Apollo Agb-21g Servicemanual

SERVICE MANUAL
AGB-21G
INTRODUCTION IMPORTANT NOTICE
II
Congratulations on your purchase of an THIS MACHINE IS DESIGNED STRICTLY
Apollo AGB-21G. FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this
127( machine to be operated on any public street,
road, or highway. Off-road use on public lands
As improvements are made on this model,
may also be illegal. Please check local regula-
some data in this manual may become out- tions before riding.
dated. If you have any questions, please con-
sult your dealer.
WARNING SAFETY INFORMATION

PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING 1. THIS MACHINE IS TO BE OPERATED
THIS MACHINE. DO NOT ATTEMPT TO BY AN EXPERIENCED RIDER ONLY.
OPERATE THIS MACHINE UNTIL YOU Do not attempt to operate this
HAVE ATTAINED A SATISFACTORY machine at maximum power until you
KNOWLEDGE OF ITS CONTROLS AND are totally familiar with its character-
OPERATING FEATURES AND UNTIL YOU istics.
HAVE BEEN TRAINED IN SAFE AND 2. THIS MACHINE IS DESIGNED TO BE
PROPER RIDING TECHNIQUES. REGULAR RIDDEN BY THE OPERATOR ONLY.
INSPECTIONS AND CAREFUL MAINTE- Do not carry passengers on this
NANCE, ALONG WITH GOOD RIDING machine.
SKILLS, WILL ENSURE THAT YOU SAFETY 3. ALWAYS WEAR PROTECTIVE
ENJOY THE CAPABILITIES AND THE RELI- APPAREL.
ABILITY OF THIS MACHINE. When operating this machine, always
wear an approved helmet with gog-
gles or a face shield. Also wear heavy
boots, gloves, and protective cloth-
ing. Always wear proper fitting cloth-
ing that will not be caught in any of
the moving parts or controls of the
machine.
4. ALWAYS MAINTAIN YOUR MACHINE
IN PROPER WORKING ORDER.
For safety and reliability, the machine
must be properly maintained. Always
perform the pre-operation checks
indicated in this manual. Correcting a
mechanical problem before you ride
may prevent an accident.
5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or
allow any gasoline to get into your
eyes, contact a doctor immediately. If
any gasoline spills onto your skin or
clothing, immediately wash skin areas
with soap and water, and change your
clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILA-
TION.
Never start the engine or let it run for
any length of time in an enclosed area.
Exhaust fumes are poisonous. These
fumes contain carbon monoxide,
which by itself is odorless and color-
less. Carbon monoxide is a dangerous
gas which can cause unconscious-
ness or can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. THE ENGINE, EXHAUST PIPE, MUF-
FLER, AND OIL TANK WILL BE VERY
HOT AFTER THE ENGINE HAS BEEN
RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
10. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the “ OFF ” position. Otherwise, fuel
may leak out of the carburetor or fuel
tank.
TO THE NEW OWNER HOW TO USE
THIS MANUAL
This manual will provide you with a good basic
understanding of features, operation, and
basic maintenance and inspection items of this PARTICULARLY IMPORTANT
machine. Please read this manual carefully INFORMATION
and completely before operating your new
machine. If you have any questions regarding
the operation or maintenance of your machine,
please consult your dealer. The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
NOTE: INVOLVED!
This manual should be considered a perma-
nent part of this machine and should remain WARNING
with it even if the machine is subsequently Failure to follow WARNING instructions could
sold. result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
NOTICE
CAUTION:
Some data in this manual may become out- A CAUTION indicates special precautions that
dated due to improvements made to this must be taken to avoid damage to the
model in the future. If there is any question machine.
you have regarding this manual or your
machine, please consult your dealer. NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
F.I.M. MACHINE WEIGHTS:
MANUAL FORMAT
Weights of machines without fuel
All of the procedures in this manual are organized
The minimum weights for motocross
in a sequential, step-by-step format. The informa-
machines are:
tion has been complied to provide the mechanic
for the class 125cc ....................... minimum
with an easy to read, handy reference that contains
64 kg
comprehensive explanations of all disassembly,
In modifying your machine (e.g., for weight repair, assembly, and inspection operations.
reduction), take note of the above limits of In this revised format, the condition of a faulty
weight. component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
Bearings
Pitting/damage → Replace.
INDEX
GENERAL INFORMATION 1
SPECIFICATIONS 2
REGULAR INSPECTION AND ADJUSTMENTS
3
ENGINE 4
CHASSIS 5
ELECTRICAL 6
7
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
2 Clutch lever
NOTE:
3 Engine stop switch
The machine you have purchased may differ
4 Front brake lever
slightly from those shown in the following.
5 Throttle grip
6 Fuel tank cap Designs and specifications are subject to
7 Engine start switch change without notice.
8 Fuel tank
9 Air filter
: Left side cover
21 Drive chain
22 Shift pedal
23 Side stand
24 Right side cover
25 Fuel cock
26 Kick starter cank
27 Front fork
28 Spark plug
29 Rear brake pedal
2: Front axle
1-1
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the
number to your dealer for positive
identification of the model you own.
2. If your machine is stolen, the authorities
will need the number to search for and
identify your machine.
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is
stamped on the right of the steering head pipe.
ķ
ENGINE SERIAL NUMBER
The engine serial number is stamped into
the elevated part of the right-side of the
engine.
1-2
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign
material before removal and disassem-
bly.
When washing the machine with high
pressured water, cover the parts follows.
Silencer exhaust port
Side cover air intake port
2. Use proper tools and cleaning equip-

ment. Refer to “SPECIAL TOOLS” sec-
tion.
3. When disassembling the machine, keep

mated parts together. They include
gears, cylinders, pistons, and other
mated parts that have been “mated”
through normal wear. Mated parts must
be reused as an assembly or replaced.
4. During the machine disassembly, clean

all parts and place them in trays in the
order of disassembly. This will speed up
assembly time and help assure that all
parts are correctly reinstalled.
5. Keep away from fire.
1-3
GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should
be replaced when an engine is over-
hauled. All gasket surfaces, oil seal lips,
and O-rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.
LOCK WASHERS/PLATES AND COTTER

PINS
1. All lock washers/plates and cotter pins
must be replaced when they are
removed. Lock tab(s) should be bent
along the bolt or nut flat(s) after the bolt
or nut has been properly tightened.
BEARINGS AND OIL SEALS

1. Install the bearing(s) and oil seal(s)
with their manufacturer’s marks or num-
bers facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-
weight lithium base grease to the seal
lip(s). Oil the bearings liberally when
installing.
CAUTION:
Do not use compressed air to spin the
bearings dry. This causes damage to the
bearing surfaces.
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace pis-
ton pin clips after one use. Replace dis-
torted circlips. When installing a circlip
, make sure that the sharp-edged cor-
ner is positioned opposite to the thrust
it receives. See the sectional view.
Shaft
1-4
CHECKING OF CONNECTION
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector

two or three times.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin
and reinsert the terminal into the con-
nector.
6. Connect:
Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.
NOTE:
If there in no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
For a field remedy, use a contact revitalizer
available on the market.
Use the tester on the connector as shown.
1-5
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
Tool name/How to us Illustration Tool name/How to us Illustration
Crankcase separating tool Clutch holding tool
This tool is used to hold the clutch

These tool is used to remove the when removing or installing the clutch
crankshaft from either case. boss securing nut.
Flywheel puller Valve guide remover
This tool is used to remove the flywheel This tool is needed to remove and
magneto. install the valve guide.
Rotor holding tool Steering nut wrench
This tool is used when loosening or

tightening the fly-wheel magneto This tool is used when tighten the
securing nut steering ring nut to specification.
Dial gauge and stand Pocket tester
Stand
These tools are used to check each part Use this tool to inspect the coil
for runout or bent. resistance, output voltage and amperage.
Crankshaft installing tool/pot/bolt Valve spring compressor
Spacer (crankshaft installer)
Adapter (M12)
These tools are used to install the This tool is needed to remove and
crankshaft. install the valve assemblies.
Piston pin puller set
This tool is used to remove the piston

pin.
1-6
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
CLUTCH LEVER
The clutch lever is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
SHIFT PEDAL
The gear ratios of the constant-mesh 4 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal on
the left side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter crank so the engine
can be started in any gear if the clutch is dis-
engaged. In normal practices, however, shift to
neutral before starting.
THROTTLE GRIP
The throttle grip is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
1-7
CONTROL FUNCTIONS
FRONT BRAKE LEVER

The front brake lever is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
REAR BRAKE PEDAL

The rear brake pedal is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
FUEL COCK
NO
The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the two positions:
OFF OFF:With the lever in this position, fuel will not
flow. Always return the lever to this posi-
tion when the engine is not running.
ON: With the lever in this position, fuel flows
to the carburetor. Normal riding is done
with the lever in this position
SPARK PLUG WRENCH
This spark plug wrench is used to remove
and install the spark plug.
NIPPLE WRENCH
This nipple wrench is used to tighten the
spoke.
1-8
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model name: 21G
Model code number: AGB-21G
Dimensions:
Overall length 1,,550 mm 2
2 Overall width
Overall height
600 mm
830 mm
Seat height 690 mm
Wheelbase 1,105 mm
Minimum ground clearance 260 mm
Basic weight:
With oil and full fuel tank
66kg
Engine:
Engine type Air cooled 4-stroke
Cylinder arrangement Single cylinder, forward inclined
Displacement 123.67 cm 3
Bore s stroke 54.0 s 54 mm
Compression ratio 9:1
Starting system Kickstarter and Electrical Starting
Lubrication system: Dry sump
Oil type or grade:
At 5 ˚C (40 ˚F) or higher
SF15W/40 type
SG motor oil
(Non-Friction modified)
At 15 ˚C (60 ˚F) or lower
2-1
Oil capacity:
Engine oil
Periodic oil change 0.8 L
With oil filter replacement 0.85 L
Total amount 0.9 L
Air filter: Wet type element

Fuel:
Type Premium unleaded gasoline only with a
research octane number of 90 or higher.
Premium gasoline
Tank capacity 3.5 L
Carburetor:
Type PZ26-5K
Manufacturer JINGKE
Spark plug:
Type/manufacturer A7RTC/NGK
Gap 0.6 ~ 0.7 mm
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 67/18 (3.772)
Secondary reduction system Chain drive
Secondary reduction ratio 43/15 (2.867)
Transmission type Constant mesh, 4-speed
Operation Left foot operation
Gear ratio: 1st 36/11 (2.818)
2nd 31/16 (1.938)
3rd 27/20 (1.350)
4th 24/23 (1.043)
Chassis:
Frame type Semi double cradle
Caster angle 27.3˚
Tire:
Type With tube
Size (front) 60/100-14 30M
Size (rear) 80/100-12 41M
Tire pressure (front and rear) 130 kPa (1.3 kgf/cm2 )
2-2
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/ o il d amper
Wheel travel:
Front wheel travel 200 mm
Rear wheel travel 200 mm
Electrical:
Ignition system CDI magneto
2-3
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit

Cylinder head:
Warp limit ---- 0.03 mm
Cylinder:
Bore size 54.00 ~ 54.015 mm ----
Out of round limit ---- 0.05 mm
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 32.009 ~ 32.034 mm ----
Camshaft outside diameter 31.963 ~ 31.979 mm ----
Shaft-to-cap clearance 0.030 ~ 0.071 mm
Cam dimensions
Intake “A” 26.555 ~ 26.675 mm 26.30 mm
“B” 20.99 ~ 21.01 mm 20.95 mm
Exhaust “A” 26.316 ~ 26.436 mm 26.00 mm
“B” 20.99 ~ 21.01 mm 20.95 mm
Camshaft runout limit ---- 0.03 mm
2-4
Item Standard Limit

Timing chain:
Timing chain type / No. of links 90T/90 ----
Timing chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.02 ~ 0.04 mm ----
EX 0.02 ~ 0.04 mm ----
Valve dimensions:
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 26.9 ~ 27.1 mm ----
EX 22.9 ~ 23.1 mm ----
“B” face width IN 1.1~1.5 mm ----

EX 1.1~1.5 mm ----
“C” seat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.8 ~ 1.0 mm 1.6 mm
“D” margin thickness IN 0.65~0.95 mm ----

EX 0.65~0.95 mm ----
Stem outside diameter IN 4.97~4.985 mm 4.94 mm
EX 4.955 ~ 4.97 mm 4.925 mm
Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm
EX 5.500 ~ 5.512 mm 5.550 mm
Stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.08 mm
EX 0.030 ~ 0.057 mm 0.10 mm
2-5
Item Standard Limit
Stem runout limit ---- 0.03 mm
Valve seat width IN 0.8 ~ 1.2 mm 1.6 mm
EX 0.8 ~ 1.2 mm 1.6 mm
Valve spring:
Free length IN 33.78 mm 32.5 mm
EX 35.55 mm 34.0 mm
Set length (valve closed) IN 22.45 mm ----

EX 25.45 mm ----
Compressed force
(installed) IN 52 ~ 64 N at 22.45 mm ----
EX 105 ~ 129 N at 25.45 mm ----
Tilt limit IN ---- 1.3˚/ 0.8 mm
EX ---- 1.35˚/0.8 mm
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.025 ~ 0.05 mm 0.1 mm
Piston size “D” 53.965 ~ 53.975 mm ----
D
Measuring point “H” 10 mm ----
Piston off-set 0.4 mm /IN-side ----
2-6
Item Standard Limit

Piston pin bore inside diameter 14.002 ~ 14.013 mm 14.04 mm
Piston pin outside diameter 13.994 ~ 14.000 mm 13.98 mm
Piston rings:
Top ring:
%
7
Type Barrel ----

Dimensions (B s T) 0.98 s 2.00mm ----
End gap (installed) 0.10 ~ 0.25 mm 0.60 mm
Side clearance (installed) 0.040 ~ 0.080 mm 0.12 mm
2nd ring:
B
T
Type Taper ----

Dimensions (B s T) 0.98 s 2.20 mm ----
End gap (installed) 0.15 ~ 0.30 mm 0.60 mm
Side clearance 0.040 ~ 0.080 mm 0.12 mm
Oil ring:
B
T
Dimensions (B s T) 1.92 s 2.45 mm ----

End gap (installed) 0.20 ~ 0.50 mm ----
Crankshaft:
Crank width “A” 40.15~ 40.20 mm ----
Runout limit “C” 0.03 mm 0.05 mm
Big end side clearance “D” 0.15 ~ 0.35mm 0.60 mm
Small end free play “F” 0.4 ~ 1.0 mm 2.0 mm
2-7
Item Standard Limit

Clutch:
Friction plate thickness 2.85 ~2.95 mm 2.7 mm
Quantity 3 ----
Clutch plate thickness 1.4 ~ 1.6 mm ----
Quantity 3 ----
Warp limit ---- 0.1 mm
Clutch spring free length 20.5 mm 19.5 mm
Quantity 4 ----
----
----
Clutch release method Inner push, cam push ----

Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
Kickstarter:
Type Kick and ratchet type ----
Carburetor:
Type/manufacturer PZ26-5K / ¾
JINGKE
I. D. mark JK ----
Main jet (M.J) 85# ¾ ----
Main air jet (M.A.J) ø1.0 ¾ ----
Jet needle (J.N) 26-5 ¾ ----
Idle jet (I.J ) 38# ¾ ----
Float needle valve size (F.N.A) ø2.0 ¾ ----
Float weight (F.W) 8g ¾ ----
Float height (F.H) 2.0 ~ 3.0 mm ¾ ----
Air throttle (A.T) B6L ¾ ----
2-8

MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your dealer.
Every Every
After Every third fifth As re-
Item Remarks
break-in race (or (or quired
500 km) 1,000 km)
ENGINE OIL
Replace ƽ ƽ
Inspect ƽ ƽ
OIL FILTER ELEMENT, OIL STRAINER
Clean ƽ
VALVES
The engine must be cold.
Check the valve clearances ƽ ƽ
Check the valve seats
Inspect ƽ
and valve stems for wear.
Replace ƽ
VALVE SPRINGS
Check the free length and
Inspect ƽ
the tilt.
Replace ƽ
VALVE LIFTERS
Check for scratches and
Inspect ƽ
wear.
Replace ƽ
CAMSHAFTS Inspect the camshaft sur-
Inspect ƽ face.
Replace ƽ Inspect the decompres-
sion system.
TIMING CHAIN SPROCKETS, TIMING
CHAIN Check for wear on the
Inspect ƽ teeth and for damage.
Replace ƽ
PISTON
Inspect ƽ ƽ Inspect crack
Clean ƽ Inspect carbon deposits
Replace ƽ and eliminate them.
PISTON RING
Inspect ƽ Check ring end gap
Replace ƽ ƽ
PISTON PIN
Inspect ƽ
Replace ƽ
CYLINDER HEAD Inspect carbon deposits
Inspect and clean ƽ and eliminate them.
Change gasket
CYLINDER
Inspect and clean ƽ Inspect score marks
Replace ƽ Inspect wear
CLUTCH Inspect housing, friction
Inspect and adjust ƽ ƽ plate, clutch plate and
Replace ƽ spring
TRANSMISSION
Inspect ƽ
Replace bearing ƽ
3-1

Every Every
Item Remarks
500 km) 1,000 km)
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect ƽ Inspect wear
ROTOR NUT
Retighten ƽ ƽ
EXHAUST PIPE, SILENCER, PRO-
TECTOR
Inspect and retighten ƽ ƽ
Clean ƽ
Replace ƽ * Whichever comes first
CRANK
Inspect and clean ƽ ƽ
CARBURETOR When using a high-pres-
Inspect, adjust and clean ƽ ƽ sure washer, make sure
that water does not enter
the accelerator pump.
SPARK PLUG
Inspect and clean ƽ ƽ
Replace ƽ
DRIVE CHAIN Use chain lube
Lubricate, slack, alignment ƽ ƽ Chain slack: 30 ~ 40 mm
Replace ƽ
OUTSIDE NUTS AND BOLTS Refer to “STARTING

Retighten ƽ ƽ AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate ƽ ƽ Use foam air-filter oil or
Replace ƽ equivalent oil
OIL FILTER
Replace ƽ ƽ
OIL STRAINER (frame)
Clean ƽ
FRAME
Clean and inspect ƽ ƽ
FUEL TANK, COCK
Clean and inspect ƽ ƽ
BRAKES
Adjust lever position and pedal height ƽ ƽ
Lubricate pivot point ƽ ƽ
Check brake disc surface ƽ ƽ
Check fluid level and leakage ƽ ƽ
Retighten brake disc bolts, caliper ƽ ƽ
bolts, master cylinder bolts and union
bolts
Replace pads ƽ
Replace brake fluid ƽ Every one year
3-2

Every Every
Item Remarks
500 km) 1,000 km)
FRONT FORKS
Inspect and adjust ƽ ƽ
Replace oil ƽ ƽ
Replace oil seal ƽ
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube ƽ ƽ Lithium base grease
REAR SHOCK ABSORBER (After
Inspect and adjust ƽ ƽ rain ride)
Lube ƽ ƽ Molybdenum disulfide
Retighten ƽ ƽ grease
DRIVE CHAIN GUIDE AND ROLLERS
Inspect ƽ ƽ
SWINGARM Molybdenum disulfide
Inspect, lube and retighten ƽ ƽ grease
RELAY ARM, CONNECTING ROD Molybdenum disulfide
Inspect, lube and retighten ƽ ƽ grease
STEERING HEAD
Inspect free play and retighten ƽ ƽ
Clean and lube ƽ Lithium base grease
Replace bearing ƽ
TIRE, WHEELS
Inspect air pressure, wheel run-out, ƽ ƽ
tire wear and spoke looseness
Retighten sprocket bolt ƽ ƽ
Inspect bearings ƽ
Replace bearings ƽ
Lubricate ƽ Lithium base grease
THROTTLE, CONTROL CABLE
SAE 10W-30 motor oil
Check routing and connection ƽ ƽ
Inspect dirt and wear on
Lubricate ƽ ƽ
ƽ ƽ the throttle cable on the
Inspect and clean (throttle cable)
carburetor side.
3-3
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine
Check that a fresh gasoline is filled in the fuel tank. Check the
Fuel
fuel line for leakage.
Check that the oil level is correct. Check the crankcase and
Engine oil
frame oil line for leakage.
Check that gears can be shifted correctly in order and that the
Gear shifter and clutch
clutch operates smoothly.
Check that the throttle grip operation and free play are correctly
Throttle grip/Housing
adjusted. Lubricate the throttle grip and housing, if necessary.
Brakes Check the play of front brake and effect of front and rear brake.
Check drive chain slack and alignment. Check that the drive
Drive chain
chain is lubricated properly.
Check for excessive wear and tire pressure. Check for loose
Wheels
spokes and have no excessive play.
Check that the handlebar can be turned smoothly and have no
Steering
excessive play.
Front forks and rear shock
Check that they operate smoothly and there is no oil leakage.
absorber
Check that the clutch and throttle cables move smoothly. Check
Cables (wires) that they are not caught when the handlebars are turned or
when the front forks travel up and down.
Check that the exhaust pipe is tightly mounted and has no
Exhaust pipe
cracks.
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose.
Lubrication Check for smooth operation. Lubricate if necessary.
Bolts and nuts Check the chassis and engine for loose bolts and nuts.
Check that the CDI magneto, CDI unit, and ignition coil are con-
Lead connectors
nected tightly.
3-4
CLUTCH ADJUSTMENT
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play $
Out of specification m Adjust.
Clutch lever free play $ :

5 ~ 10 mm
2. Adjust:
Clutch lever free play
Clutch lever free play adjustment steps:

Loosen the locknuts .
Adjust the free play by changing their
tightening position.
Tighten the locknuts.
NOTE:
Make minute adjustment on the lever side
using the adjuster .
After adjustment, check proper operation of
clutch lever.
THROTTLE CABLE ADJUSTMENT

1. Check:
Throttle grip free play a
Throttle grip free play a :

3 ~ 5 mm
2. Adjust:
Throttle grip free play
Throttle grip free play adjustment steps:

Slide the adjuster cover.
Turn the adjuster until the specified free
play is obtained.
Tighten the locknut.
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting, turn the handlebar to
right and left and make sure that the
engine idling does not run faster.
3-5
THROTTLE CABLE ADJUSTMENT/
THROTTLE LUBRICATION
THROTTLE LUBRICATION
1. Remove:
Screw (throttle grip cap)
2. Apply:
Lithium soap base grease
On the throttle cable end
3. Install:
Screw (throttle grip cap)

4 Nm (0.4 m · kg)
T.
R.
AIR FILTER REPLACE

NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
Screw
3-6
ENGINE OIL LEVEL INSPECTION
2. Install:
Fitting Screw
5 Nm (0.5 m · kg)
T.
R.

1. Start the engine, warm it up for several
minutes, and then turn off the engine and
wait for five minutes.
2. Place the machine on a level place and
hold it up on upright position by placing
the suitable stand under the engine.
3. Remove:
Oil tank cap
3-7
4. Inspect:
Oil level
Oil level should be between maximum
and minimum marks.
Oil level is low m Add oil to proper
level.
NOTE:
When inspecting the oil level, do not screw the
oil tank cap into the oil tank. Insert the gauge
lightly.
Temp. oC
-20 -10 0 10 20 30 40 50
10W-30
Recommended oil:
10W-40
Refer to the following chart for
15W-40 selection of oils which are suited
20W-40 to the atmospheric temperatures.
20W-50 Recommended engine oil classi-
fication:
-4 14 30 50 68 86 104 122
oF
API STANDARD:
API “SG” or higher grade
(Designed primarily for motor-
cycles)
D
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD D or higher.
E Do not use oils labeled “ENERGY CON-
SERVING II” E or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
5. Install:
Oil tank cap
6. Start the engine and let it warm up for
several minutes.
7. Turn off the engine and inspect the oil
level once again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
3-8
ENGINE OIL REPLACEMENT
ENGINE OIL REPLACEMENT
1. Start the engine and warm it up for sev-
eral minutes, and then turn off the engine
and wait for five minute.
2. Place the machine on a level place and
hold it on upright position by placing the
suitable stand under the engine.
3. Place a suitable container under the
engine.
a
4. Remove:
Oil cap
5. Fill:
Engine oil
Oil quantity:
Total amount:
0.9 L
Periodic oil change:
0.8 L
With oil filter replacement:
0.85 L
6. Check:
Oil leakage
7. Check:
Engine oil level
OIL PRESSURE INSPECTION

1. Check:
Oil pressure
Checking steps:
Slightly loosen the oil pressure check bolt
.
Start the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt. If no oil comes out after one minute,
turn the engine off so it will not seize.
Check oil passages and oil pump for dam-
age or leakage.
Start the engine after solving the prob-
lem(s) and recheck the oil pressure.
Tighten the oil pressure check bolt.
Oil pressure check bolt:
10 Nm (1.0 m • kg)
T.
R.
3-9
PILOT SCREW ADJUSTMENT
ENGINE IDLING SPEED ADJUSTMENT
PILOT SCREW ADJUSTMENT
1. Adjust:
Pilot screw
Adjustment steps:
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num-
ber as the factory-set number of turns out.
Turn in the pilot screw until it is lightly
seated.
Turn out the pilot screw by the factory-set
number of turns.
Pilot screw:
1-5/8 turns out (example)
ENGINE IDLING SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it
up.
2. Attach:
Inductive tachometer
To spark plug lead.
3. Adjust:
Engine idling speed
Adjustment steps:
Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.
Turn the throttle stop screw until the
engine runs at the lowest possible speed.
To increase idle speed m Turn the throt-
tle stop screw in A.
To decrease idle speed m Turn the throt-
tle stop screw out B .
Engine idling speed:

1,400 ~ 1,600 r/min
3 - 10
CHASSIS/BRAKE SYSTEM AIR BLEEDING
CHASSIS
BRAKE SYSTEM AIR BLEEDING
WARNING
Bleed the brake system if:
The system has been disassembled.
A brake hose has been loosened or
removed.
The brake fluid is very low.
The brake operation is faulty.
A dangerous loss of braking performance
A may occur if the brake system is not prop-
erly bleed.
1. Remove:
Reservoir cap
Diaphragm
2. Bleed:
Brake fluid
A Front
B Rear
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube tightly
to the caliper bleed screw .
d. Place the other end of the tube into a
B container.
e. Slowly apply the brake lever or pedal
several times.
f. Pull the lever in or push down on the
pedal. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever
or pedal limit has been reached; then
release the lever or pedal.
Bleed screw:
6 Nm (0.6 m • kg)
T.
R.
i. Repeat steps (e) to (h) until of the air

bubbles have been removed from the
system.
3 - 11
FRONT BRAKE ADJUSTMENT
REAR BRAKE ADJUSTMENT
NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the
reservoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
3. Install:
Diaphragm
Reservoir cap
FRONT BRAKE
1. Check:
Brake lever position A
Brake lever position A :
Standard position Extent of adjustment

100 mm Unavailable
REAR BRAKE ADJUSTMENT

1. Check:
Brake pedal height A
Brake pedal height A :

10 mm
2. Adjust:
Brake pedal height
Pedal height adjustment steps:

Loosen the locknut .
Turn the adjusting nut until the pedal
height D is within specified height.
Tighten the locknut.
WARNING
Adjust the pedal height between the
maximum and the minimum
After the pedal height adjustment, make
sure that the rear brake does not drag.
3 - 12
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
Brake pad thickness A
Out of specification m Replace as a
set.
Brake pad thickness:

4.0 mm
<Limit>: 1.0 mm
2. Replace:
Brake pad
Brake pad replacement steps:

Remove Bolt 1 and 2
Loosen the Caliper
Remove Bolt 3 and 4
Replace the Brake pad
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
Bleed screw 3 and 4 :

18 Nm (1.8 m • kg)
T.
R.
Install the Caliper Bolt 1 and 2
Bolt (brake caliper):

25 Nm (2.5 m • kg)
T.
R.
3. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL
INSPECTION” section.
4. Check:
Brake lever operation
A softy or spongy feeling m Bleed
brake system.
Refer to “BRAKE SYSTEM AIR
BLEEDING” section.
3 - 13
REAR BRAKE PAD INSPECTION AND REPLACEMENT
REAR BRAKE PAD INSPECTION AND

REPLACEMENT
1. Inspect:
Brake pad thickness A
Out of specification m Replace as a
set.
Brake pad thickness:

4 mm
<Limit>: 1.0 mm
2. Replace:
Brake pad
Brake pad replacement steps:

Remove the Screw 1 and 2.
Remove the Nut 3.
Loosen the Caliper
Reeplace the Brake pad.
3 - 14
REAR BRAKE PAD INSPECTION AND REPLACEMENT
CAUTION:
Tighten the bleed screw 1 and 2.
Bleed screw 1 and 2:
18 Nm (1.8m kg)
T.
R.
Nut 3 (brake caliper):
20 Nm (2.0m kg)
T.
R.
3. Inspect:
Brake fluid level
INSPECTION” section.
4. Check:
Brake pedal operation
A softy or spongy feeling m Bleed
A
brake system.
BLEEDING” section.
BRAKE FLUID LEVEL INSPECTION

1. Place the brake master cylinder so that
its top is in a horizontal position.
2. Inspect:
Brake fluid level
Fluid at lower level m Fill up.
B D Lower level
A Front
B Rear
Recommended brake fluid:

DOT #3 or DOT #4
WARNING
Use only designated quality brake fluid to
avoid poor brake performance.
Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
Be sure that water or other contaminants
do not enter master cylinder when refill-
ing.
Clean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts.
3 - 15
SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION
SPROCKETS INSPECTION
1. Inspect:
Sprocket teeth a
Excessive wear m Replace.
NOTE:
Replace the drive sprocket, rear wheel
sprocket and drive chain as a set.
DRIVE CHAIN INSPECTION

1. Remove:
Master link clip
Joint
Drive chain
2. Clean:
Drive chain
Place it in kerosene, and brush off as
much dirt as possible. Then remove the
drive chain from the kerosene and dry
the drive chain.
3. Measure:
Drive chain length (10 links) a
Out of specification m Replace.
Drive chain length (10 links):

<Limit>: 144.4 mm
4. Check:
Drive chain stiffness a
Clean and oil the drive chain and hold
as illustrated.
Stiff m Replace drive chain.
3 - 16
DRIVE CHAIN SLACK ADJUSTMENT
5. Install:
Drive chain ķ
Joint ĸ
Master link clip Ĺ
CAUTION:
Be sure to install the master link clip to the
direction as shown.
Turning direction
6. Lubricate:
Drive chain
Drive chain lubricant:

SAE 10W-30 motor oil or suit-
able chain lubricants
DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the
2. Check:
Drive chain slack A
Above the seal guard installation bolt.
Drive chain slack:

30 ~ 50 mm
NOTE:
Before checking or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust the drive chain
slack with the rear wheel in this “tight chain”
position.
3 - 17
FRONT FORK INSPECTION
3. Adjust:
Drive chain slack
Drive chain slack adjustment steps:

Loosen the axle nut and locknuts .
Adjust the drive chain slack by turning the
adjusters .
To tighten m Turn the adjuster coun-
terclockwise.
To loosen m Turn the adjuster clock-
wise and push wheel forward.
Turn each adjuster exactly the same
amount to maintain correct axle alignment.
NOTE:
Turn the adjuster so that the drive chain is in
line with the sprocket, as viewed from the
rear.
CAUTION:
Too small drive chain slack will overload
the engine and other vital parts; keep the
slack within the specified limits.
Tighten the axle nut while pushing down
the drive chain.
Axle nut:
65 Nm (6.5 m • kg)
T.
R.
Tighten the locknuts.
Locknut:
12 Nm (1.2 m • kg)
T.
R.
FRONT FORK INSPECTION

1. Inspect:
Front fork smooth action
Operate the front brake and stroke the
front fork.
Unsmooth action/oil leakage m Repair
or replace.
3 - 18
CHECKING THE BATTERY
ELECTRICAL SYSTEM
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
First aid in case of bodily contact:
External
SKIN – Wash with water.
EYES – Flush with water for 15 minutes and
get immediate medical attention.
Internal
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
1. Disconnect:
battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then
the positive lead 2 .
2. Remove:
Screw (Battery bracket ) :
3-19
CAUTION:
Add only distilled water. Tap water contains
minerals which are harmful to the battery.
3. Charge:
battery
Battery charging amperage and time

0.4 amps/10 hrs
WARNING
Do not quick charge a battery.
CAUTION:
To ensure maximum performance, always
charge a new battery before using it.
Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
When charging a battery, be sure to re-
NOTE: move it from the motorcycle. (If charging
Replace the battery whenever: has to be done with the battery mounted on
battery voltage does not rise to specification or the motorcycle, disconnect the negative
bubbles fail to rise during charging, lead from the battery terminal.)
sulphation of one or more battery cells occurs To reduce the chance of sparks, do not
(as indicated by the battery plates turning plug in the battery charger until the battery
white or material accumulating in the bottom of charger leads are connected to the battery.
the battery cell),
specific gravity readings after a long, slow Before removing the battery charger lead
charge indicate that one battery cell’s charge clips from the battery terminals, be sure to
is lower than the rest, turn off the battery charger.
warpage or buckling of the battery plates or in- Make sure that the battery charger lead
sulators is evident. clips are in full contact with the battery ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate heat in the contact area and a weak clip
spring may cause sparks.
If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
3-20
CHECKING THE FUSES
REAR SHOCK ABSORBER INSPECTION
CHECKING THE FUSE
The following procedure applies to all of the
fuses.
CAUTION:
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing
a fuse.
Check:
fuse
a. Connect the pocket tester to the fuse and

check it for continuity.
NOTE:
Set the pocket tester selector to “7 1”.
b. If the pocket tester indicates “d”, replace the

fuse.
REAR SHOCK ABSORBER INSPECTION

1. Inspect:
Swingarm smooth action
Abnormal noise/unsmooth action m
Grease the pivoting points or repair the
pivoting points.
Damage/oil leakage m Replace.
3-21
REAR SHOCK ABSORBER SPRING PRELOAD
ADJUSTMENT
REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT
1. Elevate the rear wheel by placing the
2. Remove:
Rear frame
3. Loosen:
Locknut
4. Adjust:
Spring preload
By turning the adjuster .
Stiffer m Increase the spring preload.

(Turn the adjuster in.)
Softer m Decrease the spring preload.
(Turn the adjuster out.)
Spring length (installed) A :
Standard length Extent of adjustment

140 mm 135 ~ 140 mm
* For EUROPE
NOTE:
Be sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.
The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
5. Tighten:
Locknut
6. Install:
Rear frame (upper)
40 Nm ( 4 m • kg )
T.
R.
Rear frame (lower)

40 Nm ( 4 m • kg )
T.
R.
3 - 22
TIRE PRESSURE CHECK/SPOKES INSPECTION AND
TIGHTENING/WHEEL INSPECTION
TIRE PRESSURE CHECK

1. Measure:
Tire pressure
Standard tire pressure:

2
130 kPa ( 1.3 kgf/cm )
NOTE:
Check the tire while it is cold.
Loose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
is low.
A tilted tire valve stem indicates that the tire
slips off its position on the rim.
If the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position.
SPOKES INSPECTION AND TIGHTENING

1. Inspect:
Spokes
Bend/damage m Replace.
Loose spoke m Retighten.
2. Tighten:
Spokes 3 Nm (0.3 m · kg)
T.
R.
NOTE:
Be sure to retighten these spokes before and
after break-in. After a practice or a race check
spokes for looseness.
WHEEL INSPECTION
1. Inspect:
Wheel runout
Elevate the wheel and turn it.
Abnormal runout m Replace.
3 - 23
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play m Replace.
STEERING HEAD INSPECTION AND

ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering stem
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play m Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action m Adjust steering ring
nut.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:

Remove the number plate.
Remove the handlebar and handlebar
upper bracket.
Loosen the steering ring nut using the
steering nut wrenchĸ.
3 - 24
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the steering ring nut using
steering nut wrench ĺ.
NOTE:
Apply the lithium soap base grease on the
thread of the steering stem.
Set the torque wrench to the steering nut
wrench so that they form a right angle.
Steering ring nut (initial tightening):

30 Nm ( 3 m • kg )
T.
R.
Loosen the steering ring nut one turn.
Retighten the steering ring nut using the
steering nut wrench.
WARNING
Avoid over-tightening.
Check the steering stem by turning it lock

to lock. If there is any binding, remove the
steering stem assembly and inspect the
steering bearings.
Install the upper bracket , washer, steer-
ing stem nut , handlebar , handlebar
upper holder .
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
Steering stem nut:

70 Nm ( 7 m • kg )
T.
R.
Handlebar upper holder:

25 Nm ( 2.5 m • kg )
3 - 25
ELECTRICAL/SPARK PLUG INSPECTION
ELECTRICAL
SPARK PLUG INSPECTION
1. Remove:
Spark plug
2. Inspect:
Electrode
Wear/damage m Replace.
Insulator color
Normal condition is a medium to light
tan color.
Distinctly different color m Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
Plug gap D
Use a wire gauge or thickness gauge.
Out of specification m Regap.
Spark plug gap:

0.6 ~ 0.7 mm
4. Clean the plug with a spark plug cleaner

if necessary.
5. Tighten:
Spark plug
15 Nm (1.5 m • kg)
T.
R.
NOTE:
Before installing a spark plug, clean the gas-
ket surface and plug surface.
Finger-tighten D the spark plug before
torquing to specification E .
3 - 26
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Remove:
Timing mark accessing screw
2. Check:
Ignition timing
Checking steps:
Start the engine and let it warm up. Let the
engine run at the specified speed.
Engine speed:
1,400 ~ 1,600 r/min
Visually check the stationary pointer D is

within the firing range E on the rotor.
Incorrect firing range m Check rotor and
pickup assembly.
3. Install:
Timing mark accessing screw
3 - 27
! ! ! !
ENGINE
SEAT, FUEL TANK AND SIDE COVERS
3
7
2
1 5
4
9 6
Order Job / Part name Q’ty Remarks
Remove the parts in the order listed.

1 LEFT TANK COVER 1
2 RIGHT TANK COVER 1
3 SEAT 1
4 LEFT FENDER PLATE 1
5 RIGHT FENDER PLATE 1
6 TAIL FENDER 1
7 FUEL TANK 1
8 FUEL CAP 1
9 PET-COCK 1
For installation, reverse the removal procedure.
4-1
! ! !
REMOVAL POINTS
Fuel Tank , Side covers and Seat
Remove:
Bolt for Tank Cover
Seat Bolt
Bolt for Fuel Tank
Fuel Tank
Screw for Tank Cover and Seat
Left Tank Cover
Right Tank Cover
Screw for Fender plate
Left Fender plate
Right Fender plate
Screw for Fender plate
Seat
4-2
EXHAUST PIPE AND SILENCER
2
3
6
NEW

1 BOLT 1
2 HOOP 1
3 RUBBER MAT 1
4 NUT M6×14 2
5 EXHAUST MUFFLER 1
6 EXHAUST PIPE SEAL 1
4-3
INSPECTION
Silencer and exhaust pipe
1. Inspect:
Gasket
Damage m Replace.
ASSEMBLY AND INSTALLATION

Silencer and exhaust pipe
1. Install:
Gasket
Exhaust muffler
Nut (exhaust pipe)
15 Nm (1.5 m • kg)
T.
R .
2. Install:
Washer
Bolt (silencer)
25 Nm (2.5 m • kg)
T.
R.
NOTE:
First, temporarily tighten the Nut ķ(exhaust
pipe), then tighten the bolt ĸ
4-4
CRBURETOR & AIR-FITER
CRBURETOR & AIR-FITER
NEW
NEW
NEW

1 SCREW FOR AIR-FITER CLAMP 1
2 AIR-FITER 1
3 CRBURETOR 1
4 GASKET,HEAT INSULATING, 2
CRBURETOR
5 O-RING 1
6 INLET PIPE 1
7 O-RING 1
8 GASKET 1
4-5
! ! ! !
CARBURETOR DISASSEMBLY
NEW
NEW

1 UPPER COVER 1
2 GASKET,UPPER COVER 1
3 RETURN SPRING,AIR THROTTLE 1
4 V-CLIP 1
5 E-CIRCLIP 1
6 NEEDLE,JET 1
7 AIR THROTTLE 1
8 O-RING 1
9 ADJUSTING SCREW,AIR THROTTLE 1
10 SPRING,ADJUSTING SCREW 1
11 O-RING 1
12 WASHER 1
13 ADJUSTING SCREW SPRING 1
14 IDLE FOAM JET 1
15 MAIN JET,OIL 1
16 MAIN JET,FOAM 1
17 MAIN MEASURING HOLE 1
18 IDLE JET 1 For installation, reverse the removal procedure.
4-6
NEW
NEW

19 FLOAT COMP 1
20 NEEDLE VALVE,CARBURETOR 1
FLOAT
21 HOOK,NEEDLE VALVE 1
22 FLOAT PIN 1
23 GASKET,FLOAT CHAMBER 1
24 DRAIN SCREW 1
25 O-RING 3
27 SCREW UNIT,FLOAT CHAMPER 1
28 PIPE CLIP 1
29 HOSE 1
4-7
CARBURETOR
INSPECTION
Carburetor
1. Inspect:
Carburetor body
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.
2. Inspect:
Adjust Screw,Mixture
Idle Jet
Main Measuring Hole and Main Nozzi
Main Jet
Drain Screw
Damage → Replace.
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.
Needle valve
1. Inspect:
Needle valve
Valve seat
Grooved wear b → Replace.
Dust c → Clean.
Jet needle
1. Inspect:
Jet needle
Bends/wear → Replace.
Clip groove
Free play exists/wear → Replace.
Clip position
Standard clip position:
No.4 Groove
4-8
! ! ! !
SPROCKET REPLACEMENT
SPROCKET REPLACEMENT
7
5
8
13
10
13
3 12
11

1 COVER,L.RR.CRANKCASE 1
2 INITIATIVE CHAIN DRIVER RIVET 1
PLANK
3 DRIVING GEAR 1
4 SHIFT PEDAL 1
5 GUAGE OIL LEVER 1
6 KICK STARTER 1
7 SPARK PLUG CAP 1
8 ENGINE SKID PLATE 1
9 SIDE STAND 1
10 RIGHT FOOT PAGS 1
11 LEFT FOOT PEGS 1
12 BRACKET FOR PEDAL 1
13 AXLE 2
4-9

CYLINDER HEAD
CYLINDER HEAD
6
NEW
2 NEW 11
10
NEW
NEW
NEW
7 8
5 9
4
NEW

1 Spark plug 1
2 Bolt M6 x 110 1
3 Cylinder cover L / Gasket 1
4 Timing driven sprocket 1
5 Valve cover / O-ring 1
6 Valve cover / O-ring 1
7 Cylinder cover 1
8 Gasket,cylinder cover 1
9 Cylinder head 1
10 Gasket,cylinder head 1
11 Rectangle ring 1
4 - 10
CYLINDER HEAD
REMOVING THE CYLINDER HEAD
1. Remove:
Long Bolt A
Nut B
2. Align:
“I” mark a on the generator rotor (with the
stationary pointer b on the crankcase cov-
er)
a. Turn the primary pulley counterclockwise.

b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark c on the cam-
shaft sprocket with the mark d on the cylin-
der head.
3. Loosen:
Bolt 1
4. Remove:
Bolt 2
4 - 11
CYLINDER HEAD
5 Remove Chain Tensioner
Bolt 1
Washer 2
Spring Chain Tensioner Push Road
Chain Tensioner Push Road Assembly
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire a .
While holding the generator rotor bolt with a
wrench, remove the bolt.
4 - 12
CYLINDER HEAD
6. Remove:
cylinder head
NOTE:
Loosen the nuts ķĸĹĺĻ
in the proper sequence.
Loosen each nut 1/2 of a turn at a time.
After all of the nuts are fully loosened, remove
them.
CHECKING THE CYLINDER HEAD

1. Eliminate:
combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
spark plug threads
valve seats
2. Check:
cylinder head
Damage/scratches Replace.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
Cylinder head warpage

Less than 0.03 mm
a. Place a straightedge 1 and a thickness

gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 600 grit wet abrasive paper
on the surface plate and resurface the cylin-
der head using a figure-eight sanding pat-
tern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
4 - 13
CYLINDER HEAD
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
timing chain tensioner 1
Cracks/damage Replace.
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER
The following procedure applies to both of the
1
tappet covers and O-rings.
1. Check:
tappet cover camshaft sprocket cover
O-ring
Damage/wear Replace the defective
part(-s).
INSTALLING THE CYLINDER HEAD
1. Install:
dowel pins 1
O-ring (New) 2
gasket (New) 3
2. Install:
cylinder head
NOTE:
Apply engine oil onto the threads of the cylin-
der head nuts.
Tighten the cylinder head nuts in the proper
tightening sequence as shown and torque
them in two stages.
Cylinder head nut and bolt

M7 ( 1 4 ) 15Nm
M6 ( 5 ) 10Nm
M6 ( 6 ) 10Nm
M6 ( 7 ) 10Nm
M30( 8 ) 20Nm
4 - 14
CYLINDER HEAD
INSTALLING THE CAMSHAFT SPROCKET

1. Align:
“I” mark on the generator rotor
(with the mark on the generator rotor cover)
a. Turn the crankshaft counterclockwise.

b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark a on the gen-
erator rotor with the mark b on the genera-
tor rotor cover.
NOTE:
Be sure to keep the timing chain as tight as pos-
sible.
2. Install:
timing chain
(onto the camshaft sprocket)
camshaft sprocket
(onto the camshaft)
NOTE:
The notch a on the camshaft should face to-
wards the intake side of the engine.
Align the camshaft marks a with the edge of
the cylinder head as shown.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
3. Install:
Timing chain tensioner bolt 1 and washer (New)
12 Nm (1.2 m kg)
Camshaft sprocket bolts 2

6 Nm (0.6 m kg)
4 - 15

CAMSHAFT /VALVES AND VALVE SPRINGS
NEW
NEW

1 RIGHT COVER,CYLINDER HEAD 1
2 GASKET 1
3 SHAFT,VALVE RROCKER ARM 2
4 ADJUSTING NUT 2
5 ADJUSTING SCREW 2
6 VALVE RROCKER ARM 2
7 CAM SHAFT 1
8 VALVE COTTER 4
9 PETAINER,VALVE SPRING 2
10 VALVE INNER SPRING 2
11 VALVE OUTER SPRING 2
12 VALVE STEM SEAL 2
13 INTAKE VALVE 1
14 EXHAUST VALVE 1
4 - 16
REMOVING THE ROCKER ARMS AND CAM-

SHAFT
1. Loosen:
locknuts 1
adjusting screws 2
2. Remove:
3 4
intake rocker arm shaft
exhaust rocker arm shaft
intake rocker arm 3
exhaust rocker arm 4
3. Remove:
camshaft 1
CHECKING THE CAMSHAFTS

1. Check:
camshaft bushings
Damage/wear Replace.
camshaft lobes
Blue discoloration/pitting/scratches
Replace the camshaft.
4 - 17
2 Measure:
camshaft lobe dimensions A
Out of specification Replace the cam-
shaft.
Camshaft lobe dimension limit

Intake
26.30 mm
A Exhaust
26.00 mm
3. Check:
camshaft oil passage
Obstruction Blow out with compressed air.
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
rocker arm
2. Check:
rocker arm shaft
Blue discoloration/excessive wear/pit-
ting/scratches Replace or check the lu-
brication system.
3. Check:
camshaft lobe
Excessive wear Replace the camshaft.
4. Measure:
rocker arm inside diameter
Out of specification Replace.
Rocker arm inside diameter

10.000 10.015 mm
Limit 10.1 mm
5. Measure:
rocker arm shaft outside diameter
Out of specification Replace.
Rocker arm shaft outside

diameter
9.98 9.995 mm
Limit 9.910 mm
4 - 18
6. Calculate:
rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification Replace the defective

part(-s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.005 0.035 mm
INSTALLING THE CAMSHAFT AND ROCK-

ER ARMS
1. Lubricate:
rocker arm shaft
Recommended lubricant
Molybdenum disulfide oil
2. Install:
exhaust rocker arm 4
exhaust rocker arm shaft 2
NOTE:
Make sure that the exhaust rocker arm shaft is
completely pushed into the cylinder head.
3. Install:
intake rocker arm 3
intake rocker arm shaft 1
NOTE:
Insert the camshaft into the hole in the cylinder
head and the intake rocker arm shaft as shown .
4. Lubricate:
Camshaft
Camshaft
Camshaft bearing
Engine oil
4 - 19
REMOVING THE VALVES

valves and related components.
NOTE:
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.
1. Check:
valve sealing
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent a into the intake and

exhaust ports.
b. Check that the valves properly seal.
There should be no leakage at the valve seat
1.
2. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3 .
3. Remove:
upper spring seat 1
valve springs 2
oil seal 3
valve 4
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
4 - 20
CHECKING THE VALVES AND VALVE GUIDES

valves and valve guides.
1. Measure:
valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification Replace the valve

guide.
Valve-stem-to-valve-guide clear-
ance
Intake
0.015 0.042 mm
Limit: 0.08 mm
Exhaust
0.030 0.057 mm
Limit: 0.10 mm
2. Replace:
valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 C in an oven.
a. Remove the valve guide with a valve guide

remover 1 .
b. Install the new valve guide with a valve guide

installer 2 and valve guide remover 1 .
c. After installing the valve guide, bore the
valve guide with a valve guide reamer 3 to
obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
4 - 21
3. Eliminate:
carbon deposits
(from the valve face and valve seat)
4. Check:
valve face
Pitting/wear Grind the valve face.
valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness

0.65 0.95 mm
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always re-
place the oil seal.
Valve stem runout

Limit: 0.03 mm
CHECKING THE VALVE SEATS

valves and valve seats.
1. Eliminate:
carbon deposits
(from the valve face and valve seat)
2. Check:
valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
Valve seat width
Intake: 0.8 1.2mm
Limit: 1.6 mm
Exhaust: 0.8 1.2mm
Limit: 1.6 mm
4 - 22
a. Apply Mechanic’s blueing dye (Dykem) 1

onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width. Where the
valve seat and valve face contacted one
another, the blueing will have been removed.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the

valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.
4 - 23
e. Apply a fine lapping compound to the valve
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
valve spring free length a
spring.
Valve spring free length (intake

and exhaust)
Inner spring
33.78 mm Limit: 32.5 mm
Outer spring
35.55 mm Limit: 34.0 mm
2. Measure:
compressed spring force a
spring.
b Installed length
Compressed spring force

Intake and exhaust inner
spring
52 64 Nm at 22.45 mm
Intake and exhaust outer
spring
105 129 Nm at 25.45 mm
3. Measure:
valve spring tilt a
spring.
Spring tilt limit

Intake and exhaust inner spring
1.3 /0.8 mm
Intake and exhaust outer spring
1.35 /0.8 mm
4 - 24
INSTALLING THE VALVES

valves and related components.
1. Deburr:
valve stem end
(with an oil stone)
2. Lubricate:
valve stem
oil seal
(with the recommended lubricant)
3. Install:
valve 1
oil seal 2
valve springs 3
upper spring seat 4
(into the cylinder head)
NOTE:
Install the valve springs with the larger pitch a
facing up.
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
2 and attachment 3 .
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
4 - 25

CYLINDER AND PISTON
CYLINDER AND PISTON
NEW
NEW
8
7
9 5
4
3
NEW
NEW
1 6

1 PIN SHAFT,GUIDEROLLER 1
2 CAM CHAIN GUIDE 1
ROLLER
3 CYLINDER BLOCK 1
1
4 GASKET,CYLINDER BLOCK
1
5 DOWEL PIN
1
6 RECTANGLE RING 1
7 CIRCLIP,PISTON PIN 2
8 PISTON PIN 1
9 PISTON 1
10 PISTON RING 1
4 - 26
CYLINDER AND PISTON
REMOVING THE PISTON AND PISTON

RINGS
1. Remove:
piston pin circlip 1
piston pin 2
piston 3
NOTE:
Before removing the piston pin circlip, cover the
crankcase opening with a clean towel or rag to
prevent the circlip from falling into the crank-
case cavity.
2. Remove:
top ring
2nd ring
oil ring
NOTE:
When removing the piston ring, open the end
gap of the ring by fingers, and push up the other
side of the ring.
CHECKING THE CYLINDER AND PISTON

1. Check:
piston wall
cylinder wall
Vertical scratches Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder

bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the measure-
ments.
Cylinder bore “C” 54.00 54.015 mm

Taper limit ”T” 0.05 mm
Out of round “R” 0.005 mm
”C” = Maximum D
”T” = (Maximum D1 or D2) –
(Maximum D5 or D6)
”R” = (Maximum D1, D3 or D5)
– (Minimum D2, D4 or D6)
4 - 27
CYLINDER AND PISTON
b. If out of specification, rebore or replace the
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
1 7.0 mm from the bottom edge of the piston.
Piston size “P”

Standard 53.965 53.975 mm
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.025 0.05 mm
f. If out of specification, rebore or replace the

rings as a set.
CHECKING THE PISTON RINGS

1. Measure:
piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.04 0.08 mm
<Limit>: 0.12mm
2nd ring
0.04 0.08 mm
<Limit>: 0.12mm
4 - 28
CYLINDER AND PISTON
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the pis-
ton crown as shown.
a 5.0 mm
3. Measure:
piston ring end gap
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap

Top ring
0.10 0.25 mm
<Limit>: 0.60 mm
2nd ring
0.15 0.30 mm
<Limit>: 0.60 mm
Oil ring
0.2 0.5 mm
CHECKING THE PISTON PIN

1. Check:
piston pin
Blue discoloration/grooves Replace the
piston pin and then check the lubrication sys-
tem.
2. Measure:
piston pin outside diameter a
pin.
Piston pin outside diameter

13.994 14.000 mm
3. Calculate:
piston-pin-to-piston clearance
Out of specification Replace the piston pin
and piston as a set.
4 - 29
CYLINDER AND PISTON
Piston-pin-to-piston clearance =
Piston pin bore size b –
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.002 0.019 mm
INSTALLING THE PISTON AND CYLINDER

1. Install:
top ring 1
2nd ring 2
upper oil ring rail 3
oil ring expander 4
lower oil ring rail 5
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Install:
piston 1
piston pin 2
piston pin clip 3 New
NOTE:
Apply engine oil onto the poston pin.
Make sure that the mark “IN” on the piston
points towards the intake side of the cylinder.
Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the clip from falling into the crankcase.
3. Install:
gasket 1 New
dowel pins 2
4. Lubricate:
piston
piston rings
cylinder
Engine oil
4 - 30
CYLINDER AND PISTON
5. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
6. Install:
cylinder 1
NOTE:
While compressing the piston rings with one
hand, install the cylinder with the other hand.
Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cavity.
4 - 31
! ! ! !
CLUTCH
CLUTCH
NEW
NEW
NEW
ˣ ˢ
ˡ
NEW ˠ
NEW
NEW 2 1

1 DECORATE COVER,R CRANK 1
CASE COVER
2 GASKET,DECORATE COVER 1
3 CLUTCHLEVER PIN 1
4 CLUTCHLEVER ASSY 1
5 CLUTCH CAM SHAFT SPRING 1
6 O-RING 1
7 CLUTCH SHIFTING PLATE 1
8 CLUTCH PRESSURE PLATE 1
9 OIL SEAL 1
10 OIL SEAL 1
11 R ,CRANK CASE COVER 1
12 GASKET,R ,CRANK CASE COVER 1
13 CLUTCH PUSH ROD 1
14 OIL TUBE 1
15 OIL THIMBLE SPRING 1
16 OIL THIMBLE 1
17 BEARING 1
18 CLUTCH END COVER 1 For installation, reverse the removal procedure.
4 - 32
! ! ! !
CLUTCH
CLUTCH
NEW
NEW
NEW
ˣ ˢ
ˡ
NEW ˠ
NEW
NEW 2 1
19 GASKET,END COVER 1
20 NUT 1
21 WASHER 1
22 THURST WASHER 1
23 CLUTCH ASSY 1
24 DRIVER GEAR 1
25 SLEEVE 1
26 BUSH 1
27 CIRCLIP 1
28 DRIVEN GEAR CAM 1
4 - 33
! ! ! !
CLUTCH
CLUTCH
1 CIRCLIP 1
2 PLATE 3
3 CLUTCH DRIVE FRICTION PLATE 3
4 CLUTCH CENTER SLEEVE 1
5 DRIVE PLATE 1
6 CLUTCH CUSHION SPRING 1
7 CLUTCH SPRING 1
8 CLUTCH OUTER CASE 1
1
4 - 34
CLUTCH
REMOVING THE CLUTCH

1. Remove:
Screw -
2. Straighten the lock washer tab

3. Remove:
clutch boss nut
washer
NOTE:
While holding the clutch boss with the univer-
sal clutch holder , loosen the clutch boss nut.
4. Remove:
snap spring
CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:
friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness

2.85 2.95 mm
<Limit>: 2.7 mm
CHECKING THE CLUTCH PLATES

clutch plates.
1. Check:
clutch plate
Damage Replace the clutch plates as a
4 - 35 set.
CLUTCH
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification Replace the clutch
plates as a set.
Clutch plate warpage limit

Less than 0.1 mm
CHECKING THE CLUTCH SPRINGS

clutch springs.
1. Check:
clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
clutch spring free length
Out of specification Replace the clutch
springs as a set.
Clutch spring free length

20.5 mm
<Limit>: 19.5 mm
CHECKING THE CLUTCH OUTER CASE

1. Check:
clutch outer case dogs
Damage/pitting/wear Deburr the clutch
outer case dogs or replace it.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
CHECKING THE CLUTCH CENTER SLEEVE

1. Check:
clutch center sleeve splines
Damage/pitting/wear Replace the clutch
center sleeve.
NOTE:
Pitting on the clutch sleeve splines will cause er-
ratic clutch operation.
4 - 36
CLUTCH
INSTALLING THE CLUTCH ASSY

1. Install:
put the clutch spring into the clutch outer case.
put the drive plate into the clutch outer case.
2. Lubricate:
friction plates
upper plates
Engine oil
3. Install:
friction plates
upper plates
NOTE:
First, install a friction plate and then alternate
between a upper plate and a friction plate.
4. Install:
pressure plate and install clutch circlip
4 - 37
CLUTCH
CHECKING THE CLUTCH PUSH RODS

1. Check:
oil tube 1
oil thimble spring 2
oil thimble 3
Cracks/damage/wear Replace the de-
fective part(-s).
2. Measure:
oil thimble spring free length
Out of specification Replace the oil thim-
ble spring.
Oil thimble spring free length

17.5 mm
INSTALLING THE CLUTCH

1. Install:
clutch assy 1
NOTE:
Make sure that the teeth on the lock washer are
correctly aligned with the grooves on the clutch
boss.
thrust washer ,make sure the “OUT SIDE”

mark on the washer is upturned.
2. Tighten:
clutch boss nut 5
60 Nm (6.0 m kg)
NOTE:
While holding the clutch boss with the universal
clutch holder , tighten the clutch boss nut.
3. Bend the lock washer tab along a flat side

of the nut.
4 - 38
CLUTCH
4. Install:
oil tube 1
oil thimble spring 2
oil thimble 3
screw ķĺ
6 Nm (0.6 m • kg)
5. Check
clutch assy
NOTE:
Make sure that the teeth on the lock washer are
correctly aligned with the grooves on the clutch
boss.
4 - 39
! ! ! !
OIL PUMP
OIL PUMP
1
3
NEW
1 OIL PUMP 1
2 OIL FILTER SCREEN 1
3 GEAR 1
4 - 40
OIL PUMP
REMOVING THE OIL PUMP

1. Remove:
Screw -
2. Remove:
gasket of oil pump
gear of oil pump
NOTE:
Remove the gasket of oil pump and check the
state.Replace if worn or if reuse if questionable.
3. Check:
Remove the oil pump and inspect oil way for
smoothness.clean oil way as necessary.
Check whether the gear is worn.
4 - 41

MAGNETO AND STARTER GEAR
14
3
11
9
7
NEW 10
NEW
NEW
8
6
13
12 NEW

1 FRONT COVER, LEFT CRANKCASE 1
2 GASKET, LEFT CRANKCASE 1
3 STATOR , MAGNETO 1
4 NUT 1
5 COTOR , MAGNETO 1
6 CIRCLIP 10 1
7 DRIVEN SPROCKET, STARTING 1
MOTOR
8 DRIVE SPROCKET, STARTING 1
MOTOR
9 STARTING MOTOR DRIVE CHAIN 1
10 OIL SEAL 19×30×5 1
11 OIL SEAL 1
12 CHAIN PROTECT PLATE 1
13 CHAIN GUIDE PLATE 1
14 WOODRUFF KEY 1
4 - 42
REMOVING THE GENERATOR ROTOR
1. Remove:
bolt 1 (magneto)
NOTE:
Loosen the bolt (generator rotor) 1 while
holding the rotor with a sheave holder 2 .
Do not allow the sheave holder to touch the
projection on the rotor.
2. Remove:
generator rotor 1
woodruff key
3. Remove:
circlip 1
bolt
CHECKING THE STARTER CLUTCH

1. Check:
starter clutch drive gear 1
starter clutch gear 2
Burrs/chips/roughness/wear Replace
the defective part(-s).
4 - 43
2. Check:
starter clutch operation
a. Hold the starter clutch.

b. When turning the starter clutch gear clock-
wise a , the starter clutch and the starter
clutch gear should engage.
If the starter clutch gear and starter clutch do
not engage, the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch gear counter-
clockwise b , it should turn freely.
If the starter clutch gear does not turn freely,
the starter clutch is faulty and must be re-
placed.
3. Inspect:
dowel pins 1
compression springs 2
spring caps 3
Wear/Damage Replace.
4. Inspect:
starter wheel gear
(contacting surface)
Pitting/Wear/Damage Replace.
INSTALLING THE STARTER CLUTCH

1. Install:
starter clutch assembly 1
30 Nm (3.0 m kg)
2. Unloosen the starter clutch assembly by us-
ing the center punch.
3. Install:
compression springs 1
spring caps 2
dowel pins 3
4 - 44
INSTALLING THE GENERATOR ROTOR
1. Install:
starter wheel gear 1
woodruff key 2
2. Install:
starting motor drive chain
drive gear
cirlip
bolt
chain protect plate
3. Install:
generator rotor 1
NOTE:
Clean the tapered portion of the crankshaft
and the rotor hub.
When installing the rotor, make sure the wood-
ruff key is properly seated in the key way of the
crankshaft and turning the starter wheel gear
clockwise.
4. Tighten:
generator rotor 2
50 Nm (5.0 m kg)
NOTE:
Tighten the bolt while holding the generator ro-
tor with the sheave holder .
4 - 45

CAM CHAIN-TENSIOR
CAM CHAIN-TENSIOR
9
12
11
13 8
10
7
14
6
5
2
3
NEW
4
NEW

1 CLIP, VOLTAGE WIRE 1
2 LOWER PAN, OIL INSULATING 1
3 O-RING 1
4 OIL SEAL 1
5 BOLT M14×1.5 1
6 WASHER 1
7 SPRING, CHAIN TENSIONER PUSH 1
ROD
8 CHAIN TENSIONER PUSH ROD 1
9 TIGHTENING ROD HEAD 1
10 TIMING CHAIN 1
11 TIGHTENING ARM SHAFT 1
12 TIGHTENING ARM 1
13 TIGHTENING IDLER WHEEL SET 1
14 OIL PUMP DRIVE SPROCKET 1
4 - 46
CAM CHAIN-TENSIOR
CAM CHAIN TENSIOR
1. Remove:
bolt of cam chain tensior
roller of cam chain tensior 2
cam chain 3
2. Check:
aluminium washer
spring of chain tensior push rod
INSTALLING THE CAM CHAIN TENSIOR

1. Install:
bolt of cam chain tensior 1
20 Nm (2.0 m • kg)
4 - 47
! ! ! !
CRANKSHAFT AND GEARSHIFT ARM

1 BOLT, LOCATING PLATE 1
LOCATING PLATE GROUP
2 RETURN SPRING, LOCATING 1
PLATE
3 RETURN SPRING, GEARSHIFT 1
LEVER
4 BUSH 1
5 GEARSHIFT LEVER BODY ASSY 1
6 TENSION SPRING, GEARSHIFT 1
LEVER
7 STOP PLATE 1
8 BOLT M8×11 1
9 CIRCLIP 16 1
10 SPRING 1
11 SPRING SHAFE SPRING BASE 1
4 - 48
! ! ! !

12 CONTACT, GEAR INDICATION 1
13 CYLINDER STUD BOLT B M7 X 204 2
14 CYLINDER STUD BOLT A M7 X 212 2
15 OIL DRAIN PLUG M12×1.5 1
16 WASHER 12.5×1.5×20 1
17 BOLT M6×65 3
18 BOLT M6×60 1
19 BOLT M6×45 1
20 BOLT M6×60 1
21 BREATHER TUBE C100-2# 1
22 LEFT CRANKCASE 1
23 GASKET, CRANKCASE 1
24 RIGHT CRANKCASE 1
25 TIE-IN, BREATHER TUBE 1
4 - 49
DISASSEMBLING THE CRANKCASE

1. Gearshift arm :
Remove:
bolt of locating plate
bolt of locating plate
2. Remove:
cirlip
spring
spring seat
4 - 50
CRANKSHAFT
DISASSEMBLING THE CRANKCASE

1. Remove:
crankcase bolts 1 ~ 5
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).
The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
2. Remove:
right crankcase
NOTE:
Set the left crankcase half under then put in the
flat head screw driver to the separating slit .
CAUTION:
First check that the shift drum segment’s
teeth and the drive axle circlip are properly
positioned, then remove the right crank-
case.
Do not damage the crankcase mating sur-
faces.
4 - 51

CRANKSHAFT
CRANKSHAFT
8 7
5
2
6
4 1

1 TIMING DRIVE SPROCKET 1
2 BEARING (6205) 1
3 BEARING (6205) 1
4 PIN 1
5 ROLLER BEARING 1
6 JOINT RED 1
7 LEFT CRANKSHAFT 1
8 RIGHT CRANKSHAFT 1
4 - 52
CRANKSHAFT
CHECKING THE CRANKSHAFT AND CON-

NECTING ROD
1. Measure:
crankshaft runout
Out of specification Replace the crank-
shaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Crankshaft runout
Less than 0.03 mm
2. Measure:
big end axial clearance
Out of specification Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end axial clearance

0.15 0.35 mm
Limit 0.6 mm
3. Measure:
crankshaft width
Out of specification Replace the crank-
shaft.
Crankshaft width
40.15 40.20 mm
4. Check:
crankshaft sprocket 1
Damage/wear Replace the crankshaft.
bearing 2
Cracks/damage/wear Replace the
crankshaft.
5. Check:
crankshaft journal
Scratches/wear Replace the crankshaft.
crankshaft journal oil passage
Obstruction Blow out with compressed air.
4 - 53
CRANKSHAFT
CHECKING THE BEARINGS AND OIL SEALS

1. Check:
bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals
CHECKING THE TIMING CHAIN, CAM-

SHAFT SPROCKET, AND TIMING CHAIN
GUIDES
1. Check:
timing chain
Damage/stiffness Replace the timing
chain and camshaft sprocket as a set.
2. Check:
camshaft sprocket
More than 1/4 tooth a wear Replace the
camshaft sprocket and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
timing chain guide (exhaust side)
timing chain guide (intake side)
timing chain guide (top side)
Damage/wear Replace the defective
part(-s).
4 - 54
CRANKSHAFT
INSTALLING THE CRANKSHAFT

1. Install:
crankshaft 1
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, apply
grease onto the oil seal lips and apply en-
gine oil onto each bearing.
ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Apply:
sealant
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery a .
3. Install:
dowel pins
right crankcase
4. Tighten:
crankcase right half
10 Nm (1.0 m kg)
NOTE:
Tighten the screws in decreasing numerical or-
der (see numbers on the illustration).
4 - 55

TRANSMISSION DEVICE,SHIFT DRUM ,GEAR FORKS

1 RATCHET SPRING PLATE 1
2 WASHER 17 1
3 CIRCLIP 1
4 SPRING 1
5 RATCHET SPRING BASE 1
6 STARING RATCHET WHEEL 1
7 CIRCLIP 1
8 WASHER 1
9 STARING GEAR 1
10 SPRING SHAFE 1
11 BEARING 1
12 PIN 2
13 PIN 3
14 PIN 2
14-1 PRING CLIP 2
15 GEAR FORK 1
16 GEAR FORK 1
17 DRUM 1 For installation, reverse the removal procedure.
4 - 56
! ! ! !

18 MAINSHAFT 1
19 COUNTERSHAFT 1
20 BEARING 6203 1
21 BEARING 6201 1
22 BEARING 6001 1
23 BEARING 6203 1
24 OIL SEAL 17X29X5 1
4 - 57
REMOVING THE TRANSMISSION

1. Loosen:
screw 1
2. Remove:
screw 1
contact ,gear indication 2
3. Remove:
drive axle assembly 1
main axle assembly 2
gearshift drum assy 3
Remove them at same the time.
4.Gearshift drum assy dissembly.

Remove:
clip. gearshift drum 1
pin. gearshift drum 2
4 - 58
CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift
forks and related components.
Check:
shift fork cam follower 1
shift fork pawl 2
Bends/damage/scoring/wear Replace
the shift fork.
CHECKING THE SHIFT DRUM

1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum.
shift drum segment
4 - 59
CHECKING THE TRANSMISSION

1. Measure:
main axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the main
axle.
Main axle runout limit

0.02 mm
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
Drive axle runout limit

0.02 mm
3. Check:
transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(-s).
transmission gear dogs

Cracks/damage/rounded edges Replace
the defective gear(-s).
4. Check:
transmission gear engagement
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Damage/bends/looseness Replace.
4 - 60
INSTALLING THE TRANSMISSION, SHIFT

FORKS AND SHIFT DRUM
1. Install:
main axle 1
drive axle 2
gearshift drum assy 3
Put them into the crankcase at same the time.
2. Check:
shift cam operation
Unsmoothy operation Repair.
NOTE:
Check the transmission and shift forks for
smooth operation by turning the shift cam with
your hand.
4 - 61
! ! ! !
FRONT WHEEL AND REAR WHEEL
FRONT WHEEL
3
1
4 5 6 2
7
NEW
6 5
4
NEW

1 NUT(FRONT WHEEL AXLE) 1
2 FRONT RIM AXLE 1
3 FRONT TIRE 1
4 COLLAR FR.WHEEL 2
5 OIL SEAL 2
6 BEARING 2
7 FRONT-BRAKE DISK 1
5-1
! ! ! !
REAR WHEEL
1 3
5 6
8
9
7
NEW
9
8
5
5
4 10
NEW
2

1 NUT(FRONT WHEEL AXLE) 1
2 FRONT RIM AXLE 1
3 CHAIN PULLER 2
4 REAR WHEEL 1
5 COLLAR RE.WHEEL 3
6 DRIVEN SPROKET 1
7 OIL SEAL 2
8 BEARING 2
9 FRONT-BRAKE DISK 1
5-2
REMOVAL POINTS
Rear wheel
1. Remove:
Wheel
NOTE:
Push the wheel forward and remove the drive
chain .
Wheel bearing (if necessary)

1. Remove:
Bearing
NOTE:
Remove the bearing using a general bearing
puller .
INSPECTION
Wheel
1. Measure:
Wheel runout
Out of limit → Repair/replace.
Wheel runout limit:

Radial : 2.0 mm
Lateral : 2.0 mm
2. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
NOTE:
Replace the bearings, oil seal and wheel collar
as a set.
5-3
! !
Wheel axle
1. Measure:
Wheel axle bends
Out of specification → Replace.
Use the dial gauge .
Wheel axle bending limit:

0.5 mm
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
Brake disc
1. Measure:
Brake disc deflection (only rear brake
disc)
Use the dial gauge .
Out of specification → Inspect wheel
runout.
If wheel runout is in good condition,
replace the brake disc.
Brake disc deﬂection limit:

Rear:
<Limit>: 0.15 mm
2. Measure:
Brake disc thickness b
Out of limit → Replace.
Brake disc thickness:

Front:
3.0 mm
<Limit>: 2.5 mm
Rear:
3.0 mm
<Limit>: 2.5 mm
5-4
Front wheel
1. Install:
Bearing (left)
Middel spacer
Bearing (right)
Oil seal
Collar (left)
Collar (right)
NOTE:
bearing and oil seal lip when installing.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the out-
er race.
2. Install:
Brake disc
Bolt (brake disc)
12 Nm (1.2 m • kg)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
3. Install:
Collar
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
4. Install:
Wheel
NOTE:
Install the brake disc between the brake pads
correctly.
5-5
5. Install:
Wheel axle
NOTE:
wheel axle.
6. Install:
Nut (wheel axle)
50Nm (5 m · kg )
T.
R.
5-6
Rear wheel
1. Install:
Bearing (left)
Bearing (right)
Middle spacer
Oil seal
Left Collar
Right Collar
NOTE:
bearing and oil seal lip when installing.
Install the bearing with seal facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Right side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
ACHTUNG:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake disc
Bolt (brake disc)
14 Nm (1.4 m · kg)
T.
R.
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
5-7
3. Install:
Rear wheel sprocket
Bolt (rear wheel sprocket)
25 Nm (2.5m · kg)
T.
R.
Washer (rear wheel sprocket)
Nut (rear wheel sprocket)
NOTE:
Tighten the nuts in stage, using a crisscross
pattern.
4. Install:
Left Collar
NOTE:
seal lip.
5. Install:
Right Collar
NOTE:
seal lip.
6. Install:
Wheel
NOTE:
Install the brake disc between the brake
pads correctly.
7. Install:
Drive chain
NOTE:
Push the wheel forward and install the drive
chain.
5-8
7. Install:
Left drive chain puller
Wheel axle
NOTE:
Install the left drive chain puller, and insert
the wheel axle from left side.
wheel axle.
8. Install:
Left drive chain puller
Bolt (wheel axle)
Adujust bolt (wheel axle)
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.
9. Adjust:
Drive chain slack A
Drive chain slack:

30 ~ 40 mm
Refer to “DRIVE CHAIN SLACK

ADJUSTMENT” section in the CHAP-
TER 3.
10. Tighten:
Reft drive chain puller
Nut (wheel axle)
65 Nm (6.5 m · kg)
T.
R.
Locknut
12 Nm (1.2 m · kg)
T.
R.
5-9
! ! ! !
FRONT BRAKE AND REAR BRAKE
FRONT BRAKE
2
6 NEW
NEW
3
1
NEW
NEW
2

1 FR,CALIPER ASSY. 1
2 UNION BOLT 2
3 FR,BRAKE HOSE 1
4 BRAKE LEVER 1
5 BRAKE MASTER CYLINDER 1
BRACKET
6 BRAKE MASTER CYLINDER 2
5 - 10
! ! ! !
REAR BRAKE
NEW
NEW
NEW
3
NEW

1 UNION BOLT. 2
2 REAR,CALIPER ASSY. 1
3 REAR,BRAKE HOSE 1
4 REAR MASTER CYLINDER ASSY 1
5 REAR.BRAKE PEDAL 1
5 - 11
REMOVAL POINTS
Brake fluid
1. Remove:
[Front]
Brake master cylinder cap
NOTE:
Do not remove the diaphragm.
[Rear]
NOTE:
Do not remove the diaphragm.
2. Connect the transparent hose to the

bleed screw and place a suitable con-
tainer under its end.
3. Loosen the bleed screw and drain the

brake fluid while pulling the lever in or
pushing down on the pedal.
CAUTION:
ACHTUNG:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled
fluid immediately.
5 - 12
Brake caliper piston
1. Remove:
Brake caliper piston
Use compressed air and proceed care-
fully.
WARNING
Cover piston with rag and use extreme
caution when expelling piston from cylin-
der.
Never attempt to pry out piston.
Caliper piston removal steps:

Insert a piece of rag into the brake caliper
to lock one brake caliper.
Carefully force the piston out of the brake
caliper cylinder with compressed air.
Brake caliper piston and spring plate

1. Remove:
Piston (Brake caliper)
Pad support (Brake caliper)
Wear/damage/ → Replace
CAUTION:
ACHTUNG:
Never attempt to take out t h e piston .
INSPECTION
Brake master cylinder
1. Inspect:
Brake master cylinder inner surface b
Wear/scratches → Replace master cyl-
inder assembly.
Stains → Clean.
WARNING
Use only new brake fluid.
5 - 13
2. Inspect:
Diaphragm
Crack/damage → Replace.
3. Inspect:
Brake master cylinder piston
Brake master cylinder cup
Wear/damage/score marks → Replace
brake master cylinder kit.
Brake hose
1. Inspect:
Brake hose
Crack/damage → Replace.
5 - 14
WARNING
All internal parts should be cleaned in
new brake fluid only.
Internal parts should be lubricated with
brake fluid when installed.
Front braker caliper

1. Install:
Pad support
Brake pad
Pad pin
2. Install:
Brake caliper
Bolt (front brake caliper)
5 - 15
Rear braker caliper

1. Install:
Pad support
Brake pad
Pad pin
2. Install:
Brake caliper
Right spacer (rear wheel)
Nut (rear wheel)
5 - 16
.
Brake master cylinder kit
1. Clean:
Clean them with brake fluid.
2. Install:
Brake master cylinder cup (primary)
Brake master cylinder cup (secondary)
To brake master cylinder piston
.
NOTE:
Apply the brake fluid on the brake master cyl-
inder cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
3. Install:
Spring
To brake master cylinder piston .
NOTE:
Install the spring at the smaller dia. side.
4. Install:
[Front]
Circlip
Brake master cylinder boot
To brake master cylinder .
[Rear]
Push rod
Brake master cylinder boot
To brake master cylinder
NOTE:
Apply the brake fluid on the brake master
cylinder kit.
Apply the lithium soap base grease on the tip
of the push rod.
When installing the circlip, use a long nose
circlip pliers.
5 - 17
.
Front brake master cylinder
1. Install:
Brake master cylinder bracket
Bolt (brake master cylinder bracket)
9 Nm ( 0.9 m • kg )
T.
R.
NOTE:
Install the bracket so that the arrow mark b
face upward.
First tighten the bolts on the upper side of the
brake master cylinder bracket, and then
tighten the bolts on the lower side.
2. Install:
Brake lever
Bolt (brake lever)
6 Nm ( 0.6 m • kg )
T.
R.
Front brake master cylinder
NOTE:
brake lever sliding surface, bolt and contacting
surface of the brake master cylinder piston.
Rear brake master cylinder
1. Install:
Copper washer
Brake hose
Union bolt
25 Nm (2.5 m• kg)
T.
R.
WARNING
Always use new copper washers.
CAUTION:
ACHTUNG:
Install the brake hose so that its pipe por-
tion directs as shown and lightly
touches the projection on the brake
master cylinder.
5 - 18
2. Install:
Bolt (brake master cylinder)
9 Nm (0.9 m · kg)
T.
R.
3. Install:
Spring
Brake pedal
Pin
Washer
Cotter pin
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTTER 3 .
Front brake hose

1. Install:
Union bolt
25 Nm (2.5 m · kg)
T.
R.
Copper washer
Brake hose
WARNING
CAUTION:
ACHTUNG:
After installing,brake hose s h o u l d be instal-
led as shown direction.wrong installation case
brake hose broken.
5 - 19
2. Install:
Copper washer
Brake hose
Union bolt
25 Nm (2.5 m · kg)
T.
R.
WARNING
Rear brake hose

1. Install:
Copper washer
Brake hose
Union bolt
25 Nm (2.5 m · kg)
T.
R.
WARNING
ı
Brake hose
Brake caliper
Swing arm
2. Install:
Brake holder
CAUTION:
ACHTUNG:
After installing,brake hose s h o u l d be instal-
led as shown direction.wrong installation case
brake hose broken.
5 - 20
Brake fluid
1. Fill:
Brake fluid
Until the fluid level reaches “LOWER”
level line .
Recommended brake fluid:

DOT #3 or DOT #4
WARNING
Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
ACHTUNG:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
2. Air bleed:
Brake system
BLEEDING” section in the CHAPTER
3.
3. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
INSPECTION” section in the CHAP-
TER 3.
5 - 21
4. Install:
[Front]
Diaphragm
Screw (brake master cylinder cap)
2 Nm (0.2 m · kg)
T.
R.
[Rear]
Diaphragm
Bolt (brake master cylinder cap)
2 Nm (0.2 m · kg)
T.
R.
CAUTION:
ACHTUNG:
After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.
5 - 22
! ! ! !
STREERING
STREERING
2
3

1 NUT STEERING UPPER M22 1
2 WASHER STEEL). 1
3 STEERING STEM LOCK NUT 1
4 BEARING ASSY 1
5 TRIPLE CLAMP(STEERING STEM) 1
ASSY
5 - 23
! ! ! !
FRONT FORK
FRONT FORK
4
2
6
6

1 FRONT NUMBER PLATE 1
2 FRONT FENDER 1
3 SCREW 2
4 SCREW . 4
5 FRONT.FORK ASSY 1
5 - 24
FRONT FORK AND STEERING
Installation
1. Install:
Front fork
NOTE:
Temporarily tighten the pinch bolts (lower
bracket).
Do not tighten the pinch bolts (upper bracket)
yet.
2. Tighten:
Front fork .
4. Tighten:
Pinch bolt (upper bracket)
15 Nm (1.5 m · kg)
T.
R.
Pinch bolt (lower bracket)

15 Nm (1.5 m · kg)
T.
R.
CAUTION:
ACHTUNG:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
Brake hose holder
Bolt (brake hose holder)
9 Nm (0.9 m · kg)
T.
R.
5 - 25
REMOVAL POINTS
Steering ring nut
1. Remove:
Steering ring nut
Use the steering nut wrench
WARNING
Support the steering stem so that it may
not fall down.
ı Lower bearing
1. Remove:
Lower bearing
Use the floor chisel .
CAUTION:
ACHTUNG:
Take care not to damage the steering shaft
thread.
Ball race
1. Remove:
Ball race
Remove the ball race using long rod
and the hammer.
INSPECTION
Steering stem
1. Inspect:
Steering stem
Bend/damage → Replace.
5 - 26
Bearing and ball race

1. Wash the bearings and ball races with a
solvent.
2. Inspect:
Bearing
Ball race
Pitting/damage → Replace bearings
and ball races as a set.
Install the bearing in the ball races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the ball races, replace
bearings and ball races as a set.

Lower bracket
1. Install:
Lower bearing
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Ball race
Upper bearing
Ball race cover
NOTE:
bearing and ball race cover lip.
3. Install:
Lower bracket
NOTE:
bearing, the portion b and thread of the steer-
ing stem.
5 - 27
4. Install:
Steering ring nut
30 Nm (3 m · kg)
T.
R.
Tighten the steering ring nut using the
steering nut wrench 3 .
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
5. Check the steering stem by turning it lock

to lock. If there is any binding, remove
the steering stem assembly and inspect
the steering bearings.
6. Install:
Lower
Upper bracket
Front fork
NOTE:
Temporarily tighten the pinch bolts (lower
bracket).
Do not tighten the pinch bolts (upper bracket)
yet.
7. Install:
Upper bracket
Washer
Steering stem nut
70 Nm (7.0 m · kg)
T.
R.
8. After tightening the nut, check the steer-

ing for smooth movement. If not, adjust
the steering by loosening the steering
ring nut little by little.
5 - 28
9. Tighten:
Pinch bolt (upper bracket)
15 Nm (1.5 m · kg)
T.
R.
Pinch bolt (lower bracket)
15 Nm (1.5 m · kg)
T.
R.
CAUTION:
ACHTUNG:
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5 - 29
! ! ! !
HANDLEBAR
HANDLEBAR
10
12
11
14

1 CROSS BAR COVER 1
2 CROSS BAR FOAM. 1
3 GRIP .R 1
4 THROTTLE HOUSEING 1
5 THROTTLE CABLE 1
6 GRIP .L 1
7 START SWITCH ASSY 1
8 CLUTCH LEVER ASSY. 1
9 CLUTCH CABLE ASSY 1
10 SCREW WITH NUTM8X80 4
11 RISER SET FOR HANDLEBAR 2
12 HANDLEBAR 1
13 RISER SET FOR HANDLEBAR 2
14 UPPER TRIPLECLAMP 1
5 - 30
HANDLEBER
REMOVAL POINTS
1. Remove:
CAUTION:
ACHTUNG:
Do not let the brake master cylinder hang
on the brake hose.
Keep the brake master cylinder cap side
horizontal to prevent air from coming in.
Grip
1. Remove:
Grip
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
INSPECTION
Handlebar
1. Inspect:
Handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
5 - 31
HANDLEBER

Handlebar
1. Install:
Handlebar
Handlebar upper holder
Bolt (handlebar upper holder)
25 Nm (2.5 m · kg)
T.
R.
NOTE:
The handlebar upper holder should be
installed with the punched mark b forward.
First tighten the bolts on the front side of the
handlebar upper holder, and then tighten the
bolts on the rear side.
2. Install:
Left grip
Apply the adhesive to the handlebar .
NOTE:
Before applying the adhesive, wipe off
grease or oil on the handlebar surface b
with a lacquer thinner.
3. Install:
Right grip
Collar
Apply the adhesive on the tube guide
.
NOTE:
Before applying the adhesive, wipe off
grease or oil on the tube guide surface b
with a lacquer thinner.
5 - 32
HANDLEBER
4. Install:
Collar
Grip cap cover
Throttle grip
NOTE:
throttle grip sliding surface.
5. Install:
Throttle cables
To tube guide .
NOTE:
throttle cable end and tube guide cable wind-
ing portion.
6. Install:
Throttle cable cap
Screw (throttle cable cap)
4 Nm (0.4 m · kg, 2.9 ft · lb)
T.
R.
WARNING
After tightening the screws, check that the
throttle grip moves smoothly. If it does
not, retighten the bolts for adjustment.
7. Install:
Grip cap cover
Cover (throttle cable cap)
5 - 33
HANDLEBER
8. Install:
Bolt (brake master cylinder bracket)
9 Nm (0.9 m • kg)
T.
R.
NOTE:
Install the bracket so that the arrow mark b
faces upward.
First tighten the bolt on the upper side of the
brake master cylinder bracket, and then
tighten the bolt on the lower side.
9. Install:
Engine start button
Engine stop switch
Bolt (clutch lever holder)
9 Nm (0.9 m • kg)
T.
R.
Clutch lever holder
Screw (Engine start button)

T.
R.
4 Nm(0.4 m • kg)
10. Install:
Bolt (clutch lever)
NOTE:
clutch cable end .
11. Adjust:
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
Hot starter lever free play
5 - 34
! ! ! !
SWINGARM AND REAR SHOCK ABSORBER
SWINGARM AND REAR SHOCK ABSORBER
10
11 1
23
4 5
6
6 5
12 4 3
13
14 15
7
17
16

1 REAR SHOCK 1
2 NUT 1
3 WSHER 2
4 NEEDLE BEARING 2
5 BUSHING 2
6 NEEDLE BEARING 1
7 MIDDLE AXLE BOLT 1
8 REAR SWING ARM ASSY 1
9 CLIP 1
10 CHAIN GUARD 1
11 REAR FORK DUST COVER 1
12 BOLT 1
13 WSHER 1
14 CHAIN ROLLER 1
15 COLLAR 1
16 CHAIN GUIDE-BRACKET 1
17 LT.CHAIN-GUIDE BRACKET set) 1
5-
REAR SHOCK ABSORBER AND SWINGARM
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
rear shock absorber assembly lower bolt 1
NOTE:
While removing the rear shock absorber as-
sembly lower pin, hold the swingarm so that it
does not drop down.
3. Remove:
rear shock absorber assembly upper bolt 1
rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm and relay arm.
REMOVING THE DRIVE CHAIN

WARNING
NOTE:
2. Remove:
chain cover
3. Remove:
master link clip
(with interlocking slip-joint pliers )
4. Remove:
master link plate 1
master link 2
5. Remove:
drive chain
5-36
REMOVING THE SWINGARM

WARNING
NOTE:
2. Check:
swingarm side play A
swingarm vertical movement B
a. Check the tightening torque of the pivot shaft

nut .
Pivot shaft nut

50 Nm (5.0 m kg)
b. Check the swingarm side play A by moving

the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end

of the swingarm)
1.0 mm
d. Check the swingarm vertical movement B

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers,
bearings, washers, and dust covers.
5-37
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
spring
Damage/wear Replace the rear shock
absorber assembly.
bolts
Bends/damage/wear Replace.
CHECKING THE SWINGARM

1. Check:
swingarm
Bends/cracks/damage Replace.
2. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash:
pivot shaft
spacer
bearings
Recommended cleaning solvent

Kerosine
5-38
4. Check:
spacer 1
bearings 2
Damage/pitting Replace.
CHECKING THE DRIVE CHAIN

1. Measure:
10-link section a of the drive chain
Out of specification Replace the drive
chain.
10-link drive chain section

limit (maximum)
144.4 mm
NOTE:
While measuring the 10-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosine and remove
any remaining dirt.
c. Remove the drive chain from the kerosine
and completely dry it.
5-39
4. Check:
drive chain rollers 1
Damage/wear Replace the drive chain.
drive chain side plates 2
Damage/wear Replace the drive chain.
Cracks Replace the drive chain and make
sure that the battery breather hose is proper-
ly routed away from the drive chain and be-
low the swingarm.
5. Lubricate:
drive chain
Engine oil or chain lubricant
suitable for non-O-ring chains
6. Check:
drive sprocket
rear wheel sprocket
More than 1/4 tooth a wear
drive chain sprockets as a set.
Bent teeth Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
INSTALLING THE REAR SHOCK ABSORB-

ER ASSEMBLY
1. Install:
40 Nm(4.0 m • kg)
NOTE:
When installing the rear shock absorber assem-
bly, lift up the swingarm.
5-40
INSTALLING THE SWINGARM

1. Lubricate:
bearings
spacers
pivot shaft
Molybdenum disulfide grease
2. Install:
Swingarm 50 Nm (5.0 m kg)
3. Install
rear wheel
Refer to “INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY” and ”REAR
WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
30 50 mm
INSTALLING THE DRIVE CHAIN

1. Lubricate:
drive chain
master link (New)
Engine oil or chain lubricant
suitable for non-O-ring chains
2. Install:
master link 1
master link plate 2
3. Install:
master link clip 1
CAUTION:
The closed end of the master link clip must
face in the direction of drive chain rotation.
Never install a new drive chain onto worn
drive chain sprockets; this will dramatical-
ly shorten the drive chain’s life.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack

30 50 mm
5--41
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.
5-42
! ! ! ! ! ! !
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL COMPONENTS
2 Starter Solenoid
3 Rectifier/Regulator
4 %DWWHU\ 7
5 CDI magneto
6 Spark plug
7 Ignition coil 2
8 CDI unit
6
5
WIRING DIAGRAM
Starter Solenoid
Mount Bolt
Engine
D poofdups
Jhojujpo
D pjm
Battery
Fuse 10A
Starter
Starter Switch
DE J
ON/OFF
C py
N bhofup
D poofdups
Rectifier
Key
Switch
6-1
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
Spark *Clean or replace

Spark gap test
spark plug.
No spark
Check entire ignition
system for connection. No good
Repair or replace.
(couplers, leads and
ignition coil)
OK
No good
Check engine stop switch. Replace.
OK
Check ignition coil. Primary coil No good Replace.
No good
Secondary coil Replace.
OK
No good
Check CDI magneto. Pickup coil Replace.
No good
Charging coil Replace.
OK
No good
Replace CDI unit.
*marked: Only when the ignition checker is used.

NOTE:
Remove the following parts before inspection.
1) Seat
2) Fuel tank
Use the following special tools in this inspection.
6-2
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the spark plug cap from spark
plug.
2. Remove the ignition coil cap.
3. Connect the dynamic spark tester
(ignition checker ) as shown.
Ignition coil
Spark plug
4. Kick the kickstarter crank.

5. Check the ignition spark gap.
6. Start engine, and increase spark gap until
misfire occurs.
Minimum spark gap:

6.0 mm
COUPLERS, LEADS AND IGNITION COIL

CONNECTION INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
Ignition coil and spark plug as they are
fitted
Push in the ignition coil until it closely
contacts the spark plug hole in the cyl-
inder head cover.
ENGINE START STOP SWITCH INSPECTION

1. Inspect:
Engine stop switch conduct
Tester (+) lead → Black/White lead 2

Tester (–) lead → Green lead 3
B/W G Tester selec-

2 3 tor position
PUSH IN
Ω ×1
FREE
No continuous while being pushed → Replace.
Continuous while being freed → Replace.
6-3
IGNITION SYSTEM
. Inspect:
Engine start switch conduct
Tester (+) lead → Red/Yellow lead 4

Tester (–) lead → Black lead 5
B R/Y Tester selec-

5 4 tor position
PUSH IN
Ω ×1
FREE
No continuous while being pushed → Replace.
Continuous while being freed → Replace.
6-4

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SERVICE MANUAL

WARNING SAFETY INFORMATION

VEHICLE IDENTIFICATION NUMBER

2. Use proper tools and cleaning equip-

3. When disassembling the machine, keep

4. During the machine disassembly, clean

5. Keep away from fire.

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

3. Connect and disconnect the connector

Tool name/How to us Illustration Tool name/How to us Illustration

Crankcase separating tool Clutch holding tool

This tool is used to hold the clutch

This tool is used when loosening or

This tool is used to remove the piston

FRONT BRAKE LEVER

REAR BRAKE PEDAL

Model name: 21G

Model code number: AGB-21G

Air filter: Wet type element

Size (rear) 80/100-12 41M

Tire pressure (front and rear) 130 kPa (1.3 kgf/cm2 )

Item Standard Limit

Out of round limit ---- 0.05 mm

Camshaft outside diameter 31.963 ~ 31.979 mm ----

Shaft-to-cap clearance 0.030 ~ 0.071 mm

Intake “A” 26.555 ~ 26.675 mm 26.30 mm

“B” 20.99 ~ 21.01 mm 20.95 mm

Exhaust “A” 26.316 ~ 26.436 mm 26.00 mm

“B” 20.99 ~ 21.01 mm 20.95 mm

Camshaft runout limit ---- 0.03 mm

Item Standard Limit

EX 0.02 ~ 0.04 mm ----

EX 22.9 ~ 23.1 mm ----

“B” face width IN 1.1~1.5 mm ----

EX 0.8 ~ 1.0 mm 1.6 mm

“D” margin thickness IN 0.65~0.95 mm ----

EX 4.955 ~ 4.97 mm 4.925 mm

Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm

EX 5.500 ~ 5.512 mm 5.550 mm

Stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.08 mm

EX 0.030 ~ 0.057 mm 0.10 mm

Item Standard Limit

Stem runout limit ---- 0.03 mm

Valve seat width IN 0.8 ~ 1.2 mm 1.6 mm

EX 0.8 ~ 1.2 mm 1.6 mm

Set length (valve closed) IN 22.45 mm ----

EX 105 ~ 129 N at 25.45 mm ----

Tilt limit IN ---- 1.3˚/ 0.8 mm

Item Standard Limit

Piston pin outside diameter 13.994 ~ 14.000 mm 13.98 mm

Type Barrel ----

Side clearance (installed) 0.040 ~ 0.080 mm 0.12 mm

Type Taper ----

Side clearance 0.040 ~ 0.080 mm 0.12 mm

Dimensions (B s T) 1.92 s 2.45 mm ----

Runout limit “C” 0.03 mm 0.05 mm

Big end side clearance “D” 0.15 ~ 0.35mm 0.60 mm

Small end free play “F” 0.4 ~ 1.0 mm 2.0 mm