
RETAINER
SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX
PART
PART
FRONT WHEEL INSTALLATION

Insert the front wheel between the front forks.
Insert the disk, taking precautions not to damage the
pad, and assemble the wheel.
Align the slots of the speedometer gear with the tangs
of the RH. fork slider.
Insert the front axle into the speedometer gear box and
the wheel hub.
SPEEDOMETER
SPEEDOMETER
GEAR
BOX
SPEEDOMETERGEAR
GEARBOX
BOX
Install the axle nut.

Install the speedometer cable, and tighten with screws.
Place the front wheel on the ground, and tighten the
axle nut to the specified torque.
TORQUE VALUE : 5.0-7.0 kgfm
AXLE
AXLE
NUT
AXLENUT
NUT
FRONT
FRONT
CALIPER
FRONTCALIPER
CALIPER
FRONT FORK
REMOVAL
-Front brake caliper
-Front fender
-Front wheel
FRONT
FRONT
WHEEL
AXLE
FRONTWHEEL
WHEELAXLE
AXLE
13-7
When removing the front fork, loosen the flange bolt

lightly.
STEERINGSTEM
STEMCOMP
COMP
STEERING
STEM
COMP
STEERING
NOTE
Support the vehicle securely under the engine not

to turn over it.
Loosen the flange bolt, but do not remove it.
Loosen the 4 setting bolts securing the RH./LH. front
fork, remove the RH./LH. front fork.
After removal of RH. front fork, loosen the flange bolt
and remove the front brake hose clamp A.
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
FLANGE
BOLT
FRONT
FRONT
FORK
BOLT
FRONTFORK
FORKBOLT
BOLT
DISASSEMBLY
Remove the fork pipe bolt.
!
FRONT
FRONT
FORK
PIPE
FRONTFORK
FORKPIPE
PIPE
SOCKETBOLT
BOLT
SOCKET
SOCKET
BOLT
NOTE
If the screw is completely loosened, the fork tube

cap bolt may spring out by the force fo the spring.
Take due precautions.
Remove the fork spring, and expand and release
the fork pipe several times to drain fork oil.
Wrap the bottom case with a piece of cloth, and
remove the socket bolt.
NOTE
If the socket bolt turns idle, but cannot be

removed, temporarily assemble the spring and
the fork tube cap bolt first.
Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.
13-8
Remove the dust seal.
DUST
SEAL
DUST
DUSTSEAL
SEAL
DUST
SEAL
OIL
OIL
SEAL
STOP
RING
OILSEAL
SEALSTOP
STOPRING
RING
Remove the oil seal stop ring.

! NOTE
Take precaution not to damage the interior and

exterior rim of the bottom case.
Remove the fork pipe from the bottom case.

Remove the cution spring, pipe seat and oil lock piece
from the fork pipe.
BOTTOM
BOTTOM
CASE
BOTTOMCASE
CASE
FORK
FORK
BOLT
FORKBOLT
BOLT
FRONT
CUSHION
SPRING
FRONT
FRONTCUSHION
CUSHIONSPRING
SPRING
PIPESEAT
SEAT
PIPE
PIPE
SEAT
Check and inspect the each parts.
FORK
FORK
PIPE
FORKPIPE
PIPE
RESOUND
SPRING
RESOUND
RESOUNDSPRING
SPRING
RESOUND
BOTTOM
BOTTOM
CASE
BOTTOMCASE
CASE
OIL
OIL
LOCK
PIECE
OILLOCK
LOCKPIECE
PIECE
SOCKET
SOCKET BOLT
BOLT
SOCKET
BOLT
13-9

FRONT FORK INSPECTION
Place the fork spring on a level place, and measure the
free length.
If the free length deviates from the service limit,
replace the springs with new ones.
Check components for damage or abnormal wear.
Replace defective parts with new ones.
SERVICE LIMIT : FORK SPRING : 266.3mm
FRONT
FRONT
FORK
SPRING
FRONTFORK
FORKSPRING
SPRING
FORK
PIPE
FORK
FORKPIPE
PIPE
FORK
PIPE
Set the fork pipe on a V-blocks, and measure fork pipe

deflection by rotating with a dial gauge.
SERVICE LIMIT : Replace if the deflection is greater
than 0.2mm
Check the slider bush contact face.

If the slider bush is extensively damaged, replace the
bottom case.
OIL
SEAL
STOP
RING
OIL
OILSEAL
SEALSTOP
STOPRING
RING
OIL
SEAL
STOP
RING
FRONT FORK ASSEMBLY

Wash parts with clean oil prior to assembling.
Assemble the rebound spring and the fork piston to the
fork tube.
Assemble the fork pipe to the bottom case.
Wrap the bottom case with a piece of cloth, and fix it to

the vise.
Apply screw locking agent to the socket bolt thread,
and assemble the socket bolt to the fork piston.
TORQUE VALUE : 2.0kgfm
!
NOTE
When a vise is used to hold the bottom case, do not
insert the case itself but insert the bracket.
13-10

Apply ATF to a new oil seal.
Assemble the oil seal to the bottom case.
Insert the oil seal with special tools until the attachment
groove of the bottom case set ring is exposed.
FORK SEAL DRIVER
TOOLS : FORK SEAL DRIVER

FORK SEAL DRIVER BODY
DUST
DUST
SEAL
DUSTSEAL
SEAL
Install the oil seal stopper ring.

Accurately assemble the oil seal stop ring to the bottom
case.
Install the dust seal.

Fill a prescribed amount of automatic transmission
fluid(ATF) into the fork tube.
CAPACITY : 90cc
FORK OIL
OIL LEVEL
Slowly press the fork tube 2-3 times to discharge air.
Assemble the springs to the fork pipe.

!
NOTE
Install the spring with the smaller pitch side facing

downward.
13-11
Assemble the fork bolt to the fork pipe.

FORK
PIPE
BOLT
FORK
FORKPIPE
PIPEBOLT
BOLT
ASSEMBLY
STEERING
STEERING
STEM
STEERINGSTEM
STEM
Align the part of groove with the setting bolt

connection.
Tighten the front fork setting bolt to the specified
torque.
TORQUE VALUE : 7.5 kgfm
FRONT
FRONT
FORK
FRONTFORK
FORK
FLANGE
BOLT
FLANGE
FLANGEBOLT
BOLT
STEERING STEM
HANDLE
POST
COMP
HANDLE
HANDLEPOST
POSTCOMP
COMP
HANDLE
REMOVAL
- Handle cover
- Rear handle cover
- Front cover
- Handle bar
- Front wheel
FLANGE
BOLT
FLANGE
U-NUT
FLANGEBOLT
BOLT
FLANGE
BOLT
U-NUT
U-NUT
U-NUT
SETTING
SETTING
HANDLE
COLLAR
SETTINGHANDLE
HANDLECOLLAR
COLLAR
STEERING
STEM
SOCKET
STEERING
STEERINGSTEM
STEMSOCKET
SOCKET
NOTE
Be careful not to turn over the vehicle.
Remove the steering stem lock nut with steering stem

lock nut socket.
Remove the steering top nut with steering stem socket.
STEERING
STEERING
STEM
LOCK
NUT
STEERINGSTEM
STEMLOCK
LOCKNUT
NUT
13-12
STEERING
STEERING
STEM
COMP
STEERINGSTEM
STEMCOMP
COMP
Remove the front fork.

Check the steel ball, cone race and ball race for damage
and wear if possible, replace it.
Check the bottom cone race for wear and damage.
STEERING
UNDER
BALL
ASS
STEERING
STEERINGUNDER
UNDERBALL
BALLASS
ASS YYY
STEERING
UNDER
BALL
ASS
STEERING
STEERINGUNDER
UNDERBALL
BALLASS
ASS YYY
STEERING
UNDER
BALL
ASS
Remove the steering top ball race from the head pipe.
Remove the steering bottom ball race.
Check the ball race for wear and damage, if necessary,
replace it.
INSTALLATION
Install the steering head dust seal washer and dust seal
onto the steering stem.
Press in the steering bottom cone race using the
steering stem driver.
Install the under ball assy into the steering stem.
TOOL : STEERING STEM DRIVER
STEERING
TOP
THREAD
NUT
STEERING
STEERINGTOP
TOPTHREAD
THREADNUT
NUT
STEERING
TOP
THREAD
NUT
Insert the steering stem into the head pipe.

Install the steering upper ball assy into the steering
stem.
Install the top cone race and steering top thread onto
the steering head.
Tighten the top thread to specified torque, then loosen
the top thread turn.
TORQUE VALUE : 0.15~0.25 kgfm
Recheck that the steering stem moves smoothly

without play or binding.
Tighten the steering stem lock nut temporarily.
TOOLS : STEERING STEM LOCK NUT SOCKET
STEERING STEM SOCKET
Install the following parts

-Front fork
-Front wheel
-Steering handle
-Inner box
13-13
REAR WHEEL/SUSPENSION/REAR SWING ARM
14-0
14. REAR WHEEL / SUSPENSION / REAR SWING ARM

14-5
REAR CUSHION
14-6
REAR SWING ARM
REAR WHEEL 14-3
SERVICE INFORMATION
!
CAUTION
Use the specified tire lever and rim protector to remove or assemble tires to protect the rim from being damage.
SPECIFICATIONS
ITEM
REAR WHEEL RIM RUN OUT

REAR CUSHION SPRING FREE LENGTH
STANDARD VALUE
SERVICE LIMIT
2.0 mm
219 mm
215 mm
TORQUE VALUES :
REAR CUSHION UPPER BOLT
REAR CUSHION UNDER BOLT
REAR CUSHION ROD LOCK NUT
REAR AXLE NUT
3.5~4.5fm
3.5~4.5fm
3.0~4.5fm
6.0~8.0fm
14
14-1
TROUBLESHOOTING
Wobble or vibration in motorcycle
Bent wheel tire
Faulty tire
Axle not tightened properly
Insufficient air in tire
Wheel out of balance
Soft suspension
Weak springs
Rear damper improperly adjusted, oil leakage
Hard suspension
Rear damper improperly adjusted
Bent shock absorber rod
Suspension noise
Loose fasteners
Worn shock
14-2
REAR WHEEL
REMOVAL
Support the motorcycle on the main stand.
Remove the muffler.
MUFFLER
MUFFLER
MUFFLER
Remove the rear brake caliper assembly with brake hose

from the rear swing arm.
Loosen the rear axle nut.
Remove the rear swing arm.
REAR
SWING
ARM
REAR
REARSWING
SWINGARM
ARM
REAR
SWING
ARM
Remove the rear wheel inside collar.
REAR
REARWHEEL
WHEELINSIDE
INSIDECOLLAR
COLLAR
REAR
WHEEL
INSIDE
COLLAR
Remove the rear wheel.

REAR
WHEEL
REAR
REARWHEEL
WHEEL
REAR
WHEEL
REAR
BRAKE
DISK
REAR
REARBRAKE
BRAKEDISK
DISK
REAR
BRAKE
DISK
14-3
DIAL
DIAL
GAUGE
DIALGAUGE
GAUGE
FINAL
FINAL
SHAFT
FINALSHAFT
SHAFT
REAR
REAR
WHEEL
REARWHEEL
WHEEL
( 14-6)
REAR
REAR
WHEEL
INSIDE
COLLAR
REARWHEEL
WHEELINSIDE
INSIDECOLLAR
COLLAR
REAR
REAR
SWING
ARM
REARSWING
SWINGARM
ARM
Install the EX. muffler.
14-4
REAR CUSHION
REAR
REAR
CUSHION
REARCUSHION
CUSHION
REMOVAL
UNDER
UNDER
UNDER
Remove the upper bolt.

Remove the lower bolt.
Remove the rear cushion.
BOLTS
BOLTS
BOLTS
ATTACHMENT
ATTACHMENT
ATTACHMENT
DISASSEMBLY
Install the compressor attachment as shown in the
figure.
Install the cushion on the cushion compressor, and
compress the spring.
TOOL : REAR CHUSION COMPRESSOR
ATTACHMENT
REAR CHUSION COMPRESSOR
REAR
CUSHION
COMPRESSOR
REAR
REARCUSHION
CUSHIONCOMPRESSOR
COMPRESSOR
REAR
CUSHION
COMPRESSOR
ATTACHMENT
ATTACHMENT
ATTACHMENT
Fix the upper metal and loosen the hex nut.

Remove the upper metal.
Remove the hex nut, upper metal, stopper rubber and
the spring from the rear damper comp.
UPPER
UPPER
METAL
UPPERMETAL
METAL
INSPECTION
REAR
REAR
CUSHION
SPRING
REARCUSHION
CUSHIONSPRING
SPRING
Measure the rear cushion spring free length.

Check the damper rod for deflection or damage.
SERVICE LIMIT : 215mm
FREE
FREE
LENGTH
FREELENGTH
LENGTH
14-5

INSTALLATION
Install the spring, stopper rubber to the damper comp.
Apply thread locking agent to the hex nut, and install
the rear cushion compressor attachment on the damper
rod.
Fix the upper metal, and tighten the hex nut.
TORQUE VALVE : 3.0~4.5kgf m
TOOLS : REAR CHUSION COMPRESSOR ATTACHMENT
REAR CHUSION COMPRESSOR
!
NOTE
Install the spring with the smaller pitch side

facing downward.
Install the rear cushion.
Tighten the top and bottom of the cushion with bolts.
TORQUE VALVE : UPPER SIDE : 3.5~4.5kgf m
LOWER SIDE : 3.5~4.5kgf m
REAR SWING ARM
REAR
BRAKE
CALIPER
REAR
REARBRAKE
BRAKECALIPER
CALIPER
REMOVAL
Remove the EX. Muffler.
REAR
REAR
SWING
ARM
REARSWING
SWINGARM
ARM
Remove the rear brake caliper.

Loosen the rear axle U-nut.
Remove the rear swing arm.
14-6
DISASSEMBLY
Disassemble the rear wheel outside collar from the rear
swing arm.
Disassemble the oil seal (28 x 42 x 7) and radial ball
bearing (6302UU).
OIL
OIL
SEAL
OILSEAL
SEAL
OUTSIDE
OUTSIDE
COLLAR
OUTSIDECOLLAR
COLLAR
INSTALLATION
REAR
SWING
ARM
REAR
REARSWING
SWINGARM
ARM
REAR
SWING
ARM

Install the rear swing arm to the rear wheel axle bolt.
Tighten the rear wheel axle nut.
Install the rear caliper.

Install the muffler.
14-7
MEMO
MEMO
BRAKE SYSTEM
15-0
BRAKE SYSTEM
15. BRAKE SYSTEM

TROUBLESHOOTING15-2
BRAKE FLUID 15-3
FRONTBRAKEPADREPLACEMENT15-5
REAR BRAKE PAD 15-6
FRONT BRAKE CALIPER 15-6

REAR BRAKE CALIPER 15-8
MASTER CYLINDER15-11
BRAKE DISK 15-13
SERVICE INFORMATION
GENERAL SAFETY
Do not allow foreign material to enter the system when replenishing brake fluid.
To prevent chemical changes, do not mix different types of brake fluid.
Do not use the old brake fluid again.
Brake fluid can cause damage to painted, plastic, and rubber surfaces. Take precaution not to allow parts to be
contaminated by the brake fluid.
Do not reuse sealing washers.
Clean the disassembled parts with brake fluid, and check for any clogged passage with compressed air.
Bleed the brake hose after removing it.
Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking
performance, if contaminated, replace the pad with a new one and clean the disk.
SPECIFICATIONS
ITEM
STANDARD
SERVICE LIMIT
FRONT BRAKE CALIPER PISTON A O.D
33.928-33.878mm
33.848mm
FRONT BRAKE CALIPER CYLINDER A I.D
33.96-34.01mm
34.01mm
FRONT BRAKE CALIPER PISTON B O.D
25.33-25.37mm
25.30mm
FRONT BRAKE CALIPER CYLINDER B I.D
25.41-25.46mm
25.46mm
REAR BRAKE DISK THICKNESS
4.0mm
3.0mm
REAR BRAKE DISK RUNOUT
3.0mm
REAR BRAKE MASTER CYLINDER I.D
13.5mm
13.543mm
REAR BRAKE MASTER CYLINDER PISTON O.D
13.5mm
13.378mm
REAR CALIPER CYLINDER I.D
34.0mm
34.039mm
REAR CALIPER PISTON O.D
34.0mm
33.914mm
15
15-1
BRAKE SYSTEM
TROUBLESHOOTING
Brake lever / pedal soft or spongy
Brake lever / pedal hard
Air bubbles in the hydraulic system.

Leaking hydraulic system.
Contaminated brake pad / disk .
Worn caliper piston seal.
Worn master cylinder piston seal.
Worn brake pad.
Contaminated caliper.
Caliper not sliding properly.
Worn brake pad / disk.
Low fluid level.
Clogged fluid passage.
Warped / deformed brake disk.
Sticking / worn caliper piston.
Sticking / worn master cylinder piston.
Worn brake disk.
Contaminated master cylinder.
Bent brake lever / pedal.
Clogged / restricted brake system.

Sticking / worn caliper piston.
Clogged / restricted fluid passage.
Worn caliper piston seal.
Sticking / worn master cylinder piston.
Bent brake lever / pedal.
Brakes grab or pull to one side

Contaminated brake pad / disk.
Misaligned wheel.
Clogged / restricted brake hose.
Clogged / restricted brake hose joint.
Brakes drag
Contaminated brake pad / disk.
Misaligned wheel.
Worn brake pad / disk
Hydraulic system contaminated with dust.
15-2
BRAKE SYSTEM
BRAKE FLUID
MASTER
CYLINDER
MASTER
MASTERCYLINDER
CYLINDER
MASTER
CYLINDER
! CAUTION
A contaminate disk or pad reduces braking

power. Do not allow the disk or pad to be
contaminated by oil.
Replace contaminated pads, and remove
pollutants from the disk completely.
Check the brake fluid level often and replenish
new fluid as required.
Do not spill fluid on painted, plastic or rubber
parts.
FR.
FR.
BRAKE
BREEDER
VALVE
FR.BRAKE
BRAKEBREEDER
BREEDERVALVE
VALVE
FR.
FR.
BRAKE
MASTER
CYLINDER
FR.BRAKE
BRAKEMASTER
MASTERCYLINDER
CYLINDER
Remover the fluid maintenance lid.

Remove the oil cup cap, diaphragm plate, and
diaphragm from the master cylinder.
Connect the bleeder hose to the bleeder valve. Loosen
the bleeder valve, and pump the brake lever repeatedly.
When there is no more fluid flowing out of the bleeder
valve. Stop pumping the brake lever.
CALIPER
CALIPER
CALIPER
BREEDER
BREEDER
VALVE
BREEDERVALVE
VALVE
FRONT
FRONT
BRAKE
LEVER
FRONTBRAKE
BRAKELEVER
LEVER
FRONT BRAKE AIR BLEEDING

<When the brake bleeder is available>
BRAKE BREEDER
Fill the reservoir with DOT 3 or 4 brake fluid up to the

upper level.
! CAUTION
To prevent chemical changed.Do not use

different type of brake fluid.
Connect the recommended brake bleeder to the bleeder
valve.
Loosen the bleeder valve while pumping the brake
lever.
Repeat this operation until the brake fluid flows out of
the brake bleeder.
Add brake fluid.
BRAKE
BRAKE
FLUID
BRAKEFLUID
FLUID
! NOTE
Check the fluid level often and replenish fluid

if the amount of fluid is reduced to the lower
level.
Read the users manual carefully prior to
disassembling or using the brake bleeder.
Protect the bleeder valve with tape to prevent
air from entering the bleeder valve.
Repeat the above procedures until no air bubbles
appear in the bleeder hose.
Squeeze the bleeder valve and operate the brake lever
to check the ingress of air.
15-3
BRAKE SYSTEM
BREEDERVALVE
VALVE
BREEDER
BREEDER
VALVE
BREEDER
BREEDER
HOSE
BREEDERHOSE
HOSE
<When the brake bleeder is not available>

Fill the brake fluid up to the upper limit line.
Connect the transparent bleeder hose to the bleeder
valve and place the other end of the hose in a container.
Squeeze the brake lever, then open the bleeder
valve 1/2 turn, and close the valve.
! NOTE
Do not release the brake lever until the bleeder valve

has been closed.
FR.
BRAKE
LEVER
FR.
FR.BRAKE
BRAKELEVER
LEVER
FR.
BRAKE
LEVER
Release the brake lever slowly and wait several

seconds after it reaches the end of its travel.
Repeat the above steps and until bubbles
cease to appear in the fluid at the end of the hose.
Check the fluid level often, and add fluid if the fluid
level is near the lower level.
If no air leaks out of the bleeder hose, operate the brake
lever to check the presence of air.
Tighten the bleeder valve.
DIAPHRAGM
PLATE
DIAPHRAGM
DIAPHRAGMPLATE
PLATE
DIAPHRAGM
PLATE
Be sure that the brake fluid is up to the upper level of

the master cylinder and refill if necessary
Reinstall the diaphragm, diaphragm plate and oil cup
cap.
REAR BRAKE BLEEDLING (INTERLOCK)

RR.
RR.
BRAKE
BREEDER
VALVE
RR.BRAKE
BRAKEBREEDER
BREEDERVALVE
VALVE
REARCALIPER
CALIPER
REAR
REAR
CALIPER
The rear brake is apply to interlocking system, when

squeezing the right side brake lever, the front and rear
brake works at once.
Fill the brake fluid up to the upper limit line.
Connect the breeder hose to the breeder valve on
the rear caliper and bleed air.
BREEDER
BREEDER HOSE
HOSE
BREEDER
HOSE
15-4
BRAKE SYSTEM
If no air leaks out of the breeder hose after operate
the brake lever, stop pumping it.
RR.
RR.BRAKE
BRAKELEVER
LEVER
RR.
BRAKE
LEVER
FR.
FR.
BREEDER
VALVE
FR.BREEDER
BREEDERVALVE
VALVE
FR.
FR.
BRAKE
HOSE
FR.BRAKE
BRAKEHOSE
HOSE
HANGER
HANGER
PIN
HANGERPIN
PIN
Connect the breeder hose to the breeder valve on

the front caliper and bleed air.
Fill the brake fluid up to the upper limit line and
install the diaphragm, plate and oil cup cap.
Install the fluid maintenance lid.
FRONT BRAKE PAD

REPLACEMENT
FLANGE
FLANGE
BOLT
FLANGEBOLT
BOLT
Loosen the hanger pin on the front caliper.

! NOTE
When replacing brake pads, replace whole set.

Do not remove the brake hose when replacing brake
pads.
BRAKE
PAD
BRAKE
BRAKEPAD
PAD
Remove the brake caliper from the front fork.

Loosen the hanger pin from the brake pad.
Install the hanger pin to the new brake pads.
Install the brake caliper to the front fork.
15-5
BRAKE SYSTEM
RR.
CALIPER
RR.
RR.CALIPER
CALIPER
LOCK
PLATE
LOCK
LOCKPLATE
PLATE
REAR BRAKE PAD

REPLACEMENT
Flatten the lock plate pawl and loosen the hanger pin.
! NOTE
When replacing brake pads, replace whole set.

Do not remove the brake hose when replacing brake
HANGER
HANGER
PIN
HANGERPIN
PIN
PAD
PAD
SPRING
PADSPRING
SPRING
RR.
RR.
BRAKE
PAD
RR.BRAKE
BRAKEPAD
PAD
FR.
FR.
CALIPER
FR.CALIPER
CALIPER
pads.
Loosen the rear brake bolt and remove the brake
caliper.
Loosen the new brake pad, lock plate, hanger pin and
replace the pads.
Install in the revers order of removal.
FRONT BRAKE CALIPER

REMOVAL
Drain the brake fluid.
Loosen the oil bolt securing the brake hose.
Loosen the 2 bolts securing the caliper.
! NOTE
Avoid spilling fluid on painted, plastic or rubber parts.
! CAUTION
Keep oil off the brake disk or pad, because the

contaminated brake disk or pads reduce the braking
performance if contaminated. Replace the pad with a
new one and clean the disk.
15-6
BRAKE SYSTEM
DISASSEMBLY
AIR
AIR
GUN
AIRGUN
GUN
Remove the pad spring, pad comp, caliper bracket,

boot from the caliper body.
Wrap the caliper with a piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
Remove the piston from the caliper while blowing the
low-pressure air in the opening of the brake hose.
PISTON
PISTON
PISTON
PISTON
! CAUTION
PISTON
SEAL
PISTON
PISTONSEAL
SEAL
PISTON
DUST
DUST
SEAL
DUSTSEAL
SEAL
Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.
Disassemble the piston seal and the dust seal.
! NOTE
Pay attention not to damage the inner sunface of the

caliper.
Clean the piston and inside of the caliper with the brake
fluid.
CALIPER
BODY
CALIPER
CALIPERBODY
BODY
CALIPER
INSPECTION
Check the caliper cylinder bore for scoring, scratches,
or other damage.
Measure the caliper cylinder I.D.
SERVICE LIMIT : CYLINDER I.D.A : 34.01mm
CYLINDER I.D.B : 25.46mm
Check the caliper piston outer diameter part for

scratches or other damage.
Measure the piston outer diameter.
SERVICE LIMIT : PISTON O.D.A : 33.848MM
PISTON I.D.B : 25.30MM
PISTON
PISTON
PISTON
PISTON
15-7
BRAKE SYSTEM
HANGER
PIN
HANGER
HANGERPIN
PIN
LHCALIPER
CALIPERBODY
BODY
LH
CALIPER
BODY
LH
RH
RH
CALIPER
BODY
RHCALIPER
CALIPERBODY
BODY
PISTON
PISTONA
A
PISTON
A
PISTON
AA
PISTON
PISTONAA
PISTON
BRAKE
BRAKE
PAD
BRAKEPAD
PAD
ASSEMBLY
Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper.
Install the piston in the caliper with the groove side of
the piston facing the pad.
PISTON
PISTON
PISTONBB
B
PAD
SPRING
PAD
PADSPRING
SPRING
PAD
SPRING
SOCKET
SOCKET
BOLT
SOCKETBOLT
BOLT
Install the RH./LH. caliper body.

Install the socket bolt.
Install pad spring to the caliper.
Install caliper hanger pin bolt to the pad comp and
caliper bracket to the caliper body.
Install the brake pad to the caliper.
INSTALLATION
FR.
FR.CALIPER
CALIPER
FR.
CALIPER
Install the brake caliper to the from fork, and front axle.
Install the caliper to the specified torgue.
Install the brake hose to the caliper body with the new
2 oil bolts washer and oil bolts.
Install the oil bolt to the specified torgue.
Fill the brake fluid, and bleed air.

RR.
RR.
BRAKE
HOSE
RR.BRAKE
BRAKEHOSE
HOSE
REAR BRAKE CALIPER

REMOVAL
Loosen the rear brake hose bolt and remove the brake
hose.
Loosen the 2 bolts and remove the rear brake caliper.
RR.
RR.
CALIPER
RR.CALIPER
CALIPER
15-8
BRAKE SYSTEM
DISASSEMBLY
AIR
AIR GUN
GUN
AIR
GUN
Remove the rear brake caliper.

Check the caliper assembly.
Remove the pad spring, slide pin, caliper bracket and
boot from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
PISTON
PISTON
PISTON
DUST
DUST
SEAL
DUSTSEAL
SEAL
Wrap the caliper with a piece cloth to avoid piston and

brake fluid leakage and facing the piston downward.
Remove the piston from the caliper, while blowing the
low-pressure air in the opening of the brake hose.
! CAUTION
Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.
Disassemble the piston seal and the dust seal.

Clean the piston and inside of the caliper with the brake
fluid.
CALIPER
CALIPER
BODY
CALIPERBODY
BODY
PISTON
PISTON
PISTON
PISTON
INSPECTION
Check the caliper cylinder bore for scoring scratches or
other damage.
Measure the caliper cylinder I.D
CYLINDER I.D.B : 25.07mm
Check the caliper piston outer diameter part for

scratches or other damage.
Measure the piston outer diameter .
15-9
BRAKE SYSTEM
CALIPER
CALIPER
CALIPER
CALIPER
COMP
COMP
COMP
COMP
RH.SIM(DC)
RH.SIM(DC)
RH.SIM(DC)
LOCKPLATE
PLATE
LOCK
PLATE
LOCK
HANGER
HANGER
HANGER
PIN
PIN
PIN
PISTON
PISTON
PISTON
SEAL
SEAL
SEAL
SEAL
ASSEMBLY
Clean the piston seal and dust seal with the brake fluid
and install them into the grooved side of the caliper
with the grooved side toward the pad.
PAD
PAD
PAD
CALIPER
CALIPER
CALIPER
BRACKET
BRACKET
BRACKET
DUST
DUST
SEAL
DUSTSEAL
SEAL
PISTON
PISTON
PISTON
PISTON
PAD
PAD
SPRING
PADSPRING
SPRING
Coat the cyliton grease to the boot.

Connect the boot to the piston of the caliper.
DUST
PLUG
DUST
DUSTPLUG
PLUG
INSTALLATION
Tighten the caliper hanger pin bolt, and install the
caliper bracket in the caliper.
Install the rear brake hose in the caliper.
RR.
RR. BRAKE
BRAKE HOSE
HOSE
RR.
BRAKE
HOSE
15-10
BRAKE SYSTEM
MASTER CYLINDER
MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER
REMOVAL
Drain the front rear brake fluid.
Remove the front rear stop switch.
Loosen the brake hose oil bolt.
Loosen the master cylinder holder bolt.
Remove the master cylinder.
! CAUTION
BRAKE
BRAKE
LEVER
BRAKELEVER
LEVER
PIVOT
PIVOT
BOLT
PIVOTBOLT
BOLT
Brake fluid causes damage to the painted, plastic or

rubber parts. Do not spill fluid on these parts.
If contaminated, gently wipe off the fluid with a piece

of cloth or wash in water. Close hose joints properly to
prevent leakage of brake fluid.
Clean the disassembled parts with brake fluid, and use
compressed air to verify each passage is not clogged.
Do not allow the disassembled parts to be
contaminated by waste material or dust.
MASTER
MASTER
CYLINDER
MASTERCYLINDER
CYLINDER
DISASSEMBLY
Remove the front / rear stop switches.
Remove the piston boot, cir clip from the master
cylinder.
TOOL : SNAP RING PLIERS
Remove the washer piston spring from the master

cylinder.
Clean the master cylinder, reserve, master piston with
the recommended brake fluid.
MASTER
MASTER
CYLINDER
SET
MASTERCYLINDER
CYLINDERSET
SET
STOP
STOP
SW
STOPSW
SW
LEVER
LEVER
LEVER
BOOT
BOOT
BOOT
BOOT
CIR
CLIP
CIR
CIRCLIP
CLIP
MASTER
MASTER
CYLINDER
BODY
MASTERCYLINDER
CYLINDERBODY
BODY
15-11
BRAKE SYSTEM
INSPECTION
PISTON
PISTON
PISTON
Check the piston periphery for scores, scratches or

nicks replace if necessary.
Check the primary and secondary cups for wear.
SECONDARY
SECONDARY
CUP
SECONDARYCUP
CUP
PRIMARY
CUP
PRIMARY
PRIMARYCUP
CUP
! NOTE
If there is any leak of fluid, when installing

new piston, it may indicate the side wear of the
cylinder by the direction of the piston
contacting face. In this case, the master
cylinder must be replaced also.
Check the master cylinder for scores, scratches or nicks
and replace if necessary.
OIL CUP CAP
DIAPHRAGM
PLATE
BOOT
CIR CLIP
DIAPHRAGM
SPRING
WASHER
MASTER
CYLINDER BODY
LEVER
ASSEMBLY
! CAUTION
Replace the piston, spring, cups and snap ring

as a set.
Be sure that each part is free from dust or dirt
before reassembly.
When cleaning with the brake fluid, use the
specified brake fluid.
STOP SW
Apply the recommendatory brake fluid to the cup,

cylinder and inside of cylinder, and install the spring,
primary cup, piston.
! CAUTION
When installing the cups, do not allow to close

the cup ends.
Install the spring with its smaller direction of
coil ends toward the piston.
Install the side of primary cup toward the
spring.
Install the cir clip to the master cylinder groove firmly.
TOOL : SNAP RING PLIERS
Install the boot to the master cylinder.
15-12
BRAKE SYSTEM
INSTALLATION
Install the front rear master cylinder to the handle.
! NOTE
BRAKE
BRAKE
HOSE
OIL
BOLT
BRAKEHOSE
HOSEOIL
OILBOLT
BOLT
Install the holder with its UP mark facing

upwards, and align the holder joint with the
punch mark on the handle bar.
Tighten the holder upper bolt first.
Install the brake hose to the master cylinder with 2 new

sealing washers and the hose bolt.
Loosen the 2 flat screws, remove the oil cup cap,

diaphragm plate and diaphragm.
Fill the brake fluid, and bleed air.
Install the diaphragm, diaphragm plate and the oil cup
cap, tighten the 2 flat screws.
BRAKE DISK
INSPECTION
Measure the brake disk for the thickness.
TOOL : MICRO METER
RR.
RR.
BRAKE
DISK
RR.BRAKE
BRAKEDISK
DISK
FR.
BRAKE
DISK
FR.
FR.BRAKE
BRAKEDISK
DISK
FR.
Check the brake disk for wobbles.
FR.
FR.
BRAKE
DISK
FR.BRAKE
BRAKEDISK
DISK
SERVICE LIMIT : 0.02MM

TOOL : DIAL GAUGE
RR.
BRAKE
DISK
RR.
RR.BRAKE
BRAKEDISK
DISK
RR.
15-13
CHARGING SYSTEM
15A
16-0
CHARGING SYSTEM
16. CHARGING SYSTEM

BATTERY 16-3
CHARGING SYSTEM INSPECTION 16-4

A.C. GENERATOR INSPECTION16-5
REGULATOR RECTIFIER INSPECTION 16-5
SERVICE INFORMATION
! WARNING
Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.
!
CAUTION
This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
When charging the battery, remove the battery from the frame and do not open stopper.
There is the possibility of damaging the regulator/rectifier, etc. if the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that the
battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss in
battery strength.
It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
For information on generator disassembly, refer to section 9.
16
SPECIFICATIONS
ITEM
BATTERY
A.C.GENERATOR
REGULATOR /
RECTIFIER
STANDARD VALUES
Capacity
12V - 10AH (MF)
Terminal-to-terminal voltage (When fully charged)
13.0 - 13.2V
Charging coil resistance value ( 20

C)
0.1 - 1.0
rpm at charging start
1,500rpm
Regulator voltage
14.5 0.5V
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER
16-1
CHARGING SYSTEM
TROUBLESHOOTING
No power (Key turned on)
Low power (Engine running)
Dead battery.
-Low fluid level.
-Low specific gravity.
-Charging system failure.
Disconnected battery cable.
Main fuse burned out.
Faulty ignition switch.
Battery undercharged.
Battery is failing.
Charging system failure.
Low power (Key turned on)

Battery undercharged.
-Low fluid level.
-Low specific gravity.
Charging system failure.
Loose battery connection.
Intermittent power
Loose battery connection.
Loose charging system connection.
Loose starting system connection.
Loose connection or short circuit in ignition system.
Loose connection or short circuit in lighting system.
Charging system failure

Loose, broken or shorted wire or connection.
Faulty regulator rectifier.
Faulty A.C generator.
CHARGING SYSTEM
Measure battery current leakage.
INCORRECT
CORRECT
Inspect the charging voltage.

UNDER 14V
Check the voltage between the battery line and

ground wire of regulator rectifier.
Check the regulator rectifier.

CORRECT
OVER 15V
14~15V
ABNORMAL
Shorted harness wire.

Faulty ignition switch.
INCORRECT

Battery is failing
Open circuit in wire harness.

Poorly connected coupler.
NORMAL
Check the resistance of the charging coil at

the charging coil line of regulator rectifier
coupler.
INCORRECT
Check the charging coil of theA.C

generator.
NORMAL
Poorly connected A.C generator coupler.

ABNORMAL
CORRECT
Check the regulator rectifier.
Faulty charging coil.

ABNORMAL
NORMAL
Faulty battery.
16-2
CHARGING SYSTEM
BATTERY
COVER
BATTERY
BATTERYCOVER
COVER
BATTERY
COVER
BATTERY
REMOVAL
Loosen the screws securing the battery cover and
remove the battery cover.
SCREW
SCREW
SCREW
CABLE
CABLE
CABLE
BATTERY
BATTERY
BATTERY
CABLE
CABLE
CABLE
Remove the battery.

Disconnect the negative battery cable first, and
then disconnect the positive cable.
The installation sequence is the reverse of removal.
BATTERY (OPEN-CIRCUIT VOLTAGE) INSPECTION

Remove the battery cable.
Disconnect the battery terminals from the battery.
Measure the voltage between the battery terminals.
FULLY CHARGED : 13.0-13.2V
INSUFFICIENTLY CHARGED : UNDER 12.3V
TOOL : DIGITAL TESTER
! NOTE
Use a voltmeter that will accurately indicate 0.1V

difference.
When measuring the battery volate after driving, leave
it for at least 30 minutes, or the accurate results cannot
be obtained because the battery voltage fluctuates just
driving.
Connect the charger positive (+) cable to the battery
positive (+) terminal.
Connect the charger negative (-) cable to the battery
negative (-) terminal.
! NOTE
The rapid charging could be possible to reduce the

battery life and cause of damage.
Avoid the rapid charging except emergency.

Be sure to the battery charging is not allow to exceed
the specified changing time and current.
16-3
CHARGING SYSTEM
CHARGING SYSTEM INSPECTION

LEAK TEST
Trun off the ignition switch, and disconnect the ground
(-) cable from the battery.
Connect an ampere meter between negative (-) terminal
and ground cable.
With the ignition switch off, measure the leakage current.
LEAK CURRENT : Not to allow to exceed 0.5A
TOOL : DIGITAL TESTER
! NOTE
When measuring current using a tester, set it to a large

AMPERE METER
BATTERY TERMINAL
range, and then bring it down the range to an

appropriate level.
Current flow larger than the range selected may blow
out the fuse in the tester.
While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.
EARTH CABLE
CHARGING VOLTAGE INSPECTION

! NOTE
Be sure that the battery is fully charged before

performing this test.
The amount of current flow may change abruptly if not
sufficiently charged. Use a battery whose voltage
between its terminals is 13.0 13.2V
If the brobes are connected in reverse order, the
registered current flow direction when charging and
discharging the battery will be reversed as well.
After warming up the engine, replace the battery with a
fully charged battery.
Connect a tester between the battery terminals.
Connect a RPM tester to the high-tension cord.
Start the engine, gradually increase the engine speed
and measure the charging voltage and charging current.
CHARGING CURRENT : 0~0.5A / 5,000rpm
CONTROL VOLTAGE : 14.50.5V / 5,000rpm
TOOLS : RPM TESTER, DIGITAL TESTER
MAIN FUSE
TERMINAL
! NOTE
Take precaution not to control the tester or wiring

MAIN FUSE
when flowing the current.

It can cause the damage for the other parts by
overflowing the current.
16-4
CHARGING SYSTEM
A.C GENERATOR INSPECTION

AC
AC
GENERATOR
COUPLER
ACGENERATOR
GENERATORCOUPLER
COUPLER
! NOTE
This test can be made without removing the stator

from the engine. Disconnect the wellow wire from the
auto bystarter.
Release the rear under cover.
Disconnect the A.C generator connector.
AC
GENERATOR
COUPLER
AC
ACGENERATOR
GENERATORCOUPLER
COUPLER
MAGNETIC
MAGNETIC
SW.
MAGNETICSW.
SW.
WINKER
WINKER
RELAY
WINKERRELAY
RELAY
Measure the resistance between the yellow wires.

Replace the stator if resistance value is high or there is
continuity between each yellow wire and ground.
Resistance : yellow~yellow 0.6~1.6
REGULATOR RECTIFIER
INSPECTION
Remove the regulator rectifier coupler.
Measure each terminal.
EURO 2
IGNITION
IGNITION COIL
COIL
IGNITION
COIL
CDIUNIT
UNIT
CDI
CDI
UNIT
REGULATOR
REGULATOR
RECTIFIER
REGULATORRECTIFIER
RECTIFIER
REGULATOR
RECTIFIER
REGULATOR
REGULATORRECTIFIER
RECTIFIER
REGULATOR
R
B
Y
Y
Y
G
B
0-5
1-4
1-4
1-4
25-40k
Y
1-3
Y
1-3
EURO 3
Tester
Tester
R
G
Y
Y
Y
R
28~36
G
28~36
Y
1-3
Unit :
G
1-4
25-40k
1-4
1-4
1-4
Unit : , (20)
Y
Y
Replace the regulator rectifier unit if the resistance

value between the terminals is abnormal.
16-5
IGNITION SYSTEM
IGNITION SYSYTEM
BATTERY
(12V 10AH)
UNIT
HEADLIGHT RELAY
G/B
B/Y
G
B/Y
FUSE
(15A)
B/W
P
B
PULSE
GENERATOR
SPARK
PLUG
17-0
IGNITION
COIL
MAIN
SW
B/Y
AC.
GENERATOR
SIDE STAND
SWITCH
IGNITION SYSTEM
17. IGNITION SYSTEM

CDI UNIT 17-3
PULSE GENERATOR INSPECTION 17-3
IGNITION COIL INSPECTION 17-4

IGNITION TIMING INSPECTION 17-5
SIDE STAND IGNITION CUT-OFF
SWITCH 17-5
SERVICE INFORMATION
GENERAL SAFETY
Follow the steps described in the troubleshooting flow chart when servicing the ignition system.
The CDI unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing.
Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (SECTION 20)
SPECIFICATIONS
ITEM
STANDARD VALUE
PRIMARY COIL
IGNITION COIL
RESISTANCE VALUE 20
SPARK PLUG GAP
WITH PLUG CAP
7.3 ~ 11.0
WITHOUT PLUG CAP
3.6 ~ 4.6
SECONDARY COIL
PULSE GENERATOR COIL RESISTANCE VALUE

SPARK PLUG
0.1 ~ 0.2
90 ~150
NGK CR8EH-9
0.8~0.9mm
17
TOOLS
DIGITAL TESTER
PVA MULTI-TESTER
DC-CDI TESTER
17-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug.
UNUSUAL CONDITION
IGNITION COIL PRIMARY VOLTAGE

PULSE GENERATOR
EXCITE COIL
17-2
PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)
Low peak voltage.
1. The multitester impedance is too low.

2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
3. The sample timing of the tester and measured pulse were not
synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in ignition system.
5. Faulty ignition system control circuit such as side stand switch.
6. Faulty ignition coil.
7. Faulty CDI unit (in case when above No. 1~6 are normal).
No peak voltage.
1. Incorrect peak voltage adaptor connections.

2. Faulty ignition switch.
3. Loose or poorly connected CDI unit connector.
4. Open circuit or poor connection in ground cord of the CDI unit.
5. Faulty ignition system control circuit such as side stand switch.
6. Faulty peak voltage adaptor.
7. Faulty CDI unit (in case when above No. 1~6 are normal).
Peak voltage is normal, but no spark

jumps at plug.
1. Faulty spark plug or leaking ignition coil secondary current ampere.

2. Faulty ignition coil.
Low peak voltage.

weak).
synchronized.(System is normal if measured voltage is over the
No peak voltage.
Low peak voltage.

weak).
synchronized.(System is normal if measured voltage is over the
No peak voltage.
IGNITION SYSTEM
CDI
CDI
UNIT
CDIUNIT
UNIT
CDI UNIT INSPECTION (EURO2)

CDI IGNITION CIRCUIT INSPECTION
! NOTE
Follow the steps described in the troubleshooting flow

chart when servicing the ignition system.
Release the seat lock with the main key.
Remove the rear under cover.
Disconnect the coupler from the CDI unit, and check the
ignition system circuits from the wiring coupler side.
Inspection Items
CDI
CDI
UNIT
CDIUNIT
UNIT
ITEM
INSPECTION
MAIN
SWITCH
Check that there is battery voltage between

main switch wire (black) and ground wire
when the ignition is ON
Check that the resistance of coil (between blue /

PULSE
yellow and green) is within the specified range.
GENERATOR
( 90~150) (20)
Check that the resistance of coil (between black
IGNITION COIL
(PRIMARY COIL) / yellow and green) is within the specified range.
( 0.1~0.2) (20)
GROUND WIRE Check continuity between ground and frame.
If there are a normality in the diagonosis above, and if
there is no spark at plug, check the CDI unit and
ignition coil by using a CDI tester.
TOOLS : CDI TESTER
DIGITAL TESTER
! NOTE
Read tester manual carefully prior to using the tester.

Replace the CDI unit if faulty.
PULSE GENERATOR INSPECTION

RESISTANCE MEASUREMENT
PULSE
PULSE
CORD
PULSECORD
CORD
Release the seat lock with the main key.

Disconnect the A.C generator 4P coupler and the blue /
yellow wire connector.
Measure the resistance between the green and blue / yellow.
STANDARD VALUE : 90~150 (20)
PVA MEASUREMENT
Disconnect the A.C generator blue / yellow wire connector.
Connect the peak voltage adaptor probes to the pulse
generator wire terminal of the wire harness side
connector and ground.
Crank the engine with the kick starter or starter motor
and measure the peak voltage of pulse generator.
PEAK VOLTAGE : OVER 1.5V
TOOL : PVA MULTI TESTER
17-3
IGNITION SYSTEM
IGNITION COIL INSPECTION

Remove the primary wire.
! NOTE
Since the resistance value of the primary coil is

inherently very small, it is difficult to distinguish it
from a shorted wire..
IGNITION
IGNITION
COIL
IGNITIONCOIL
COIL
Measure the resistance between the two terminals of

the ignition primary coil.
If the resistance value is within the specified range the
coil is good.
If resistance is (infinite), replace the coil with a new
one.
SPARK
PLUG
CAP
SPARK
SPARKPLUG
PLUGCAP
CAP
SPARK
PLUG
CAP
STANDARD VALUE : 0.1~0.2
With the spark plug cap on, measure the resistance

between the primary coil terminal and the spark plug
cap.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.
IGNITION
COIL
IGNITION
IGNITIONCOIL
COIL
IGNITION
Without the spark plug cap, measure the resistance

between the primary coil terminal and high-tension
code.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (infinite), replace the coil with
new one.
IGNITION
IGNITION
COIL
IGNITIONCOIL
COIL
FAN
FAN
SCREW
FANSCREW
SCREW
IGNITION
COIL
IGNITION
IGNITION COIL
COIL
17-4
REPLACEMENT
Remove the high-tension cord from the plug, remove
the plug cap.
Remove the wire from the ignition coil.
Remove the primary wire from the ignition coil.
Loosen the ignition coil fixing bolt securing the frame,
Remove the ignition coil.
IGNITION SYSTEM
RH
RH
SHROUD
RHSHROUD
SHROUD
IGNITION TIMING INSPECTION

! NOTE
As the system uses the CDI unit, the ignition timing

need not be adjusted, Check the ignition system if the
ignition timing is incorrect.
Warm up the engine.
! NOTE
TIMINGHOLE
HOLE
TIMING
TIMING
HOLE
Read the instruction for timing light operation.

Connect the timing light to the high-tension cord.
Start the engine and let it idle.
TIMING
TIMING
LIGHT
TIMINGLIGHT
LIGHT
IDLE SPEED : 15
BTDC 1,600rpm
The ignition timing is correct if the F mark aligns

with the index mark on the case.
Increase the engine speed by turning the throttle stop
screw and make sure the F mark begins to move
counterclockwise when the engine speed at
approximately 4,000 rpm.
SIDE
SIDE STAND
STAND SWITCH
SWITCH
SIDE
STAND
SWITCH
SIDE STAND IGNITION CUTOFF SWITCH

INSPECTION
Remove the coupler of the side stand switch linked to
the wire.
SIDESTAND
STANDDOWN
DOWN
SIDE
SIDE
STAND
DOWN
SIDESTAND
STANDSWITCH
SWITCH
SIDE
SIDE
STAND
SWITCH
SIDE
SIDE
STAND
UP
SIDESTAND
STANDUP
UP
Check for continuity between the terminal as shown

below;
ITEM
TERMINAL
SPECIFICATION
ON
(Side stand is
lowered)
GREEN AND
BLACK/WHITE
NO
CONTINUITY
OFF
(Side stand is
retracted)
GREEN AND
BLACK/WHITE
CONTINUITY
17-5
STARTER SYSTEM
STARTER SYSTEM
STARTER
RELAY
CABLE
CABLE
G/Y
G/Y
STOP LAMP
Y/R
FRONT
STOP
SWITCH
REAR
STOP
SWITCH
STARTER
SWITCH
G
MAIN
SWITCH
FUSE
BATTERY
(12V 10AH
18-0
STARTER
MOTOR
STARTER SYSTEM
18. STARTER SYSTEM

STARTER MOTOR 18-3

STARTER MAGNETIC SWITCH 18-6
SERVICE INFORMATION
GENERAL SAFETY
! WARNING
Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.
The starter motor can be maintained without removing the engine from the vehicle.
A weak battery may be unable to turn the starter motor quickly enough, or, supply adequate ignition current.
The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over.
The engine may not be turned over if the stop switch is faulty.
SPECIFICATION
ITEM
STANDARD VALUE
SERVICE LIMIT
STARTER MOTOR BRUSH LENGTH
10.2 mm
5 mm
TOOLS
DIGITAL TESTER
VERNIER CALIPER
18
18-1
STARTER SYSTEM
TROUBLESHOOTING
Starter motor will not turn.
Check for a blown main fuse before servicing.
Check that the stop light is correctly adjusted.
Check that the side stand is positioned in the condition under which the engine can be started.
With the ignition switchONand squeeze

the brake lever, check for
a click sound
from starter magnetic switch. (17-6)
CLICKS
Connect the starter motor (+) terminal to the

battery positive terminal. (Because a large
amount of current flows, do not use thin
wires). (17-3)
Starter motor does not turn.
NO CLICK.
Starter motor turns.
Faulty starter motor.
Disconnect starter magnetic switch coupler,
and check the starter magnetic switch coil
ground wire. (17-6)
Loose or disconnected
wire or cable.
NO CONTINUITY.
CONTINUITY.
Connect the starter magnetic switch coupler.
Measure the starter magnetic voltage at the
starter magnetic switch coupler. (17-6)
NO VOLTAGE.
VOLTAGE MEASURED.
Check the starter magnetic switch operation.
(17-7)
NORMAL
ABNORMAL
Starter motor turns slowly.

Low specific gravity in battery. (or dead battery)
Poorly connected battery terminal cable.
Poorly connected starter motor cable.
Faulty starter motor.
Poorly connected battery ground cable.
Damaged or worn brush.
Starter motor and engine turns, but engine does not start.
Faulty ignition system.
Engine problems.
Starter motor turns, but engine does not turn over.

Starter motor is running backwards.
-Brushes assembled improperly.
-Case assembled improperly.
-Terminals connected improperly.
Faulty starter clutch.
Damaged starter gear.
18-2
Faulty starter switch.

Faulty side stand switch.
Loose or poor contact at connector.
Faulty ignition switch or starter switch.

Loose or poor contact at connector.
Faulty brake stop switch.
Loose or poor contact at starter magnetic
switch coupler.
Faulty starter magnetic switch.
STARTER SYSTEM
STARTER MOTOR
STARTER
MOTOR
STARTER
STARTERMOTOR
MOTOR
STARTERMOTOR
MOTORCABLE
CABLE
STARTER
STARTER
MOTOR
CABLE
REMOVAL
Remove the starter motor cable from the starter
magnetic switch.
Loosen the 2 flange bolts securing the engine case,
remove the battery earth cable and starter motor.
! NOTE
FLANGE
FLANGE BOLT
BOLT
FLANGE
BOLT
Always turn the ignition switch OFF before servicing

STARTER
STARTER
MOTOR
STARTERMOTOR
MOTOR
SETTING
SETTING
BOLT
SETTINGBOLT
BOLT
the starter motor. The motor could suddenly start,

causing serious injury.
Accurately tighten the battery earth cable.
DISASSEMBLY
Remove the starter motor cable.
Before disassembling the starter motor mark the
position of the case and cover so the starter can be
assembled correctly later.
Loosen the starter motor case bolts and remove the
motor cover.
ASSEMBLY
ASSEMBLY
MARK
ASSEMBLYMARK
MARK
INSPECTION
RR.
BRACKET
RR.
RR.BRACKET
BRACKET
CORD
CORD
TERMINAL
CORDTERMINAL
TERMINAL
Check for continuity of the starter motor case.

-Between cord terminal and bracket: normal
if no continuity.
-Between cord terminal and brush : normal if there is
continuity.
If abnormal, replace with a new one.
BRUSH
BRUSH
BRUSH
BRUSHHODER
HODERSET
SET
BRUSH
HODER
SET
BRUSH
BRUSH
BRUSH
HODER
BRUSHHODER
HODER
BRUSH
HODER
BRUSH
BRUSH HODER
HODER
Loosen the brush terminal setting nut, remove the

brush holder set.
Check for continuity between and terminals
of the brush holder.
If there is continuity, replace with a new one.
18-3
STARTER SYSTEM
Remove the brush spring, and then remove the brush.
Measure the brush length. Replace the brush if it is
worn beyond the service limit.
BRUSH
BRUSH
BRUSH
SERVICE LIMIT : 5 mm
TOOL : VERNIER CALIPER
! NOTE
If replacement, replace with a brush holder set.
Check the commutator for :

-Damage or abnormal wear. Replace with a new
one.
-Discoloration of the commutator bar. Replace with
a new one.
-Metallic debris between commutator bars. Clean it
off.
COMMUTATOR
COMMUTATOR
COMMUTATOR
COMMUTATOR
Check for continuity between pairs of commutator

bars.
Make a continuity check between individual
commutator bars and the armature shaft.
There should be no continuity.
OIL
SEAL
OIL
OILSEAL
SEAL
OIL
NEEDLE
NEEDLE BEARING
BEARING
NEEDLE
BEARING
18-4
Check the needle bearing and oil seal.

-Do not rotate smoothly. Replace with a new one.
-Damage oil seal. Replace with a new one.
STARTER SYSTEM
STARTER MOTOR ASSEMBLY
BRUSH
HOLDER
SET
BRUSH
BRUSH HOLDER
HOLDER SET
SET
Install the brush and brush spring to the brush hold set.
Insert the brush terminal into the rear bracket, and
install the terminal set and flange nut.
Align the brush holder set with the rear bracket
groove, and install the brush holder set.
Apply grease to both ends of the armature shaft, and
install the 2 washers.
Push and hold the brush inside the rear bracket, and
insert the armature into the rear bracket groove.
RR.
RR.
BRACKET
RR.BRACKET
BRACKET
Align the yoke with the rear bracket mark, and install
the yoke to the amature.
! CAUTION
The sliding surfaces of the brushes can be damaged if
RR.
RR.
BRACKET
RR.BRACKET
BRACKET
they are not installed properly.

When inserting the armature into the case, hold the
armature tightly to keep the magnet from pulling the
armature against the case.
Align the front bracket with the yoke mark, and install
the front bracket.
Tighten the 2 set bolts.
MARK
MARK
MARK
MARK
FR.
FR.
BRACKET
FR.BRACKET
BRACKET
YOKE
YOKE
YOKE
RR.
RR.
BRACKET
RR.BRACKET
BRACKET
! CAUTION
When installing the cover, take care to prevent

damaging the oil seal lip with the shaft.
Overtightening the starter motor cable terminal nuts
may cause the inside the starter motor, resulting in
serious damage to the inner connectors.
SETTING
BOLT
SETTING
SETTING BOLT
BOLT
SETTING
18-5
STARTER SYSTEM
STARTER
STARTER
MAGNETIC
SWITCH
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH
STARTER MAGNETIC SWITCH

REMOVAL
Remove the center cover and battery cover.
Remove the battery (+) cable from the starter magnetic
switch terminal.
Remove the starter motor cable from the starter
magnetic switch terminal.
Disconnect the yellow / red connector and green /
yellow connector from the wire harness.
Remove the starter magnetic switch from the switch
setting bracket securing the frame.
STARTER
STARTER
MAGNETIC
SWITCH
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH
INSPECTION
Check if the starter magnetic switch clicks when it is
turned ON.
-Clicks Poorly connected battery terminal and
motor terminal of the switch. (Check
the starter magnetic switch)
-No clicks No starter magnetic switch input
voltage. (Faulty relay ground line and
starter magnetic switch)
STARTER
MAGNETIC
SWITCH
STARTER
STARTERMAGNETIC
MAGNETICSWITCH
SWITCH
STARTER
MAGNETIC
SWITCH
Starter magnetic switch voltage

Measure the voltage between the yellow / red wire (+)
and ground at the starter magnetic switch connector.
If battery voltage appears only when the starter switch
is pressed, it is normal.
Starter magnetic switch ground line

Disconnect the wire connector from the starter
magnetic switch and check for continuity between the
ground wire (green / yellow) and ground.
18-6
STARTER SYSTEM
OPERATION CHECK
Disconnect the magnetic switch wire connector.
Apply battery voltage between terminals, when the
yellow / red wire is connected to the positive (+)
battery terminal and the green / yellow wire to the
negative (-) battery terminal.
If there is continuity between battery and motor
terminal, it is normal.
18-7
MEMO
LIGHTS/SWITCHES/HORN
19. LIGHTS/SWITCHES/HORN
TROUBLESHOOTING19-1
HEADLIGHT 19-2
FRONT WINKER 19-2
REAR TAIL LIGHT 19-3
REAR WINKER 19-3
SPEEDOMETER 19-3
MAIN SWITCH 19-4
HANDLE BAR SWITCH 19-4
HORN SWITCH 19-5
FRONT/REAR STOP SWITCH 19-5
FUEL GAUGE19-6
SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.
TROUBLESHOOTING
Light not turned on when the main switch is ON
Fuel meter indicator malfunctioning
Faulty light bulb

Faulty switch
Faulty or disconnected wiring
Fuse cut
Battery discharged
Coupler separated.
Harness disconnected.
Float operation malfuction.
Fuel unit damaged.
Dim headlight
Coupler loose.
Fuel unit damaged.
Meter damaged.
Battery discharged
Wiring and switch resistance high
Fuel meter needle unstable
Headlight Hi-Low bean cannot be charged
19
Faulty light bulb

Faulty dimmer switch
19-1
HEADLIGHT BULB
REMOVAL
Loosen the washer screw securing the headlight.
Disconnect the headlight wiring.
HEAD
HEAD
LIGHT
HEADLIGHT
LIGHT
BULB REPLACEMENT
WASHER
WASHER
SCREW
WASHERSCREW
SCREW
Pull off the headlight socket.

Replace with a new bulb.
HEAD
HEAD
LIGHT
SOCKET
HEADLIGHT
LIGHTSOCKET
SOCKET
! NOTE
When replacing the bulb, be sure not to put

finger and contaminated gloves prints on the
headlight bulb, as they may create hot spots on
the bulb and cause is to fail.
Note the following when replacing the bulb.
- Do not replace while the headlight is ON.
after it is turned OFF, be sure to let it cool
down before servicing.
- Wear clean gloves while replacing the bulb.
Do not put finger prints on the headlight bulb.
- If you touch the bulb with your bare hands,
clean it with a cloth moistened with alcohol
and clean it with a clean cloth again.
- Be sure to install the rubber cover after
replacing the bulb.
HEAD
LIGHT
BULB
HEAD
HEADLIGHT
LIGHTBULB
BULB
HEAD
FRONT WINKER
BULBS REPLACEMENT
Press the lock on the side of the winker base.
Remove the winker lens.
Remove the bulb from the socket and replace with a
new bulb.
! NOTE
WINKER
BULB
WINKER
WINKERBULB
BULB
WINKER
FRONT
FRONT
WINKER
FRONTWINKER
WINKER
Pay attention not to damage the lens.

Do not apply excessive force when removing
the lens.
19-2
REAR TAIL LIGHT
REAR
WINKER
REAR
REARWINKER
WINKER
ASSEMBLY REPLACEMENT
Remove the rear upper cover.
Loosen the 2 screws securing the rear tail light.
Remove the coupler link to the tail light.
The tail light is LED light so, replace it with assembly
parts.
! NOTE
TAIL
TAIL
STOP
BULB
TAIL&&&STOP
STOPBULB
BULB
REAR
REAR WINKER
WINKER
REAR
WINKER
Pay attention not to damage the lens.

Do not apply excessive force when removing
the lens.
Check the installation of the tail light and lens
seal accurately.
REAR WINKER
BULB REPLACEMENT
Press the lock on the side of the winker base and
remove the rear winker cover.
Remove the winker lens.
Remove the bulb from the socket and replace with a
new bulb.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
REMOVAL
Remove the headlight.
Remove the wiring coupler and speedometer cable.
Loosen the flange bolt securing the pilot box on the
inner box and remove the speedometer set.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
PILOT
PILOT
BOX
PILOTBOX
BOX
Loosen the bolt securing the pilot box from the

speedometer set and remove the speedometer assembly.
19-3
MAINSWITCH
SWITCH
MAIN
MAIN
SWITCH
MAIN SWITCH
REMOVAL
Remove the front cover.
Disconnect the ignition switch wire couplers.
MAIN
MAIN
SWITCH
TERMINAL
MAINSWITCH
SWITCHTERMINAL
TERMINAL
Check for continuity between the wire terminal.

RED
BLACK
OFF
ON
PASSINGSWITCH
SWITCH
PASSING
SWITCH
PASSING
HANDLE BAR SWITCH

Disconnect the connector of handle switch.
Check for continuity between terminals.
PASSING SWITCH
BAT2
HI
RED
BLACK
HI
COLOR
DIMMER
DIMMER
SWITCH
DIMMERSWITCH
SWITCH
WINKER
WINKER SWITCH
SWITCH
WINKER
SWITCH
WINKER SWITCH
W
GRAY
SKY BLUE
ORANGE
BAT4
HI
LO
BROWN/WHITE
BLUE
WHITE
R
N
L
COLOR
DIMMER SWITCH
HI
HORN
HORN SWITCH
SWITCH
HORN
SWITCH
(N)
LO
COLOR
19-4
HEADLIGHT SWITCH
HEADLIGHT
HEADLIGHT
SWITCH
HEADLIGHTSWITCH
SWITCH
BAT2
TL
HL
Br/L
Br
OFF
P
H
COLOR
STARTER SWITCH
STARTER
STARTER
SWITCH
STARTERSWITCH
SWITCH
ST
YELLOW / RED
GREEN
FREE
PUSH
COLOR
HORN
Remove the wire connector from the horn.
Connect the horn terminal with 12V battery.
Normal if it sounds.
HORN SWITCH
HO
BAT2
LIGHT GREEN
BLACK
FREE
PUSH
HORN
HORN
HORN
COLOR
FRONT
STOP
SWITCH
FRONT
FRONT STOP
STOP SWITCH
SWITCH
FRONT / REAR STOP SWITCH

INSPECTION
Remove the front handle cover.
Check for continuity between the black and green /
yellow wire terminals inside the speedometer assembly.
-When the brake lever is pulled - CONTINUITY.
-When the brake lever is released - NO CONTINUITY.
REAR
STOP
SWITCH
REAR
REARSTOP
STOPSWITCH
SWITCH
REAR
19-5
FUEL
FUEL
TANK
FUELTANK
TANK
FUEL GAUGE
Remove the floor panel.
Remove the unit set cap, and remove the fuel gauge.
UNIT
UNIT
SET
CAP
UNITSET
SETCAP
CAP
Take precaution not to damage the wire.

Check the base packing for damage.
FUEL
GAUGE
FUEL
FUELGAUGE
GAUGE
FUEL
BASE
BASE
PACKING
BASEPACKING
PACKING
Inspect the fuel gauge.
FUEL GAUGE
FUEL
THERMISTER
ETC
OFF
1.2 L
FUEL CHECK
COLOR
19-6
YELLOW/WHITE
GREEN
MEMO
MEMO
WIRING DIAGRAM
20-1. WIRING DIAGRAM (EURO-2)
WIRING DIAGRAM
20-2. WIRING DIAGRAM (EURO-3)
SERVICE MANUAL
2009. 02 PRINTED
2009. 02 PUBLICATION
COPY PROHIBIT
SM57-0902-01E

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SM57-0902-01E

To ensure safety and optimal operating conditions of the

This manual explains how to maintain procedure for the

How to use this manual

Contents of this manual and specifications are subject

EMS(Engine Management System)

Engine Removal / Installation

LH, Crank Case Cover

A.C Generator / Starter Clutch

Cylinder Head / Valves

Cylinder Head / Piston

Transmission / Crank Shaft

Front Wheel / Front Fork

Rear Wheel / Suspension /

Lights / Switches / Horn

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

"( )" MARKED CONTENTS APPLY TO EURO 2 ONLY

TYPE / VENTURI BORE

CV type ( vacuum ) / '24.2 mm

( )MARKED CONTENTS APPLY TO EURO2 ONLY

2. Before maintenance, remove deposit or dust from the

3. Store the parts of each system discriminatively to install

4. After removing gasket, O-ring, piston pin clip and cotter

6. Check necessary place and measure necessary data

7. Align the bolts to uniform the tightening points before

8. Bolts, nuts and pieces must be tightened from the bigger

9. Check to see if the rubber part is worn out when

10. Recommended grease must be applied to or filled in

11. Maintenance needed to use the specialized tools must

14. Pay attention to installation direction in case of the

15. When blowing the ball bearing with compressed air

MANUFACTURERS NAME, BEARING No.

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

17. Check each part for proper tightening and operation

19. Install the oil seal so that the manufacturer marked

22. Install the gasket mounted in the contact surface of

23. Pay attention not to bend the cable excessively.

24. Install the boots with the installing groove by inserting

CAUTION WHEN WIRING

When measuring voltage or resistance of the cord

Recheck the condition of contact, securing and

WHITE / RED CORD

When disconnecting the battery, the minus terminal

Connect covers to the terminal after maintenance.

If the fuse is short-circuited, find out the cause and

If there is rust in the terminal, remove the rust with sand

When disconnecting the coupler, disconnect it while

Insert the lock of the coupler until the lock is fully

Release the lock by inserting the coupler slightly and

Pay attention not to damage the vinyl cover of the

Check to see if there is bended terminal and secure it to

If the wire harness coating is damaged, repair by

When removing T-start, broaden the groove of T-start

Wire band must be secured firmly in the specified

Secure the wire harness firmly using the clamp.

In case of the weld clamp, do not clamp in the welded

When clamping the wire harness, make sure that the