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How to use this manual Contents
This manual explains how to maintain procedure for the Service Information 1
General
SN125 manufactured by DAELIM MOTOR CO., LTD.
Inspections / Adjustments 2
To ensure safety and optimal operating conditions of the
vehicle, carry out regular inspections according to the External Parts 3
maintenance schedule(Section 2).
Sections 1 through 2 provide information on overall Lubrication System 4
vehicle; section 3, assembly and disassembly procedures
for external components, and section 4 describes EMS(Engine Management System) 5
maintenance procedure for the engine, frame and
electrical systems. Fuel System 6
To facilitate use of this manual, each page starts with
disassembly and system diagrams, each page starts with Engine Removal / Installation 7
disassembly and system diagrams, service information,
Engine
and troubleshooting guide. LH, Crank Case Cover
Continuously Variable 8
Transmission
Contents of this manual and specifications are subject A.C Generator / Starter Clutch 9
to change without prior notice for improvement of
vehicle quality.
Cylinder Head / Valves 10
No part of this publication may be reproduced without
written permission of DAELIM Motor Co.,Ltd.,
Cylinder Head / Piston 11
Transmission / Crank Shaft
Crank Case 12
Front Wheel / Front Fork
/ Steering 13
Frame
Rear Wheel / Suspension /

Rear Swing Arm 14
Brake System 15
Charging System 16
Ignition System 17
Electrical
Starter System 18
Lights / Switches / Horn 19
Wiring diagram(Euro2,Euro3) 20

SERVICE INFORMATION
1. SERVICE INFORMATION
SERIAL NUMBER LOCATION 1-1
WIRING DIAGRAM 1-6
1-2
SPECIFICATIONS GENERAL SAFETY 1-10
1
TORQUE VALUES 1-4
SERVICE RULES 1-10
STANDARD TORQUE VALUES 1-5 CAUTION WHEN WIRING 1-14
SYMBOLS/ABBREVIATIONS 1-5
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION
1-1
SERVICE INFORMATION
1,910mm
750mm
1,090mm
1,360mm
755mm
126mm
130kg
277kg
60
2.00
2.25
7.1 (6.8 )
1.2
25
90mm
80
90/70
stroke SOHC
1.0
1.05
13.8 380
ATDC
"( )" MARKED CONTENTS APPLY TO EURO 2 ONLY

1-2
SERVICE INFORMATION
ITEM SPECIFICATIONS
TYPE / VENTURI BORE CV type ( vacuum ) / '24.2 mm

MODEL MARK CVK
CHOKE TYPE Auto-bystarter
MAIN JET # 95
(CARBURETOR) PILOT SCREW INITIAL SETTING 2
FLOAT LEVEL 17 mm
IDLE SPEED 1.700100 rpm
CLUTCH TYPE Automatic Transmission

DRIVE TRAIN PRIMARY REDUCTION 3.000
SECONDARY REDUCTION 2.786
IGNITION SYSTEM ECU (C.D.I)

BATTERY TYPE / CAPACITY Closed type (MF) 12V 10AH
SPARK PLUG CR8EH -9 (NGK)
SPARK PLUG GAP 0.8 - 0.9 mm
FUSE CAPACITY 15A, 30A (15A)
STARTING SYSTEM Starter motor
HEADLIGHT ( HIGH / LOW ) 12V 55W / 12V 55W
ELECTRICAL
SYSTEM POSITION LIGHT 12V 5W
WINKER LIGHTS ( FR / RR ) 12V 10W4
TAIL / STOP LIGHT 12V 21 / 5W
HIGH-BEAM PILOT LED
WINKER PILOT LED
METER LIGHTS LED
LICENSE LAMP 12V 5W
( )
MARKED CONTENTS APPLY TO EURO2 ONLY
1-3
SERVICE INFORMATION
1-4
SERVICE INFORMATION
1-5
SERVICE INFORMATION
1-6
SERVICE INFORMATION
1-7
SERVICE INFORMATION
1-8
SERVICE INFORMATION
1-9
SERVICE INFORMATION
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other workers action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the
recommended parts. chasis.
3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter
each part in the right place. pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
1-10
SERVICE INFORMATION
5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data
remove the cleaning oil with compressed air. Apply oil during installation. When installing, return to the state
to seal face during installation. before removing.
7. Align the bolts to uniform the tightening points before 8. Bolts, nuts and pieces must be tightened from the bigger
tightening them when you dont know the bolt length. diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
9. Check to see if the rubber part is worn out when 10. Recommended grease must be applied to or filled in
removing it and replace it if necessary. Some rubber part the specified place.
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
performed with the right tool. applied pressure when removing press-fitted the
bearing.
1-11
SERVICE INFORMATION
13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the
ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open-
Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way
longitudinal hanging. that the face marked with manufacturer and size
Wipe the ball bearing likely to have hanging with should direct to the outer axle.
cleaning oil.(except double-sided sealed type ball
bearing) SINGLE-SEALED TYPE DOUBLE-SEALED TYPE
Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
OPEN TYPE MANUFACTURERS NAME, BEARING No.

15. When blowing the ball bearing with compressed air 16. Install the snap ring so that chamfered side directs to
after cleaning, keep the race from rotating. High speed the load-applied side. After installation, check the
rotation of the race may damage the bearing. Prior to proper installation by rotating the snap ring.
installation, apply oil or grease to the bearing.
SNAP RING
CHAMFERED EDGE
17. Check each part for proper tightening and operation 18. The brake fluid and coolant can damage the painted
after installation. plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
Pay attention not to bend or damage the lip
Apply the grease to the lip
CAVITY
MANUFACTURERS NAME
CLIP
FITTING
1-12
SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of
interior from the infiltration of dust. each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively. 24. Install the boots with the installing groove by inserting
Transformed or damaged cable may cause malfunction the boots into the groove.
or damage.
BOOTS
1-13
SERVICE INFORMATION
CAUTION WHEN WIRING

Each cord must be connected depending on its color. When measuring voltage or resistance of the cord
When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of
around the connector. Connect the coupler to the the coupler. Pay attention not to open the cord terminal
connector with same color and same pin number. and contact the tester plug from the front of the coupler
Identify the two-colored cord by main color first and in case of water-proof coupler.
then striped color . RED STRIPE
TESTER PLUG
WHITE WHITE
TUBE COUPLER.
BLACK TUBE
WHITE
Recheck the condition of contact, securing and
continuity of each part after maintenance.
BLACK CORD RED STRIPE When connecting the battery, the plus terminal must be
connected first.
After connecting the terminal, apply the grease to the
terminal.
WHITE / RED CORD
When disconnecting the battery, the minus terminal Connect covers to the terminal after maintenance.
must be disconnected first.
Make sure that the tool such as spanner do not contact
with the frame.
If the fuse is short-circuited, find out the cause and If there is rust in the terminal, remove the rust with sand
repair. Replace with the fuse having the specified paper prior to connecting.
capacity.
VALIDATION REMOVE
OF CAPACITY! THE
RUST!
1-14
SERVICE INFORMATION
Turn off the main switch before connecting/dis- When disconnecting the coupler, disconnect it while
connecting. holding the coupler body. Pull while holding the wire
Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
Insert the lock of the coupler until the lock is fully

secured.
Release the lock by inserting the coupler slightly and Pay attention not to damage the vinyl cover of the
then narrowing connection to remove the coupler. coupler.
Check to see if there is bended terminal and secure it to If the wire harness coating is damaged, repair by
avoid disconnecting. winding vinyl tape or replace it.
Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.
1-15
SERVICE INFORMATION
Insert the connector until the vinyl cover is fully inserted When removing T-start, broaden the groove of T-start
into the terminal. using the wiring driver and release the torque.
The opening of the vinyl cover must face at the ground Connect the harness and the hose to T-start and then
direction but in case of the plain connector, the draining insert until the groove is locked.
opening must face at the sky direction. When removing T-start from the frame, replace it with
the new one.
DRAINING HOLE WIRING DRIVER GROOVE SIDE
Wire band must be secured firmly in the specified Secure the wire harness firmly using the clamp.
location of the frame. In case of aluminium band, secure
the wire harness to the coated part.
In case of the weld clamp, do not clamp in the welded When clamping the wire harness, make sure that the
part. harness is not contacted with the shaft or rotating part.
When clamping the wire, pay attention not to contact The wire harness must be routed without contacting
with hot part. with the end of the lamp or any sharp edge.
The wire harness must be routed without contacting
with the end of the bolt or the piece.
1-16
SERVICE INFORMATION
In case that the wire harness is contacted with the end or The wire must not hang down or be pulled excessively.
the sharp edge, protect both parts with tube or tape.
NOT TO
PULL!
If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness
is not pressed by the parts.
Do not twist the wire harness. Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
Prior to using the tester, please read the manual care- Do not drop or throw the parts especially semiconductor
fully and understand the contents. contained parts because these parts may be damaged by
When testing the resistance of the tester, the zero the impact of the drop.
adjustment must be performed before testing.
Is this
measurement range or
configuration in accord
with the manual?
1-17
MEMO

INSPECTIONS/ADJUSTMENTS
2. INSPECTIONS/ADJUSTMENTS
SERVICE INFORMATION 2-1 ENGINE OIL 2-7
MAINTENANCE SCHEDULE 2-3 DRIVE BELT 2-7
FUEL LINE 2-4 BRAKE FLUID 2-8
2
THROTTLE GRIP OPERATION 2-4 BRAKE PAD 2-8
AIR CLEANER 2-5 BRAKE SYSTEM 2-8
SPARK PLUG 2-5 SIDE STAND 2-9
VALVE CLEARANCE 2-6 SUSPENSION 2-9
CYLINDER COMPRESSION BOLTS, NUTS, FASTENERS 2-10
RESSURE 2-6 WHEELS/TIRES 2-10
CARBURETOR IDLE SPEED 2-7 STEERING STEM 2-10
TRANSMISSION OIL 2-7 LUBRICATION POINTS 2-11
2-1
2-2
2-3
FUEL
FUEL
FUEL PUMP
FUELPUMP
PUMP
PUMP FUELTUBE
FUEL
FUEL TUBE
TUBE
THROTTLE
THROTTLE GRIP
THROTTLEGRIP
THROTTLE GRIP
GRIP
FREE
FREE
FREEPLAY
PLAY
PLAY
THROTTLE
THROTTLE CABLE
THROTTLECABLE
CABLE CARBURETOR
CARBURETOR
CARBURETOR
LOCK
LOCKNUT
LOCK NUT
NUT ADJUST
ADJUSTNUT
ADJUST NUT
NUT
THROTTLE
THROTTLE CABLE
THROTTLECABLE
THROTTLE CABLE
CABLE
RUBBER
RUBBER
RUBBER
LOCK
LOCK NUT
LOCK NUT
NUT ADJUST
ADJUST
ADJUST NUT
ADJUSTNUT
NUT
NUT
2-4
AIR
AIR
AIRCLENER
CLENER
CLENER
AIR
AIRCLEANER
AIR CLEANERELEMENT
CLEANER ELEMENT
ELEMENT
Check the element, if it is dirty or damaged replace it.
The air cleaner element made of dry process paper

filter.
Do not clean by compressed air blowing.
CHECK GAP, Remove the spark plug maintenance cover.

DEPOSITS 0.8 ~ 0.9mm
CHECK WASHER
FOR DAMAGE
CHECK FOR
CRACKS
SPECIAL
SPECIAL CYLINDER HEAD COVER
Hand-tighten the spark plug before using a wrench to
BOLT
SPECIALBOLT
BOLT CYLINDER
CYLINDERHEAD
CYLINDER HEADCOVER
HEAD COVER
COVER
tighten to the specified torque.
SPARK
SPARKPLUG
SPARK PLUGCAP
PLUG CAP
CAP
2-5
TIMINCT
TIMINCT
TIMINCT HOlLE
HOlLE
HOlLE CAP
CAP
CAP COOLING
COOLING
COOLING FAN
FAN
FAN
- Floor panel ass'y.

Loosen the 4 cylinder head bolts.
fan cover.
Remove the shroud B grommet of the timit hoile cap
on the RH. shroud.
ADJUST
ADJUST
ADJUST WRENCH
WRENCH
WRENCH
FEELER
FEELER GAUGE
FEELER GAUGE
GAUGE
TAPPET
TAPPET ADJUST
TAPPET ADJUST SCREW
ADJUST SCREW
SCREW
SPARK
SPARK
SPARK PLUG
PLUG
PLUG CAP
CAP
CAP
CYLINDER
CYLINDER
CYLINDER HEAD
HEAD
HEAD
spark plug maintenance.
COMPRESSION
COMPRESSION
COMPRESSION GAUGE
GAUGE
GAUGE
CYLINDER
CYLINDER HEAD
CYLINDER HEAD
HEAD
2-6
PILOTSCREW
PILOT
PILOT SCREW
SCREW
CARBURATOR IDLE SPEED
Erect the motorcycle on the mainstand.
Remove the rear fender, center cover.
Verify all engine adjustments satisfy specifications.
Make adjustment, If necessary.
Heat the engine to make accurate idling inspection and
adjustment.
Turn the throttle stop screw and make adjustments to
prescribed idling speed.
100RPM
IDLE SPEED : 1,700
THROTTLE
THROTTLE
THROTTLE STOP
THROTTLESTOP SCREW
STOPSCREW
STOP SCREW
SCREW
Do not over adjustment the pilot screw. it could be
effect to starting. (refer to page 6-9)
TRANSMISSION OIL
INSPECTOIN
Remove the LH. crank case. (-> 8-2)
Remove the bolt and check the oil on oil check hole.
If the oil level is low(80W/90), add the oil.
Install oil check bolt.
Make sure that the oil sealing washer is good

OIL
OIL CHECK
OILCHECK HOLE
CHECKHOLE
HOLE condition.
Erect the motorcycle on the main stand.
OIL
OIL
OILSIGHT
SIGHT
SIGHTGLASS
GLASS
GLASS
ENGINE OIL
INSPECTOIN
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER Start the engine and let it be warm fully.
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER
Stop the engine. check the oil level line of the LH.
crank case cover oil sight glass.
It is good if the oil surface is between the lower level
line and upper that of the sight glass. If the oil level is
near the lower level line or below that, full to the
upper level line with the recommended oil.
TAPPET ADJUSTING HOLE CAP

Erect the motorcycle on the main stand.
DRAIN
DRAIN
DRAINPLUG
PLUG
PLUGBOLT
BOLT
BOLT TAPPET
TAPPETADJUSTING
TAPPET ADJUSTINGHOLE
ADJUSTING HOLECAP
HOLE CAP
CAP
DRIVE FACE DRIVE

DRIVEBELT
DRIVE BELT
BELT DRIVENPULLEY
DRIVEN
DRIVEN PULLEY
PULLEY
DRIVE
DRIVEFACE
DRIVE FACE
FACE
DRIVE BELT
Remove the LH. crankcase cover.
Check the drive belt for wear or damage.
Check schedule maintenance period, replace the new
drive belt if possible.
2-7
MASTER
MASTER CYLINDER
MASTERCYLINDER
CYLINDER
BRAKE FLUID
Check the oil level inside the front brake reservoir.
If the oil level is near the lower limit line, remove
CHECK
CHECK GLASS
CHECKGLASS
GLASS the reservoir diaphrag mand fill DOT3 and DOT 4
brake fluid to the top limit line.
If the brake fluid reaches the lower limit line, check
the entire brake system for leaks.
If the brake pad is worn severely brake fluid level

can be down.
BRAKE PAD
BRAKE PAD REPLACEMENT
Check the brake pads for wear.
If the rod mark on the pad reaches the brake
ROD MARK ROD MARK
disc, replace the pads.
BRAKE PAD BRAKE PAD
DUBLE
DUBLE
DUBLE BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE REAR
REAR
REAR BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE BRAKE SYSTEM
Check the front brake hose for cracks or damage.
If any leaks are found,replace immediately
FRONT
FRONT CALLIPER
FRONT CALLIPER
CALLIPER
FRONT
FRONT
FRONT BRAKE
BRAKE
BRAKE HOSE
HOSE
HOSE REAR CALIPER
REAR
REAR CALIPER
CALIPER
BRAKE
BRAKE LEVER
BRAKE LEVER
LEVER
BRAKE LEVER FREE PLAY
Check the free play after pulling the lever.
FREE
FREEPLAY
FREE PLAY
PLAY FRONT:10~20mm
REAR:10~20mm
2-8
GREASE
GREASE
GREASE
SIDE STAND
SIDE
SIDE STAND
STAND
SIDE
SIDE STAND
SIDE STAND SWITCH
STAND SWITCH
SWITCH
SIDE
SIDE
SIDE STAND
STAND
STAND
2-9
STANDARD PRESSURE /
ITEM FRONT WHEEL REAR WHEEL
DRIVER ONLY 2.00(29
1.78 psi) 2.00(29 psi)
TIRE PRESSURE GANGE DRIVER AND A PASSENGER 2.25(32
TIRE
TIREPRESSURE
TIRE PRESSUREGANGE
PRESSURE GANGE
GAUGE
GANGE 2.29 psi) 2.25(32 psi)
STEERING STEM
2-10
LUBRICATION POINTS
Use general grease unless specified here.
Apply oil or grease to the other sliding surfaces not shown here.
CONTROL CABLE LUBRICATION

Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning.
Change it when the cable lengthened.
RR. BRAKE LEVER PIVOT

THROTTLE GRIP
STEERING HEAD BEARING
WHEEL BEARING / SPEDOMETER GEAR WHEEL BEARING

MAIN / SIDE STAND PIVOT
2-11
MEMO

EXTERNAL PARTS
SERVICE INFORMATION 3-1 SEAT SUPPORT PIPE 3-6

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

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

cable coupler (left and right)
Loosen the flange bolt securing the headlight
HEAD
HEAD LIGHT
HEAD LIGHT CABLE
LIGHT CABLE
CABLE
case.
Remove the case.
3-3
EXTERNAL PARTS
Remove the speedometer cable and

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

cover and remove the front cover.
Install in the reverse order of removal
SPECIAL
SPECIAL
SPECIAL
SCREW
SCREW
SCREW
SPECIAL
SPECIAL SCREW
SPECIAL SCREW
SCREW FRONT
FRONT
FRONT FENDER
FENDER
FENDER
FRONT FENDER
REMOVAL/ASSEMBLY
Loosen the 4 special screws (R/L).
Remove the wire grommet.
Remove the front fender.
TAPPING
TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW FRONT UNDER COVER
REMOVAL/ASSEMBLY
Loosen the 4 tapping screws (R/L) securing
the front of the floor panel.
Loosen the 2 flange bolts securing the front
under cover.
Loosen the 4 washer screws (R/L) securing
front of the floor side cover.
TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW
FRONT
FRONT UNDER
FRONT UNDER COVER
UNDER COVER
COVER FLOOR
FLOOR SIDE
FLOOR SIDE COVER
SIDE COVER
COVER
3-4
EXTERNAL PARTS
Remove the front under cover.

SEAT REMOVAL/ASSEMBLY
Release the seat lock at the back of seat.
Loosen the 2 flange nuts and remove the seat.
SEAT
SEAT
SEAT
SPECIAL SCREW
SPECIAL
SPECIAL SCREW
SCREW
REAR FENDER
REMOVAL/ASSEMBLY
Loosen the 2 special bolts.
Loosen the 2 washer bolts and remove the rear
fender.
Remove the tail light cable.
WASHER
WASHER
WASHER BOLT
BOLT
BOLT REAR
REAR
REAR FENDER
REAR FENDER
FENDER
REAR
REAR
REAR UPPER
REAR UPPER COVER
UPPER COVER
COVER REAR UPPER COVER
REMOVAL/ASSEMBLY
Pull the behind of the rear upper cover to
remove it.
3-5
EXTERNAL PARTS
SPECIAL
SPECIAL
SPECIAL SCREW
SCREW
SCREW
REAR UNDER COVER
REMOVAL/ASSEMBLY
Loosen the 4 special screw (R/L) securing the
rear under cover.
Remove it by opening the rear under cover.
REAR
REAR
REAR UNDER
REAR UNDER COVER
UNDER COVER
COVER
SEAT
SEAT
SEAT SEAT
SEAT
SEAT SUPPORT
SEAT SUPPORT
SUPPORT
SUPPORT
SEAT SUPPORT PIPE
UPPER
UPPER REMOVAL/ASSEMBLY
HANDLE COVER
HANDLE COVER
Remove the rear upper cover.
Remove the rear fender.
the bar end cap B.
BAR END
BAR
BAR END CAP
END CAP B
CAP B
B
FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT Loosen the 4 flange bolts securing the seat
support.
Loosen the cap bolt securing the truss pipe and
remove the support pipe.
CAP BOLT
CAP
CAP BOLT
BOLT
TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT CENTER COVER
REMOVAL/ASSEMBLY
Remove the rear upper and rear fender.
Remove the seat support pipe.
Loosen the 2 tapping screws and 2 flange bolts.
Remove the center cover.
CENTER
CENTER
CENTER COVER
COVER
COVER
3-6
EXTERNAL PARTS
TRUSS PIPE
REMOVAL/ASSEMBLY
Remove the bar end cap B.
Loosen the flange bolt.
Loosen the 4 cap bolts.
Remove the truss pipe.
FLOOR SIDE COVER

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

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

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

Loosen the 2 flange bolts securing the pilot
box.
FLANGE
FLANGE
FLANGE BOLT
BOLT
BOLT
Remove the speedometer cable.

SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
MUFFLER
REMOVAL/ASSEMBLY
Loosen the washer bolt securing the brake hose
clamp.
Loosen the 3 hex cap nut securing Ex. Pipe
comp.
Loosen the 2 flange bolt securing the muffler
comp.
HEX
HEX CAP
HEX CAP
HEX CAP
CAP
FLANGE
FLANGE
FLANGE BOLT
BOLT
BOLT Never performing the maintenance of the muffler
right after stopping the vehicle because the muffler
is extremely hot.
FLANGE
FLANGE
FLANGE NUT
NUT
NUT
Remove the Ex. muffler comp.
EX. PIPE
Loosen the 2 flange nuts securing the cylinder
comp.
Pull the Ex. pipe comp downward to remove it.
Replace the packing when assemblying the muffler

and Ex. pipe comp.
3-9
MEMO

LUBRICATION SYSTEM
4-1 4-4
4-2 4-7
4-3 4-8
4-3
4-4
4
4-1
LUBRICATION SYSTEM
Inclusion of water.
Low or no oil pressure
Close oil valve relief.

Clogged oil strainer.
Worn and faulty oil pump.
Internal oil leaks.
Inadequate oil viscosity.
Shout of oil quantity.
Oil pump drivegear or sprocket it is not right.
4-2
LUBRICATION SYSTEM
OIL
OIL
OILSIGHT
SIGHT
SIGHTGLASS
GLASS
GLASS
UPPER
UPPER
UPPER
UPPER
UPPER
UPPER
MIDDLE
MIDDLE
MIDDIE
MIDDLE
MIDDLE
MIDDLE
LOWER
LOWER
LOWER
LOWER
LOWER
LOWER
Loosen the oil drain plug bolt and drain engine oil.
Tighten the oil drain plug bolt.
TORQUE VALVE : 1.4kgf m
OIL
OILDRAIN
OIL DRAINPLUG
DRAIN PLUGBOLT
PLUG BOLT
BOLT TAPPER
TAPPER
TAPPERADJUST
ADJUST
ADJUSTHOLE
HOLE
HOLECAP
CAP
CAP
OIL
OIL
OIL FILTER
OILFILTER SCREEN
FILTERSCREEN
FILTER SPRING
SCREENSPRING
SCREEN SPRING
SPRING
OIL
OILCOLLAR
OIL COLLAR
COLLAR
OIL
OILFILTER
OIL FILTERSCREEN
FILTER SCREEN
SCREEN
TAPPER
TAPPER
TAPPERADJUST
ADJUST
ADJUSTHOLE
HOLE
HOLECAP
CAP
CAP
ENGINE
ENGINE
ENGINEOIL
OIL
OILREFUELING
REFUELING
REFUELING
4-3
LUBRICATION SYSTEM
FLANGE
FLANGE
FLANGEBOLTS
BOLTS
BOLTS
OIL
OIL
OIL FILTER
OILFILTER COVER
FILTERCOVER
FILTER COVER
COVER
OIL
OIL
OILFILTER
FILTER
FILTERELEMENT
ELEMENT
ELEMENT
OIL
OIL SEAL
OILSEAL
OIL SEAL
SEAL
REDUCTION
REDUCTION GEAR
REDUCTIONGEAR
GEAR
START
START
START DRIVEN
STARTDRIVEN GEAR
DRIVENGEAR
DRIVEN GEAR
GEAR
OIL
OIL
OILPUMP
PUMP
PUMP
FLAT
FLAT
FLATSCEWS
SCEWS
SCEWS
OIL
OILPUMP
OIL PUMP
PUMP
4-4
LUBRICATION SYSTEM
PLATE
PLATE
PLATE
PLATE DRIVENGEAR
DRIVEN
DRIVEN GEAR
GEAR
OIL PUMP DISASSEMBLY
OUTER
OUTER ROTOR
OUTERROTOR
OUTER ROTOR
ROTOR Loosen the screw securing the oil pump plate.
BODY
BODY
BODY Remove the oil pump body and the oil pump plate.
Clean the oil pump body, inner and outer rotors with
fresh cleaning oil.
OIL
OILPUMP
OIL PUMPSHAFT
PUMP SHAFT
SHAFT INNER
INNER
INNERROTOR
ROTOR
ROTOR
PUMP
PUMP BODY
PUMPBODY
PUMP BODY
BODY
FEELER
FEELERGAUGE
FEELER GAUGE
GAUGE
4-5
LUBRICATION SYSTEM
OUTER
OUTER
OUTERROTOR
ROTOR
ROTOR
INNER
INNER ROTOR
INNERROTOR
ROTOR
OIL
OIL
OILPUMP
PUMP
PUMPSHAFT
SHAFT
SHAFT
PUMP
PUMP
PUMPBODY
BODY
BODY
OILPUMP
OILPUMP
OILPUMPSHAFT
SHAFT
SHAFT
ROLLER
ROLLER
ROLLER
UNUT
U
U NUT
NUT DRIVENGEAR
DRIVEN
DRIVEN GEAR
GEAR
OIL
OIL PUMP
OIL PUMP
PUMP
( 9-6)
( 9-5)
( 9-4)
( 9-2)
( 9-2)
( 14-6)
( 15-8)
( 3-9)
4-6
LUBRICATION SYSTEM
OIL
OIL
OILBOLT
BOLT
BOLT
OIL
OIL
OIL RADIATOR
OILRADIATOR
RADIATOR
RADIATOR RADIATOR COVER
RADIATOR
RADIATORCOVER
RADIATOR COVER
COVER
RADIATOR RUBBER
RADIATOR
RADIATOR RUBBER
RUBBER
RADIATOR
RADIATOR COLLAR
RADIATORCOLLAR
RADIATOR COLLAR
COLLAR
FLANGE
FLANGE BOLT
FLANGEBOLT
FLANGE BOLT
BOLT
4-7
LUBRICATION SYSTEM
RADIATOR
RADIATOR
RADIATOR
RADIATOR
OIL
OIL
OILCHECK
CHECK
CHECKBOLT
BOLT
BOLT ( 8-2)
ACGENERATOR
AC
AC GENERATORCAP
GENERATOR CAP
CAP
( 8-2)
4-8
EMS(Engine Management System)
5. EMS(Engine Management System)
1. CAUTION WHEN REPAIRING THE EMS PARTS 5-2

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

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

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

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

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

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

INDICATOR
FUEL GAUGE
when the ignition key ON.

MIL
OFF Able to engine start
Starting and driving are temporary

ON
Unable
Unable to engine start
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs
fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON MIL on continuously, when the engine operating
Blink MIL blinks, when the main key is turn on (engine is stop)
5-5
FAIL-SAFE FUNCTION
If the ECU checks something wrong , the vehicle can be driven by its fail safe function.
However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation
can be impossible.
MIL
on
INTAKE : MIL on/off
INTAKE
: MIL on
If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.
intake
intake
The value of intake pressure is fixed as the

INTAKE
pressure just before when the intake pressure
sensor is out of order.
INTAKE The value of intake temperature is fixed as a
temperature just before when the intake
pressure sensor is out of order.

! CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.
5-6
HOW TO CHECK THE FAULT CODE

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

-P/W : PINK/WHITE
-P/Y : PINK/YELLOW
-B : BLACK
-G : GREEN
The diagnostic Tool.
The wireharness to check the ECU

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

5-7
HOW TO SHOW THE FAULT CODE

There are two methods to show the Fault codes.
First, the methods to show in engine operation

In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the
light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault code,
stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault code can be
verified.(refer to the fault code table)
Second,the ways of indication only turn on the ignition key.

When only ignition key is on and if the defect of each part brings out, the MIL keeps showing
the Fault code of defect part repeatedly in order to give defect information to driver.

! CAUTION
If the MILon when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started
HOW TO READ THE FAULT CODE

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

- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.
5-8
FAULT CODES TABLE
MIL INDICATION Fault Priority

code no. Description
(The number of blinks) order
00 - No failure
21 1 Injection valve failure(IV)
22 2 Idle speed actuator failure (ISA)
23 3 Electrical fuel pump failure (EFP)
Intake Manifold absolute pressure signal

12 4
failure (IMP)
13 5 Throttle position signal failure (TPS)
24 6 O2 sensor heater output failure (LSH)
14 7 Lambda signal failure (VLS)
15 8 Engine temperature signal failure (TENG)
16 9 Breathing air temperature signal failure

(TBA)
28 11 Malfunction indicate lamp failure (MIL)
5-9
HOW TO REMOVE THE FAULT CODE

Remove the fault codes in two ways;
First) Full warm up
1. Starting the engine.

- The MIL blinks continuously because the ECU memorized the fault code yet.
2. Full warm up the engine (keep idling five minutes)
3. Turn off the ignition key after full warm up the engine
4. Turn on the ignition key again, and check whether the fault code is disappeared or not.
After full warm up, it is possible to check the fault code is removed with the ignition key on/off.
If many problems happened in the EMS parts at the same time, only one defect code will is displayed
by the priority order.
Even thought repair a fault and remove the memorized fault code, another fault code blinks.
at this time, revise the fault and remove the memorized fault code by the warm up.
Second) Malfunction diagnosis tool

(refer to the scan users manual)
EMS TROUBLE SHOOTING

Inspection before diagnosis
Inspection the following before malfunction diagnosis.
Quantity of engine oil and leakage
Quantity of fuel and leakage
Blocked of air cleaner
Condition of battery
Free play of throttle cable
Cutting of fuse
Leakage of emission gas
Connection of each coupler
5-10
SEAT
SEAT
SEAT SUPPORT
SUPPORT
SUPPORT PIPE
PIPE
PIPE 6. ECU
CENTER
CENTER COVER
COVER
(ELECTRONIC CONTROL UNIT)
REMOVE

! CAUTION
Before disassemble, the key is off.
Remove the ECU coupler.
Loosen the 4 flange bolts and remove the

ECU.
FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT
ECU
ECU
ECU ASSEMBLY
Assembly is the reverse order of removal.

! CAUTION
Be sure to assemble the ECU ground wire.

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

Loosen the screw securing air cleaner connecting

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

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

throttle body and check.

! NOTE
Do not disconnect both the throttle adjust screw

and adjust nut.
5-12
DISCONNECT THE THROTTLE BODY

Disconnect fuel tank and air cleaner.
Remove the gasoline in fuel tube.
Disconnect fuel tube securing injector cap.
Disconnect TPS, ISA, MAPAT, injector coupler.
Disconnect throttle cable.

! CAUTION
Do not disconnect both the throttle adjust screw

INSULATOR
INSULATOR
INSULATOR
INSULATOR THROTTLE
THROTTLE BODY
THROTTLE BODY
BODY and adjust nut.
THROTTLE
THROTTLE BODY
THROTTLE BODY
BODY ISA
ISA
ISA
ISA REMOVE
Loosen the throttle body 2 bolts securing the
insulator.
Disconnect the TPS (Throttle position sensor).
Disconnect the ISA(Idle speed actuator).
Disconnect the MAPAT.
TPS
TPS
TPS

! CAUTION
Do not disconnect the throttle valve.
MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR
CHECKING THE THROTTLE BODY

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

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

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

INJECTOR
INJECTOR
INJECTOR CAP
CAP
CAP INJECTOR
INJECTOR
INJECTOR
INJECTOR Check the O-ring.
Check the insulator inside.
Check the insulator cap inside.
ASSEMBLY OF THE INSULATOR

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

Assemble the O-ring to the insulator.

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

Torque : 1.0 kgf m
INSTALLATION OF INSULATOR AND

THROTTLE BODY
Installation of insulator and throttle body in the
reverse order of removal.
Check the o-ring when the insulator assembly.
Assemble the insulator gasket.

! CAUTION
Replace the gasket with new one.

Install the assembled insulator and throttle
body to the cylinder head.
Torque : 1.2 kgf m
5-14
ADJUSTMENT OF THROTTLE CABLE

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

ACTUATOR
Connect each sensor and the actuator coupler.
Check the ISA.
Check the TPS.
Check the MAPAT sensor.

! CAUTION
Be sure to the valve of TPS is whether the

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

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

! CAUTION
The ECU is always initilized, before the engine

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

idling speed.

ENGINE TEMPERATURE : OVER 100
IDLE SPEED ACTUATOR : APROXIMATELY 20%
ISA
ISA
ISA
5-15
8. INJECTOR
REMOVE
INJECTOR
INJECTOR INJECTOR
INJECTOR
INJECTOR Turn off the ignition key.
INJECTOR CAP
INJECTOR CAP
CAP
Disconnect the injector coupler.

! CAUTION
Before disassemble, the key is off.
Loosen the injector cap bolt.
FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT
INJECTOR
INJECTOR
INJECTOR
INJECTOR
Disconnect the injector.
! NOTICE
Be sure to check the engine is cooling
because a little gasoline remains, It could be
still hot.
Be sure to inject the gasoline, after remove
the coupler from the ignition coil. It could be
damaged for the fire, sparked on the spark
plug.
ASSEMBLY
5-16
CHECKING METHODS BY FAULT CODES

Checking of the Injector circuit
The fault code is displayed by MIL
Checking Circuit 40 : INJECTOR control

ECU 39 : FUEL PUMP control
INJECTOR FUEL PUMP RELAY
Coupler terminal is based on wire harness.

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

MAPAT
MAPAT SENSOR
MAPAT SENSOR
MAPAT SENSOR
SENSOR TPS
TPS
TPS
Temperature sensor)
Located on the left-side of the throttle body.

! CAUTION
Before disassembly, the key is off.
REMOVE
Disconnect the MAPAT circuit sensor coupler.
MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR TPS
TPS
TPS Loosen the 2 MAPAT circuit sensor screws.
Disconnect the MAPAT sensor.
ASSEMBLY
5-18
Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))s circuit
Fault code number is displayed by MIL
The Fault code of intake pressure sensor The Fault code of intake temperature sensor
Checking circuit
MAPAT
3 : Intake
3 : pressure sensorpressure
Inhalation ground
26 : sensor
5V voltage
GROUND
27 : 26
IMP: 5V voltage
ECU 28 : TBA
27 : IMP 28 : TBA
Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input voltage of MAPATs coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
If voltage value is not normal,

Check to see if the ECU coupler is loose or if there is a bad contact.
Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited
Remark : refer to (5-20) if the intake pressure sensor is broken
refer to (5-20) if the intake temperature sensor is broken
5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-19
Checking of the intake pressure sensor

1) If voltage value is normal, turn off the ignition key.
Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler
2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler.
Refer to how to assemble or disassemble the ECU ( 5-11 )
3) Turn on the ignition key. Start engine and operate idle.

4) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor.
Measuring terminal : ECU No. 27(P/L:PINK/BLUE)
WIRE
WIRE
WIRE HARNESS
HARNESS
HARNESS
~ ECU No.3(P/G : PINK/GREEN)
Measuring voltage : 0.1[V] ~ 4.8[V]
Remarks : Measuring unit of voltage : Voltage [V]
The voltage of air pressure;
20[kPa]: 0.719 ~ 0.859[V]
107[kPa]: 4.154 ~ 4.294[V]

Check the P electric wire, P/G electric wire,
P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with the new one and it rechecks.
If measuring voltage is normal,

P/L electric wire to see if they have been broken or have
short- circuited if there is a bad contact.
badness of terminal No. 3, No. 26, No.27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.
5-20
Checking of the intake temperature sensor
1) If voltage value is normal, turn off ignition key.
2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor.
Resistance of intake pressure sensor : 2000100[], 251
Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)
Remarks : Measuring value for resistance : Resistance[ ]
The Voltage of air pressure;
24 ~ 26[ ] : 1800~2200[ ]
99 ~ 101[ ] : 161~206[ ]
3) If measuring resistance is not normal,
Replace the MAPAT sensor with new one and it rechecks.
If the measured voltage is normal,

short- circuited if there is a bad contact of terminal
No. 3, No. 26, No. 27 of ECU coupler.
Replace the ECU with the new one, it rechecks.
4) Turn on the ignition key. Start the engine and idling.
5) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor
- Measuring terminal: ECU No.28(TBA)
~ ECU No.3(IMP GROUND)
- Measuring voltage: 0.1[V] ~ 4.9[V]
Remarks : Measuring unit of voltage : Voltage [V]

P /L electric wire to see if they have been broken
or have short- circuited.
Replace the MAPAT sensor with new one and it rechecks.

short- circuited if there is a bad contact of terminal
No. 3, No. 26, No.28 of ECU coupler.
Replace ECU with the new one, it rechecks.
7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-21
10. TPS(Throttle position Sensor)

Located on the left side of throttle body.

! CAUTION
TPS
TPS
TPS
TPS
REMOVE
Disconnect the TPS coupler.
Loosen 2 TPS screws.
MAPAT
MAPAT
MAPAT SENSOR
SENSOR
SENSOR
Disconnect the TPS.
TPS
TPS
TPS
ASSEMBLY
5-22
CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM

Checking circuit
TPS
4 : SENSOR GROUND
ECU 18 : 5V SUPPLY VOLTAGE
19 : TPS
The coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the IGNITION KEY.
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPSs coupler.
If voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.
Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been
broken or have short- circuited.
5) If the value of voltage is normal, turn off the ignition key.
5-23
Checking Procedure
6) Check continuty between the Sensor Ground Terminal of TPS and Earth.
The continuty TPS : 0[ ],201

Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH
Remarks : Measuring unit for resistance : Resistance R [ ]
7) If not problem, measure the resistance of TPS.

By turning round throttle grip, measure the resistance.
The resistance of TPS
If the throttle is totally closed : 0.9~1.6[k ],201
If the throttle is totally opened : 2.3~2.6[k ],201
Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Remarks : Measuring value of resistance : Resistance[k ]
8) If resistance and the continuty are not abnormal.

Adjust correctly the position of TPS
Replace the TPS with the new one and re-check.
9) If resistance and continuty are normal, connect the TPS coupler.

10) Turn on the ignition key.
11) Measure the TPS voltage of wire-harness to check the ECU.
Rotate the throttle lever, measure the voltage
Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE)
Output voltage of TPS
-If the throttle is totally closed : 4.0~5.5[V]
-If the throttle is totally opened : 0.1~0.6 [V]
Remarks : Measuring unit for voltage : Voltage [V]
12) If the measured voltage is abnormal,

Replace the TPS with the new one, and re-check.
Check the GR/B electric wire, GR/L electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, and recheck.
13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-24
RH.
RH. SHROUD
RH. SHROUD
SHROUD
11. ETS(Engine Temperature Sensor)
Situated at the back of the cylinder head.
Remove the RH. shroud.

! CAUTION
REMOVE
Disconnect the ETS coupler.
Disconnect the ETS.
ASSEMBLY
ETS
ETS
ETS
5-25
1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)

CHECKING CIRCUIT
ETS
ECU 4 : SENSOR GROUND

5V SUPPLY VOLTAGE
20 : ETS
Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key .
2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input 5 voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
Measure the terminal voltage of ETSs coupler.

Remarks : Measuring unit for voltage : voltage [V]
If the voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.
Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS :1.6[k ]~10.6[k ],20 ~80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance R [k ]
5-26
6-1) If the measured value is not normal,

Replace the ETS with the new one, recheck.
If the measured value is normal,

Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if
the ECU coupler is a bad contact ( No.4, No. 20.)
Replace ECU with the new one, recheck.
6-2) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
Checking Procedure
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to ETS disassembly)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperatures change and testers value.
Characters of ETS
Temperature Resistance value
20 10.6[k ]~14.4[k ]
80 1.35[k ]~1.65[k ]
110 0.57[k ]~0.69[k ]
Measuring unit of resistance : Resistance R [k ]

If the value of resistance is high or out of the standard value, replace the ETS with the new one.

! CAUTION
1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.
3) Install
Tighten the ETS to the specified torque.
ETS torque : 3.0[kgf m]
5-27
ISA
ISA
ISA
INJECTOR
INJECTOR
INJECTOR
12. ISA(Idle Speed Actuator)
Located on the throttle body.

! CAUTION
REMOVE
ISA
ISA COUPLER
ISA COUPLER
ISA COUPLER
COUPLER Disconnect the ISA coupler.
Loosen 2 ISA screws.
ISA
ISA
ISA SCREW
SCREW
SCREW
Remove the ISA.
ASSEMBLY
5-28
1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.

Showing of defects codes by MIL
CHECKING CIRCUIT
ECU
ISA FUEL PUMP RELAY

Coupler terminal is based on the side of the wire-harness
CHECK PROCEDURE
1) Turn off ignition key .
2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ],20
remarks : Measuring unit of resistance : Resistance R[ ]
ISA
ISA
ISA
ISA
4) If there is not problem, check about the level of electricity flow between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : [ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-28 )
remarks : Measuring unit for resistance : Resistance R[ ]
5-29
CHECK PROCEDURE
5) If the measured resistance and continuty is abnormal.
Replace ISA with the new one, and recheck.
6) If resistance and continuty is normal, connect the coupler of ISA.

7) Turn on ignition key
8) Measure ISA voltage of wire-harness to check ECU.
Measuring terminal : B/R electric wire ~ EARTH
Output voltage of ISA : Battery Voltage [V]
Remarks : Voltage measuring unit : Voltage [V]

Check the B/R electric wire, L/G electric wire, W/R electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, recheck.
If the measured voltage is abnormal,

Check the B/R electric wire, L/G electric wire, W/B electric wire to see if they have been
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code.
5-30
13. O2(Oxygen) SENSOR

REMOVE
O2
O2
O2 SENSOR
SENSOR
SENSOR COUPLER
COUPLER
COUPLER Located on the exhaust pipe.
Disconnect the RH. floor side cover.
Disconnect the O2 sensor coupler.

! CAUTION
O2
O2
O2 SENSOR
SENSOR
SENSOR
Remove the O2 sensor on the muffler.
Check the O2 sensor.

! CAUTION
Take precaution not to impact on the O2 sensor.
ASSEMBLY
O2
O2 SENSOR
O2 SENSOR
SENSOR Assembly is the reverse order of removal.
5-31
1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT

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

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

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

If the voltage value is abnormal,
Check to see if the ECU coupler is loose or if there is bad contact.
Check the B/B electric wire, G/W electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.

Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22
Measuring terminal (side of wire-harness) : oxygen(O2)3 terminal of sensor coupler
Remarks : Measuring unit of Resistance : Resistance R[ ]
6) If the measured resistance is abnormal,

Replace the oxygen(O2)sensor with new one and recheck it.
If the measured resistance is normal,

Check the B/B electric wire, G/W electric wire to see if they have been
If the electric wire is no problem, the ECU is broken.
Replace the ECU with new one, and recheck it.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL
1) Turn off the ignition key

2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) The wire harness to check the ECU is connected to the ECU with a ECU coupler
Refer to the ECU assembly/disassembly (5-4)
4) Turn on the ignition key
5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.
Measuring terminal: (V :VIOLET) ~ (V/B:VIOLET/BLACK)
Output voltage of oxygen(O2) sensor : 0.1~0.8[V]
Remark : measuring unit of voltage : voltage[V]
Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf m]

Check the V electric wire,
V/B electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal
No. 2, No. 12 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and recheck it.

Check the V electric wire, V/B electric wire, W/B electric wire to see if they have been
6) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)
5-33
14.CHECKING OF MIL
CHECKING CIRCUIT
ECU
24 : MALFUNCTION INDICATOR LAMP OUTPUT
MALFUNCTION INDICATOR LAMP(MIL)
CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
3) Turn on the ignition key.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the lamp.
But If the lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : (B) electric wire ~ (G)electric wire => Output voltage: battery voltage
Measuring terminal : (B/Y)electric wire ~ (G)electric wire => output voltage: 9V~15V
Remarks : measuring unit of voltage : voltage[V]

Check the R/Y electric wire, B electric wire, G electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.

Check the B/Y electric wire, B electric wire, G electric wire to see if they have been
6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code.
5-34
15. CKP(Crank Position Sensor)

REMOVE
Remove the ACG coupler.
Remove the CKP coupler.
CKP is located inside the RH. crank case
cover.

! CAUTION

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

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

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

Fly wheel for the EMS system have 10 spots
on the fly wheel protrusion. It is different with
carburetor type.
Check the mark or contamination on the
protrusion.

! CAUTION
When replace the fly wheel, check the 10 spots

of protrusion part.
ASSEMBLY
CHECKING OF CKP(Crank Position

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

5-36
CHECK THE CIRCUIT OF CKP
CHECKING CIRCUIT
GREEN BLUE

BLUE
RED
ECU PIN NUMBER

ECU
30 : CRANK SIGNAL-A 22 30
30 : _ A
22 : _ B
22 : CRANK SIGNAL-B
CHECK PROCEDURE
1) Turn ON ignition key.
2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool.
When start up the ENGINE SINK ON change OFF to ON, its okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance.
- measuring resistance : 80 ~ 150[]
5-37
4) Check if crank signal A,B wires is breaks or not.
Remove the ECU, connect wire harness for inspection to wire harness of vehicle.
Check the wiring of crank signal A
- Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[]
Red
CKP_B CKP_A
1 2
Check the wiring of crank signal B

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

! CAUTION
Make sure that the key is off before assembly.
Remove the fuel hose.

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

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

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

Measure the resistance between terminals.
The FLOAT position Terminals resistance []
F : 140.5[mm] 40 5[]
1/2 : 83.5[mm] 220 5[]
E : 28.5[mm] 400 3[]

The float position is based on tank bottom plate.
Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)
wire of fuel unit terminal
Remark : measuring unit of resistance : resistance[]

If the measured resistance value is out of standard at float position, replace the fuel unit.

CHECK THE BLOW PRESSURE OF FUEL PUMP

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

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

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

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

adjust the throttle adjust screw.
5-44

THE IGNITION TIMING IS CHECKING
The coupler to check the malfunction of vehicle is

connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the enter button on the vehicle diagnosis screen.
To check the ignition angle
5-45

ENGINE REVOLUTION IS CHECKING
The coupler to check the malfunction of vehicle is
connected to the coupler of diagnostic tool.
Turn the lgnition key.
Start the engine.
Press the enter button on the vehicle diagnosis screen.
Check the engine rpm on the engine speed
5-46
MEMO

MEMO

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

Fuel is not coming out of carburetor. Oil level is too high.
Too much fuel is flowing into cylinder. Air jet is blocked.
Air cleaner is blocked. Auto bystarter is damaged.
No spark emitted from spark plug. Air cleaner is blocked.
Back firing
Idle is unstable and engine turns off after starting.
Ignition system is damaged.
Faulty idle adjustment. Mixture is too lean.
Excessively lean or rich mixture.
Air cleaner is blocked.
Suction system is experiencing secondary intake of air.
Clogged fuel system. Mis-firing occurs when driving at high speeds.
Auto bystarter is damaged.
Ignition system is damaged. Ignition system is damaged.
Using low quality gasoline. Mixture is too lean.
Air screw is adjusted improperly.
Carburetor is blocked.
Compression pressure is low. Insufficient power and high fuel consumption.
Air cleaner is blocked.

Ignition system is damaged.
Air/Fuel mixture is extremely lean Mixture is too lean.
Fuel jet is blocked.
Bad ventilation of air in tank cap.
Fuel strainer screen is blocked.
Fuel tank is bent, creased or blocked.
Float valve is damaged.
Oil level is low.
Suction system is receiving secondary suction of air.
Fuel pump is incorrect flow of oil.
6-2
FUEL SYSTEM
CRADLE
CRADLE PIPE
CRADLEPIPE
PIPE CENTER
CENTER COVER
CENTER COVER
COVER FUEL TANK
FLOOR
FLOOR
FLOORPANEL
PANEL
PANEL
REMOVAL
! WARNING
Gasoline is extremely flammable. Avoid fire during
TRUSS
TRUSS
TRUSSPIPE
PIPE
PIPECOMP
COMP
COMP work, and pay particular attention to electric sparks.
Furthermore, the evaporated (gasified) gasoline is highly
explosive. Work in a well-ventilated areas.
Release the seat lock by turning the main switch key to
SEAT
SEAT
SEATSUPPORT
SEAT SUPPORT PIPE
SUPPORTPIPE
PIPE open the seat.
Remove the following parts.
- Rear fender.
FUELCAP
FUEL
FUEL CAP
CAP - Seat support pipe.
FLOOR
FLOOR
FLOORPANEL
PANEL
PANEL - Center cover.
- Truss pipe.
- Battery.
- Floor panel.
Remove the fuel unit wiry coupler.
SPECIAL
SPECIAL
SPECIAL SCREW
SPECIALSCREW
SCREW Remove the fuel strainer tube.
Remove the flange nut.
Remove the fuel tank.
Install in the revers order removal.
FLANGE
FLANGE BOLT
FLANGE BOLT
BOLT
! CAUTION
FUEL
FUEL UNIT
FUEL UNIT
UNIT
After removing the fuel tank be sure to close
the fuel tank cap.
(Gasoline is extremely flemmable)
FUELTANK
FUEL
FUEL TANK
TANK FUELSTRAINER
FUEL
FUEL STRAINERTUBE
STRAINER TUBE
TUBE
AIR
AIR
AIRCLEANER
CLEANER
CLEANERCONNECTING
CONNECTING
CONNECTINGBAND
BAND
BAND CARBURETOR
REMOVAL
- Rear fender.
- Center cover.
- Air cleaner connecting tube band.
CARBURETOR
CARBURETOR
CARBURETOR
INSULATOR
INSULATOR
INSULATOR
6-3
FUEL SYSTEM
THROTTLE
THROTTLE CABLE
CABLE LOCK
LOCK NUT
NUT
Loosen the throttle cable lock nut and remove the
THROTTLE CABLE LOCK NUT
throttle cable from the carburetor.
Remove the fuel tube.
Remove the auto bystarter wiring.
Loosen the screw on the carburetor insulation band.
Remove the carburetor.
TOP
TOP
TOPSET
SET
SET REMOVAL
Loosen the special pan screw on the carburetor top set.
Remove the top set.
SPECIAL
SPECIAL
SPECIALPAN
PAN
PANSCREW
SCREW
SCREW
Remove the top set cover.

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

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

JET
DISASSEMBLY
PAN
PAN
PAN Loosen the 4 screws securing float chamber set.
SCREW
SCREW
SCREW
FLOAT
FLOAT
FLOATCHAMBER
CHAMBER
CHAMBERSET
SET
SET
FLOAT
FLOAT
FLOATVALVE
VALVE
VALVESET
SET
SET ARM
ARM
ARMPIN
PIN
PIN Remove the float pin, float and float valve
FLOAT
FLOAT
FLOATCOMP
COMP
COMP ! CAUTION
Do not damage the jets. because it made of
soft material and also do not use the wire
when cleaning the air and fuel passage.
Otherwise it will damage to the carburetor
body, eventually it will be effect the engine.
Namely, it is cause of bad condition of engine.
FLOAT
FLOAT
FLOATVALVE
VALVE
VALVESET
SET
SET Check the float valve and valve seat for scores,
scratches, clogging and damage replace if necessary.
SLOW
SLOW
SLOW JET
SLOWJET
JET Check the float valve operation.
MAIN
MAIN
MAINJET
MAIN JET
JET
6-5
FUEL SYSTEM
Remove the main jet, needle jet holder, needle jet, slow
jet, screw set, diaphragm comp, compression spring.
CARBURETOR BODY ! NOTE

Turn in the pilot jet and record the number of
turns it takes before it seats lightly.
Do not force the pilot screw against its seat;
The seat will be damaged.
Clean the jet and hole of carburetor body with blow the
compressed air.
TOP SET
COMPRESSION SPRING FLOAT

VALVE SET
FLOAT COMP
AUTO BYSTARTER SET
NEDDLE JET COMP
VACUUM PISTON COMP

SCREW SET FLOAT CHAMBER SET
DIAPHRAGM COMP
NEEDLE JET HOLDER SLOW JET

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

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

Install the stay plate set and 4 pan screws.
! NOTE
FLOAT
FLOAT
FLOATCHAMBER
CHAMBER
CHAMBERSET
SET
SET
Be sure to replace the float chamber body O-ring
with the new one.
Install the valve plate set, compression spring in the

vacuum piston comp.
TOP
TOP
TOPSET
SET
SET
! NOTE
Install the jet needle aligned with the grooves.
Install the diaphragm cover with its cutout aligned with

the cover.
Place the top set on the spring.
Tighten the 2 special pan screws.
6-7
FUEL SYSTEM
! NOTE
Be careful not to pinch the diaphragm, and to
COMPRESS
STRAIGHT keep the spring straight.
Install the drain tube and air-hose.
THROTTLE
THROTTLE CABLE
THROTTLECABLE
CABLE CABURETOR INSTALLATION
Install the carburetor to the carburetor insulator.
Tighten the carburetor insulator band screw.
Install the fuel tube to the carburetor.
Intall the wiring coupler of the auto bystarter.
Install the throttle cable to the carburetor.
Intall the air cleaner.
Install the center cover.
! NOTE
After adjusting the carburetor, check the
throttle grip free play.
AIR
AIR
AIR CLEANER
AIRCLEANER
CLEANER CONNECTING
CLEANERCONNECTING TUBE
CONNECTINGTUBE
CONNECTING BAND
TUBEBAND
TUBE BAND
BAND
FLANGE
FLANGEBOLT
FLANGE BOLT
BOLT
CABURETOR INSULATOR
REMOVAL
Remove
- Center cover.
- Air cleaner.
- Carburetor.
Remmove the fuel pump negative pressure tube.
Loosen the carburetor insulator 2 setting nuts.
Remove the carburetor insulator.
Remove the carburetor insulator band.
Install the reverse order of removal.
INSULATOR
INSULATOR
INSULATOR
INSULATOR
6-8
FUEL SYSTEM
O-RING
O-RING
O-RING
O-RING INSPECTION
Check the carburetor insulator O-ring for wear or
damage.
PILOT SCREW ADJUSTMENT

PILOT
PILOTSCREW
PILOT SCREW
SCREW THROTTLE
THROTTLE
THROTTLESTOP
STOP
STOPSCREW
SCREW
SCREW USING THE EMISSION ANALYZER (CO,HC)
Open the seat and remove the center cover.
Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM
! NOTE
Before adjustment the pilot screw, check the
following items.
- Fuel system electrical system for troubling.
- Do not force the pilot screw against its seat ;
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
- Emission analyzer for correction.
MUFFLER
MUFFLER
MUFFLER
MUFFLER Exhaust gas contains poisonous substance.
EMISSION
EMISSION ANALYZER
EMISSIONANALYZER
EMISSION ANALYZER
ANALYZER
Do not adjusting for a long period of time in a
closed, or poorly ventilated area.
Extend the hose (60Cm) at the tail pipe, and insert the
probe of the emission analyzer to the tail pipe, and
adjust the pilot screw with a , the Co to became
3~4%.
Adjust by the throttle stop screw, repeat steps and
until accord the idle rpm (1,800rpm) and the Co
(3~4%).
THROTTLE
THROTTLE STOP
THROTTLESTOP SCREW
STOPSCREW
SCREW
6-9
FUEL SYSTEM
When idling, check to see if the rotation is smoothly

and to return is nomal.
Install the center cover.
! CAUTION
ACCELERATION
ACCELERATION
ACCELERATION
ACCELERATION
If the engine cannot be adjusted by turning the
pilot screw within a turn, check for other
engine problems.
PILOT
PILOT SCREW
PILOTSCREW
SCREW THROTTLE
THROTTLE STOP
THROTTLESTOP SCREW
STOPSCREW
SCREW
EMISSION ANALYZER IS NOT EXIST
Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given(1).
Warm up the engine to operating temperature (60).
Adjust the idle speed with the throttle stop screw.
IDLE SPEED : 1,700 100RPM
! NOTE
Before adjustment the pilot screw, check the
following items.
- Fuel system electrical system for troubling.
ACCELERATION
ACCELERATION
ACCELERATION
- Do not force the pilot screw against its seat ;
- Spark plug for cleaning and gap adjusting.
- Valve clearance for adjusting.
When idling, check to see if the rotation is smoothly

and to return is normal.
Turn the throttle stop screw until the 1,000RPM, and
check the stopping of engine.
PILOTSCREW
PILOT
PILOT SCREW
SCREW THROTTLE
THROTTLE
THROTTLESTOP
STOP
STOPSCREW
SCREW
SCREW If the engine is stop, adjust the pilot screw with a ,
and repeat step and .
6-10
FUEL SYSTEM
! CAUTION
If the engine cannot be adjusted by turning the
pilot screw within a turn, check for other
ACCELERATION
engine problems.
ACCELERATION
ACCELERATION
ACCELERATION
After the final test of the starting and driving, readjust

if necessary.
FUEL PUMP
REMOVE
- Center cover.
FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT
- Inlet, outlet, vacuum tube.
- 2 bolts securing the fuel pump.
- Fuel pump.
FUEL
FUEL
FUELPUMP
PUMP
PUMP
FUEL
FUEL PUMP
FUELPUMP
FUEL PUMP
PUMP DISASSEMBLY
Loosen the 4 screws securing the fuel pump.

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

for damage and crack.
FUEL
FUELPUMP
FUEL PUMP
PUMP
! NOTE
After install the fuel pump, check the blowing
quantity of fuel in the outlet tube.
6-12
ENGINE REMOVAL/INSTALLATION
7. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 7-1

ENGINE REMOVAL/INSTALLATION7-2
SERVICE INFORMATION
GENERAL SAFETY
NOTE
Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to
damage the frame, engine, cable or harness. 7
Attach tape to the frame to protect it during the engine removal or installation.
The following works can be carried out without removing the engine from the vehicle body.
-TRANSMISSION (SECTION 12)

-STARTING CLUTCH (SECTION 9)
-OIL PUMP (SECTION 4)
-A.C. GENERATOR (SECTION 9)
-START MOTOR (SECTION 18)
-CONTINUOUSLY VARIABLE TRANSMISSION (SECTION 8)
-CYLINDER HEAD/ CYLINDER/ PISTON (SECTION 10,11)
-EX. MUFFLER (SECTION 3)
-CARBURETOR (SECTION 6)
-REAR SWING ARM (SECTION 14)
Items to be worked after removing engine.

-CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING
Engine oil capacity : 1.1 - When disassembled.
TORQUE VALUES :
ENGINE HANGER BOLT (FRONT) : 2.7fm
(REAR) : 3.5fm
7-1
ENGINE REMOVAL
Drain the engine oil.
Release the seat lock by turning the main switch key to
open the seat.
- Rear under cover.
- Air cleaner (2-5)
- Carburetor (6-3)
Disconnect the ACG coupler and connector wiring
connected to the ACG, disconnect the starter motor
wiring cable.
Disconnect the high-tension cord from the engine.
DRAIN
DRAIN
DRAINPLUG
PLUG
PLUGBOLT
BOLT
BOLT Remove the bleeder tube from the cylider hesd cover.
MUDGUARD BRAKEHOSE
BRAKE
BRAKE HOSE
HOSE Remove
MUDGUARD
MUDGUARD
MUDGUARD
- Muffler
- Rear brake caliper
- Swing arm
- Rear wheel mudguard
MUFFLER
MUFFLER
MUFFLER
MUFFLER FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT
REAR
REAR
REARWHEEL
WHEEL
WHEEL Loosen the U nut.
Remove the rear wheel.
RADIATER
RADIATER HOSE
RADIATERHOSE
HOSE Remove the RH. shroud.
Remove the RH. radiater hose.
7-2
REAR
REAR CUSHION
REARCUSHION
REAR CUSHION
CUSHION Loosen the rear cushion under bolt.
REAR
REAR
REARCUSHION
CUSHION
CUSHIONUNDER
UNDER
UNDERBOLT
BOLT
BOLT
SECONDARY
SECONDARY
SECONDARY
SECONDARY
Remove the SAI tube from the secondary air filter
AIR
AIR FILTER
AIRFILTER
FILTER assembly.
Loosen the 10mm U nut from the engine hanger.
Lifting the frame back side and remove the flange bolt
securing engine hanger and disassemble the frame and
engine.
ISATUBE
ISA
ISA TUBE
TUBE
ENGINE INSTALLATION
! NOTE
Take precautions not to damage wiring and
ENGINE
ENGINEHANGER
ENGINE HANGERPLATE
HANGER PLATE
PLATE cable.
Take precautions not to damage the thread part
of bolts.
Arrange the cable tube and wring in the right
positions.
TORQUE :
ENGINE HANGER NUT (FRONT) : 4.5fm
(REAR) : 4.5fm
Check the following after the engine is installed.
- Engine oil
- Electric systems
7-3
LH.CRANKCASECOVER/CONTINUOUSLYVARIABLETRANSMISSION
LH. CRANK CASE COVER
8-0
LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION
8. LH. CRANKCASE
/CONTINUOUSLY VARIABLE TRANSMISSION
SERVICE INFORMATION8-1 MOVABLE DRIVE FACE8-5
TROUBLESHOOTING 8-1 CLUTCH/DRIVEN PULLEY ASSEMBLY8-8
LH. CRANK CASE COVER 8-2 DRIVEN FACE INSPECTION 8-10
DRIVE BELT 8-3 DRIVE PULLEY INSTALLATION8-13
SERVICE INFORMATION
GENERAL SAFETY
Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil
contact. 8
Do not operate starter motor while the LH. crank case front cover is removed.
! NOTE
Take precautions not ot apply the grease oil to the movable drive face or weight roller.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER 24.000-24.013mm 24.05mm
DRIVE FACE BOSS OUTER DIAMETER 23.980-23.993mm 23.96mm
DRIVE BELT WIDTH 22mm 20.5mm
WEIGHT ROLLER OUTER DIAMETER 19.95-20.02mm 19.50mm
CLUTCH OUTER AND INNER DIAMETER 125.0-125.2mm 125.5mm
DRIVEN FACE SPRING PLAY 140mm 135mm
DRIVEN FACE OUTER DIAMETER 33.965-33.985mm 33.785mm
DRIVEN FACE INNER DIAMETER 34.000-34.025mm 34.060mm
TROUBLESHOOTING
Engine starts but motorcycle does not work. Vehicle unable to run at the maximum speed,
Drive belt worn. or lack of output
Ramp plate damaged. Drive belt worn.
Clutch shoe worn or damaged. Defective movable driven face spring.
Movable driven face spring cut. Weight roller worn.
Pulley face contaminated.
Engine stops, or the vehicle runs suddenly,
after starting.
Clutch shoe spring cut.
8-1
B-STAY
B-STAY
B-STAY
B-STAY
LH. CRANKCASE COVER
DISASSEMBLY
AIR
AIRCLEANER
AIR CLEANER
CLEANER
Remove the air cleaner and flange bolt securing B stay.
Remove the flange bolts securing LH. crankcase.
LH.
LH. CRANK
LH. CRANK CASE
CRANK CASE COVER
CASE COVER
COVER
LH.
LH.
LH.COVER
LH. COVER GASKET
COVERGASKET
GASKET Remove the LH. crankcase cover.
Remove the gasket and dowel pin.
INSTALLATION
DRIVE
DRIVE FACE
DRIVEFACE
FACE DRIVEN
DRIVENPULLEY
DRIVEN PULLEY
PULLEY
Install the new gasket and dowel pin after removing the
gasket of the crankcase surface.
! NOTE
Tighten the bolts diagonally with specified
tightening torque.
Be sure to replace a new gasket and dowel pin.
Install the LH. crankcase cover.

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

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

DRIVE BELT
belt in place as photo.
! CAUTION
Squeeze the drive belt into the pulley groove as
shown so that it slackens enough to remove the
driven pulley from the drive shaft.
DRIVEN
DRIVEN
DRIVENPULLEY
PULLEY
PULLEY
Remove the driven pulley sub assembly with the drive

belt in place.
DRIVEN
DRIVEN PULLEY
DRIVEN PULLEY
PULLEY Remove the drive belt from the driven pulley sub assy.
8-3
DRIVE BELT INSPECTION

COG
Check the drive belt for cracks, pry separation and
wear, replace as necessary.
Measure the width of the drive belt as shown.
WIDTH
SERVICE LIMIT : 20.5mm
! NOTE
Use only a genuine DAELIM replacement drive belt.
Do not get oil or grease on the drive belt or pulley
faces. Clean off any grease or oil before reinstalling.
DRIVE BELT INSTALLATION

Turn the pulley clockwise and spread the face apart
DRIVEN PULLEY SUB ASSY
while installing the drive belt and install the drive belt
to the driven pulley assy.
Install the driven pulley sub assy on the drive belt.

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

Hold the clutch outer using the universal holder and
DRIVEN
DRIVENPULLEY
DRIVEN PULLEY
PULLEY tighten the flange nut with the specified torque.
! NOTE
Do not rotate the movable drive face to became
the original position until the driven pulley to
be installed completely to the drive shaft.
8-4
Install the drive face to the LH. crank shaft.

FLANGE
FLANGE
FLANGENUT
FLANGE NUT
NUT Install the rear axel collar and temporaily install the
flange nut.
Tighten the flange nut to the specified torque using the
drive face holder.
m
TORQUE VALVE : 7.0~8.0kgf
m
UNIVERSAL HOLDER
! CAUTION
When installing the drive face match it when
the LH. crank shaft serration accurately.
MOVABLE DRIVE FACE

MOVABLE
MOVABLE
MOVABLEDRIVE
DRIVE
DRIVEFACE
FACE
FACE
REMOVAL
DRIVE
DRIVEFACE
DRIVE FACEBOSS
FACE BOSS
BOSS Remove the LH. crank case cover.
Hold the drive face holder on drive face.
Remove the drive face nut, rear axel collar, drive face.
Remove the movable drive face and drive face boss.
Remove the ramp plate, weight rollers and oil seal

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

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

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

service limit is exceeded.
Movable drive face inner diameter.
RAMP
RAMP
RAMP PLATE
RAMPPLATE
PLATE
PLATE GREASE
GREASE
GREASE
MOVABLE DRIVE FACE INSTALLATION
Install the weight roller on the movable drive face.
Apply the inside of the movable drive face with the
specified amount of grease.
SPECIFIED GREASE : ALVANIA EP2

GREASE APPLICATION : 0.5~1.5 g
Install the movable drive face boss.

OIL
OIL
OILSEAL
SEAL
SEAL
! NOTE
WEIGHTROLLER
WEIGHT
WEIGHT ROLLER
ROLLER Do not get the grease on the drive face. Remove
any misplaced grease with a degreasing agent.
Use only the specified grease in the specified amount.
MOVABLE
MOVABLE
MOVABLEDRIVE
DRIVE
DRIVEFACE
FACE
FACE Install the movable drive face boss and movable drive
face to the LH. crank shaft.
8-6
Install the drive belt into the movable drive face.

MOVABLEDRIVE
MOVABLE
MOVABLE DRIVEFACE
DRIVE FACE
FACE
Install the drive face in to the LH. crank shaft, and

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

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

face holder.
m
! NOTE
Tighten the drive face nut to the specified
torque.
8-7
DRIVEN PULLEY
REMOVAL
Remove the drive face.
Hold the clutch outer using the universal holder and
remove the 12mm flange nut, then remove the driven
pulley.

UNIVERSAL HOLDER
Remove the driven pulley sub assembly from the drive

DRIVEN
DRIVENPULLEY
DRIVEN PULLEY
PULLEY
shaft.
Remove the drive belt.
LOCK NUT WRENCH DISASSEMBLY

Remove the special nut.
LOCK NUT
TOOL : CLUTCH SPRING NUT

LOCK NUT WRENCH
CLUTCH SPRING COMPRESSOR
Remove the drive plate, driven face spring and driven

DRIVENFACE
DRIVEN
DRIVEN FACECOMP
FACE COMP
COMP DRIVEN
DRIVENFACE
DRIVEN FACESPRING
FACE SPRING
SPRING face spring guide.
SPRING
SPRING GUIDE
SPRING GUIDE
GUIDE
DRIVE
DRIVE PLATE
DRIVE PLATE
PLATE
8-8
Remove the seal collar from the driven pulley.
SEAL COLLAR
MOVABLE DRIVEN FACE

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

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

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

MOVABLE DRIVEN FACE SPRING
Measure the free length of the driven pulley spring and
replace if the service limit is exceeded.
SERVICE LIMIT : 135mm

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

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

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

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

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

INNER BEARING
SNAP RING INNER REARING
Install in a new inner bearing.

SEALED SIDE TOOLS : BEARING DRIVEN ATTACHMENT
DRIVE PILOT
SPECIFIED ! NOTE
GREASE
Install the cir-clip fimly to the groove.
SNAP RING Install the inner-bearing using a hydraulic press.
INNER NEEDLE OUTER BEARING

BEARING
8-11
DRIVEN FACE / MOVABLE DRIVEN FACE

OIL SEAL
Install new oil seal and O-ring on the movable driven

pulley face.
O-RING
MOVABLE DRIVEN FACE

GUIDE ROLLER PIN Install the movable face on the driven pulley face.
GUIDE PIN Install the guide rollers and guide pins.
GUIDE ROLLER
GUIDE PIN
DRIVEN FACE
Install the seal collar.

SEAL COLLAR
LOCK NUT WRENCH

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

LOCK NUT WRENCH
8-12
CLUTCH/DRIVEN PULLEY INSTALLATION
Turning the driven pulley assy rightside, extend the

belt assemble groove maximum.
Install the drive belt into driven pulley sub assy, install
the drive shaft.
Install the drive belt into movable drive face..

DRIVEN
DRIVEN
DRIVEN

fifi
DRIVENfifi PULLEY
PULLEY
PULLEY

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

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

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

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

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

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

UNIVERSAL HOLDER
DRIVE FACE HOLDER
Loosen the fan screw securing the starter comp and

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

STARTER
STARTER COMP
STARTERCOMP
STARTER COMP
COMP Install the stator to the RH. Crankcase cover.
Clean the tapered portion of the crankshaft.
Clean the inside part of the flywheel.
Check the woodruff key, install the flywheel by
SAI
SAI TUBE
SAITUBE
TUBE aligning the groove with the woodruff key.
Temporarily install the flywheel nut, hold the flywheel

with the universal holder, or remove the LH. crankcase
cover and tighten the flywheel nut with the specified
torque.
TORQUE VALVE : 5.0~6.0kgf m

Hold the drive face with drive face holder and install
the cooling fan.
TORQUE : 0.8~1.2kgf m
Install the RH. Shroud.

Connect the A.C.G wiring coupler and connector to the
wire harness, and install the wiring with the clamp.
Install rear under cover.
Install the muffler.
SAI
SAI
SAI REED
SAIREED VALVE
REEDVALVE
VALVE
COOLING
COOLING
COOLINGFAN
FAN
FAN SAI
SAI PIPE
SAIPIPE
PIPE
RH. CRANKCASE COVER

- Rear under cover.
- Ex. Muffler.
- Rear swing arm.
- RH shroud.
- Cooling fan.
- A.C.G starter comp.
- SAI reed valve.
Loosen the flange bolt securing the RH. Crankcase
cover.
Remove the RH crankcase cover.
RH.CRANK
RH.
RH. CRANKCASE
CRANK CASECOVER
CASE COVER
COVER
9-4
Remove the RH. Crankcase cover gasket and dowelpin.

REDUCTION
REDUCTION GEAR
REDUCTION GEAR
GEAR STARTING
STARTING
STARTINGCLUTCH
STARTING CLUTCH
CLUTCH
GASKET
GASKET
GASKET
GASKET
DOWEL
DOWEL
DOWELPIN
PIN
PIN
OIL
OILPUMP
OIL PUMP
PUMP
OIL
OILSEAL
OIL SEAL
SEAL
RH.
RH.
RH. CRANK
RH.CRANK CASE
CRANKCASE COVER
CASECOVER
COVER
REDUCTION
REDUCTION
REDUCTIONGEAR
GEAR
GEAR
SHAFT
SHAFT
SHAFT
SHAFT
STARTER
STARTER REDUCTION
STARTER REDUCTION GEAR
REDUCTION GEAR
GEAR
9-5
STARTER REDUCTION GEAR

INSTALLATION
REDUCTIONGEAR
REDUCTION
REDUCTION GEAR
GEAR
Install the starter reduction gear and shaft.
Remove the gasket residues from the RH. Crankcase.
Install a new gasket and dowel pin.

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

STARTING
STARTINGCLUTCH
STARTING CLUTCH
CLUTCH
TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER
SPECIAL
SPECIALSOCKET
SPECIAL SOCKET
SOCKET
9-6
Remove the thrust washer.

Remove the starter driven gear and starter clutch.
THRUST
THRUST
THRUSTWASHER
WASHER
WASHER
LOCK
LOCK
LOCKNUT
NUT
NUT
Check the starter driven gear and starter clutch for

OIL
OILPUMP
OIL PUMPDRIVE
PUMP DRIVEGEAR
DRIVE GEAR
GEAR proper operation.
Remove the starter clutch.
OIL
OIL PUMP
OIL PUMP
PUMP
STARTER CLUTCH INSPECTION

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

Measure the inner diameter of the starter driven gear.
AAA
SERVICE LIMT : A : 32.10 mm
B : 39.53 mm
BBB
9-7
STARTER
STARTERONEWAY
STARTER ONEWAYCLUTCH
ONEWAY CLUTCHSET
CLUTCH SET
SET
THRUST
THRUST
THRUSTWASHER
THRUST WASHER
WASHER
LOCKNUT
LOCK
LOCK NUT
NUT
Hold the drive face with the drive face holder.

Tighten the lock nut with specified torque.

TOOL : SPECIAL SOCKET (12.7X28X120)
DRIVE FACE HOLDER
SPECIAL
SPECIAL
SPECIALSOCKET
SOCKET
SOCKET
Install the following parts.

- RH. Crankcase cover
- A.C Generator
- Cooling fan
- RH. Shroud
- Rear swing arm
- Rear caliper
- EX. Muffler
- Rear under cover
- Pillion step holder
RH.
RH. CRANK
RH. CRANK CASE
CRANK CASE COVER
CASE COVER
COVER
9-8
MEMO

CYLINDER HEAD / VALVES
FLANGE NUT
IN VALVE ROCKER ARM
CAM SHAFT HORDER

EX. VALVE ROCKER ARM
CAM SHAFT COMP
EX. VALVE
INLET VALVE
CARBURETOR INSULATOR
CYLINDER HEAD COMP
SAI PIPE
CYLINDER HEAD GASKET
10-0
10. CYLINDER HEAD / VALVES
SERVICE INFORMATION 10-1 VALVES 10-6

TROUBLESHOOTING 10-2 VALVE GUIDES 10-7
CAMSHAFT 10-3 VALVE SEATS 10-8
CYLINDER HEAD 10-5 CYLINDER HEAD ASSEMBLY10-12
VALVE SPRINGS 10-6 CAMSHAFT ASSEMBLY10-13
SERVICE INFORMATION
GENERAL SAFETY
The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed
from the frame to maintain the cylinder head.
The oil of camshaft oil is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder
head.
SPECIFICATIONS
Unit : mm
10
ITEM STANDARD VALUE SERVICE LIMIT
ROCKER ARM INNER DIAMETER 12.016 - 12.034 12.060
ROCKER ARM
ROCKER ARM SHAFT OUTER DIAMETER 11.982 - 12.000 11.950
IN 33.835 - 33.995 33.625
CAMSHAFT CAM HEIGHT
EX 33.984 - 34.144 33.765
CYLINDER HEAD WARPAGE - -
IN 37.21 36.90
VALVE SPRING FREE LENGTH
EX 37.21 36.90
IN 4.972 - 4.984 4.920
VALVE STEM OUTER DIAMETER
VALVE EX 4.952 - 4.964 4.900
VALVE GUIDE VALVE GUIDE INNER DIAMETER IN,EX 5.000 - 5.012 5.030
CLEARANCE BETWEEN IN 0.016 - 0.040 0.090
STEM AND GUIDE EX 0.036 - 0.060 0.120
VALVE SEAT WIDTH 0.8 - 1.0 1.4
TORQUE VALUES
CAM CHAIN TENSIONER PIVOT BOLT 1.0 kgfm
SPARK PLUG 1.2 kgfm
CAMSHAFT HOLDER 8mm NUT 2.0 kgfm
CAM CHAIN TENSIONER MOUNTING BOLT 1.2 kgfm
CAM CHAIN TENSIONER SEALING SCREW 0.4 kgfm
CYLINDER HEAD COVER BOLT 0.9kgfm
CYLINDER HEAD BOLT 1.1 kgfm
TAPPET ADJUST NUT 0.8 kgfm
10-1
TOOLS
VALVE GUIDE REAMER
VALVE GUIDE DRIVER
VALVE SPRING COMPRESSOR
VALVE SEAT CUTTER
SEAT CUTTER IN 37(21.5mm)
EX 37(18.5mm)
IN 45(22.0mm)
EX 45(22.0mm)
IN 55(20.0mm)
EX 55(20.0mm)
TROUBLESHOOTING
Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test,
or by tracing noises to the top-end with a sounding rod or stethoscope.
Low comperssion Rough idle

Valves Low cylinder compression
-Incorrect valve adjustment (see section 3)
-Burned or bent valves Compression too high
-Incorrect valve timing Excessive carbon build-up on piston or combustion
-Broken valve spring chamber
-Uneven valve seating
Excessive noise
Cylinder head Incorrect valve adjustment
-Leaking or damage head gasket Sticking valve or broken valve spring
-Warped or cracked cylinder head Damaged or worn camshaft
Worn rocker arm and / or shaft
Cylinder, piston (see section 11) Loose or worn cam chain
Worn or damaged cam chain tensioner
Excessive white smoke Damaged cylinder head gasket
Worn valve guide or valve stem Incorrect spark plug installation
Damaged valve stem seal
Worn or damaged piston ring
10-2
CAMSHAFT
REMOVAL
- Rear fender
- Seat support pipe
SPECIAL
SPECIAL BOLTS
SPECIALBOLTS
SPECIAL BOLTS
BOLTS
- Center cover
- Truss pipe
CYLINDER
CYLINDER HEAD
CYLINDERHEAD COVER
HEADCOVER
COVER - Floor panel
Loosen the special bolt securing the cylinder head
cover and remove the cover.
Turn the crankshaft to the left, and align theTmark

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

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

Remove the camshaft holder from the cylinder head.
CAM
CAM
CAM SHAFT
CAMSHAFT HOLDER
SHAFTHOLDER
SHAFT HOLDER
HOLDER
FLANGENUT
FLANGENUT
FLANGENUT
FLANGENUT
10-3
Remove the cam chain from the camshaft.

! NOTE
Take precautions not to allow the cam chain to drop

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

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

check if it turns smoothly.
Check the bearing for wear or damage.

! CAUTION
Be sure to check the valve clearance.
CAMSHAFT
CAMSHAFT BEARING
CAMSHAFTBEARING
CAMSHAFT BEARING
BEARING
CYLINDER HEAD
CYLINDER
CYLINDERHEAD
CYLINDER HEAD
HEAD
- Rear fender
- Seat support pipe
- Center cover
- Truss pipe
FLANGE
FLANGE
FLANGE - Floor panel
BOLTS
BOLTS
BOLTS - RH. LH. shroud
- Cylinder head cover
- Cam shaft
- EX. Pipe
- Cylinder head
Remove the cylinder head gasket, dowel pin and
camchain guide from the cylinder.
CYLINDER
CYLINDER
CYLINDERHEAD
HEAD
HEADGASKET
GASKET
GASKET
CAMCHAIN
CAMCHAIN
CAMCHAIN
CAMCHAIN
CYLINDER
CYLINDER
CYLINDERHEAD
HEAD
HEAD DISASSEMBLY
SPARK
SPARK PLUG
SPARKPLUG
SPARK PLUG
PLUG
Remove the carburetor insulator.
Remove the spark plug from the cylinder head.
10-5
Remove the valve spring, valve cotter, retainer, spring

and valve. Using the valve spring compressor.
TOOL : VALVE SPRING COMPRESSOR

! NOTE
To prevent the loss of tension, do not compress the

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

Remove the carbon deposits from the inside of the
combustions chamber.

! NOTE
Take precautions not to damage the cylinder head

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

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

any one is less than the service limit.
VALVE
VALVE
VALVE
VALVES
Inspect each valve for bending, burning, scratches or
abnormal wear.
Insert the valves in their original positions in the
cylinder head.
Check that each valve moves up and down smothly,
without binding.
Measure and record the valve stem outer diameter in
three places along the valve guide sliding area.
EX: 4.900 mm
Replace the valve with a new one if the service limit is
exceeded.
10-6
VALVE
VALVE GUIDE
VALVEGUIDE
VALVE REAMER
GUIDEREAMER
GUIDE REAMER
REAMER VALVE GUIDES
INSPECTION
Insert the valve guide reamer from the combustion
chamber side and ream the guide to remove any carbon
build-up before measuring the guide.

! NOTE
Take care not to tilt or lean the reamer in the guide

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

Measure the guide-to-stem clearance with a dial
indicator while rocking the stem in the direction of
normal thrust.
EX: 0.120 mm
Measure the inner diameter of the new valve guide. If
the clearance is not within the service limit, replace the
valve.
REPLACEMENT
VALVE
VALVE
VALVEGUIDE
GUIDE
GUIDEDRIVER
DRIVER
DRIVER
Heat the cylinder head to 130

C - 140C (275F - 290F).
Support the cylinder head and drive the old guides out
of the combustion chamber side of the cylinder head.
TOOL : VALVE GUIDE DRIVER

! NOTE
Avoid damaging the head when driving the valve

giude out.

! CAUTION
Do not heat the cylinder head beyond 150

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

reamer from the combustion chamber side.

! NOTE
Take care not to tilt or lean the reamer in the guide

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

thoroughly to remove any metal particles.
VALVE SEATS
INSPECTION
Clean all intake and exhaust valves thoroughly to
remove carbon deposits.
Apply a light coating of Prussian Blue to each valve
face.
VALVE
VALVE
VALVE
VALVE
10-8
VALVE
VALVE
VALVESEAT
SEAT
SEAT Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and evenly all around the circumference.
If the valve seat width is not within specification,
reface the valve seat.

! NOTE
Valve faces and stem tips cannot be ground. If a valve

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

Reface the worn valve seat by using valve seat cutters
and grinders.
45

! NOTE
Follow the refacer manufactuers operating instructions.

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

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

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

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

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

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

the valve face, and insert the valve with a valve guide
reamer.

! NOTE
Do not excessively press and turn the valve to set it as it

may cause damage. Gently strike and set the valve.
The seat surface may become worn on one side if the
valve is set in the same position. Turn the valve slightly
when setting it.
Take precautions not to allow compound to get into the
clearance between the stem and guide while the valve is
being set.
IN/EX VALVE ASSEMBLY

CYLINDER
CYLINDER
CYLINDER VALVE
VALVE
VALVE
STEMSEAL
STEM
STEM SEAL
SEAL SPRING
SPRING
SPRING
SPRING Install the valve spring and new stem seals.
RETAINER
RETAINER
RETAINER Lubricate each valve stem with molybdenum disulfide
COTTER
COTTER
COTTER grease and insert the valve into the valve guide.
Check the valve moves up and down smoothly.
For valve spring with varying pitch, install the valve

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

Compress the valve springs with the valve spring
compressor and install the valve cotters.

! CAUTION
Compressing the valve spring more than necessary

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

firmly seat the cotters.

! CAUTION
Take necessary precautions not to damage the valve.
VALVE
VALVE
VALVESPRING
SPRING
SPRING
CYLINDER
CYLINDER
CYLINDERHEAD
HEAD
HEAD Apply engine oil to the new O-ring, and assemble it to
the carburetor insulator groove.
Tighten the carburetor insulator with mounting bolts.
Install the cam chain tensioner, and assemble pilot.
TORQUE : 1.0 kgf m
Install the spark plug.
TORQUE : 1.2 kgf m
CYLINDER
CYLINDER
CYLINDER GASKET
GASKET
GASKET CYLINDER HEAD ASSEMBLY
Clean any gasket material from the cylinder mating surface.
Install the cam chain guide to the cylinder.
Install the dowel pins and new gasket.
DOWEL
DOWEL
DOWELPIN
PIN
PIN
CAM
CAMCHAIN
CAM CHAIN
CHAIN
CYLINDER
CYLINDER HEAD
CYLINDERHEAD
HEAD Install the cylinder head.
10-12
CAMSHAFT ASSEMBLY
EX.
EX.
EX.VALVE
VALVE
VALVEROCKER
ROCKER
ROCKERARM
ARM
ARM
IN.
IN.VALVE
VALVEROCKER
ROCKERARM
ARM Apply engine oil to the rocker arm shaft, and assemble
IN. VALVE ROCKER ARM
the rocker arm to the camshaft holder.
EX.ROCKER
EX.
EX. ROCKERARM
ROCKER ARMSHAFT
ARM SHAFT
SHAFT IN.ROCKER
IN.
IN. ROCKERARM
ROCKER ARMSHAFT
ARM SHAFT
SHAFT
CAM
CAMSHAFT
CAM SHAFTHOLDER
SHAFT HOLDER
HOLDER
Tighten the rocker arm shaft with 6mm bolts, and align
CAM
CAM SHAFT
CAM SHAFT HOLDER
SHAFT HOLDER
HOLDER
the bolt hole of the camshaft holder with the fitting side
of the rocker arm shaft.
Check the camshaft assembly for abnormal condition,

CAM
CAMSHAFT
CAM SHAFT
SHAFT CAM
CAM
CAMCHAIN
CHAIN
CHAIN and place it on the cylinder head.
Put the cam chain and cam sprocket on the cam
sprocket.
Slowly rotate the crankshaft counterclockwise, and

align theTmark of the flywheel with the index mark
of the RH. crank case cover.

! CAUTION
Take precautions not to allow the cam chain to come

T-MARK
T-MARK
T-MARK off the camshaft timing gear while turning the
camshaft.
10-13
Apply engine oil to the camshaft, and install it on the

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

CAM
CAM
CAMSHAFT
SHAFT
SHAFTHOLDER
HOLDER
HOLDER Install the cam shaft holder.

! CAUTION
The hole of the camshaft holder and the fitting section

of the rocker arm shaft fit section must be in alignment.
Of IN and EX, the shorter rocker arm should be
installed on the IN side.
Install the cam cover plate.

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

! CAUTION
If the cam chain tensioner lifter is dropped, the shaft

will advance by the spring force.
10-14
HARDCLIP
HARDCLIP
HARDCLIP TENSIONER
TENSIONER
TENSIONERLIFTER
LIFTER
LIFTER Fix the tensioner shaft with a hard clip.
Assemble a new gasket to the tensioner lifter, and
install the tensioner lifter on the cylinder.
Tighten the tensioner mounting bolts.
Remove the tensioner shaft clip from the tensioner

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

cylinder head.
Adjust the valve clearance.
VALVE CLEARANCE : INHALE 0.12 0.02mm

EXHALE 0.12 0.02mm
FEELER
FEELER GAUGE
FEELERGAUGE
GAUGE
Remove oil from the cylinder head cover grooves, and

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

SPARK
SPARKPLUG
SPARK PLUGCAP
PLUG CAP
CAP
10-15
CYLINDER / PISTON
CYLINDER
TOP RING
SECOND RING
OIL RING
CYLINDER GASKET
PISTON
11-0
CYLINDER / PISTON
11. CYLINDER / PISTON
SERVICE INFORMATION 11-1 PISTON / PISTON RING 11-3

TROUBLESHOOTING 11-1 CYLINDER INSTALLATION 11-6
CYLINDER 11-2
SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the
cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the
cylinder fins.
Take care not to damage the cylinder wall and piston.
Check parts after disassembling, and clean and dry with an air hose prior to taking measurements.
SPECIFICATIONS
Unit : mm
INNER DIAMETER 56.000 - 56.010 mm 56.100 mm
TAPER - 0.050 mm
CYLINDER
OUT-OF-ROUND - 0.005 mm
HEAD CONTACT WARPAGE - 0.020 mm
PISTON SKIRT OUTER DIAMETER 55.925 - 55.945 mm 55.825 mm 11
PISTON PIN HOLE INNER DIAMETER 15.002 - 15.008 mm 15.040 mm
PISTON PIN OUTER DIAMETER 14.994 - 15.000 mm 14.960 mm
PISTON,
PISTON-TO-PISTON PIN CLEARANCE 0.002 - 0.014 mm 0.020 mm
PISTON PIN,
PISTON RING-TO- TOP 0.040 - 0.067 mm 0.110 mm
PISTON RING
GROOVE CLEARANCE SECOND 0.025 - 0.052 mm 0.080 mm
PISTON RING TOP / SECOND 0.10 - 0.25 mm 0.50 mm
JOINT GAP OIL RING (SIDE RAIL) 0.20 - 0.70 mm 1.10 mm
CYLINDER-TO-PISTON CLEARANCE 0.055 - 0.090 mm 0.200 mm
CONNECTING ROD SMALL END INNER DIAMETER 15.010 - 15.028 mm 15.060 mm
GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN 0.010 - 0.034 mm 0.040 mm
TROUBLESHOOTING
Comperssion too low Overheating
Worn piston Excessive carbon build-up on top of piston
Worn, damaged piston ring
Worn cylinder
Abnormal noise
Excessive smoke Worn cylinder and piston
Worn cylinder, piston or piston rings Worn connecting rod small end bearing or piston pin
Improper installation of piston ring Damaged piston ring
Scored or scratched piston or cylinder wall Excessive carbon build-up on top of piston
11-1
CYLINDER / PISTON
CYLINDER
CYLINDER
CYLINDER
CYLINDER
REMOVAL
Remove EX. pipe.
Remove the cylinder head cover.
Remove the cam shaft.
Remove cylinder head.
Remove the cam chain guide from the cylinder.
Remove cylinder
CAM
CAM
CAM CHAIN
CAMCHAIN GUIDE
CHAINGUIDE
CHAIN GUIDE
GUIDE
Remove the gasket and dowel pin. Carefully remove

any adhering gasket material from the cylinder / head
mating surface. Do not scratch the surface.

! NOTE
Take care not to damage the cylinder mating surface.
CYLINDER
CYLINDERGASKET
CYLINDER GASKET
GASKET
PISTON
PISTON
PISTON
WEAR INSPECTION
CYLINDER GAUGE
CYLINDER GAUGE
Inspect the cylinder wall for scratches and wear.
Measure and record the cylinder inner diameter at three
levels in both an X and Y axis.
Take the maximum reading to determine the cylinder
wear.
Measure the piston outer diameter.

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

an X and Y axis. Take the maximum reading to
determine the out-of-round.
TOP
TOP Calculate the cylinder for taper at three levels in an X
and Y axis. Take the maximum reading to determine
the taper.
MIDDLE
MIDDLE
If any of the cylinder measurements exceed the service
limits, replace the cylinder.
SERVICE LIMIT : OUT-OF-ROUND : 0.005 mm
TAPER : 0.05 mm
BOTTOM
BOTTOM
11-2
CYLINDER / PISTON
WARPAGE INSPECTION
Check the cylinder for warpage by placing a straight
edge and feeler gauge across the stud holes. Replace
the cylinder if the service limit is exceeded.

! NOTE
Any clearance between the cylinder and head due to

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

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

the possibility of the clip falling into the crankcase.
Remove the piston pin clip using a pair of pliers.

Press the piston pin out of the piston.
PISTON
PISTON
PISTONPIN
PIN
PINCLIP
CLIP
CLIP

! NOTE
Do not damage or scratch the piston.

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

! NOTE
Do not damage to the piston by piston ring when

PISTON RING
PISTON RING removing.
Measure the clearance between the piston ring and

piston grooves.
SERVICE LIMIT : TOP : 0.110 mm

SECOND : 0.080 mm
OIL RING : 0.280 mm
Inspect the piston for wear or damage.
11-3
CYLINDER / PISTON
11-4
CYLINDER / PISTON
MARK
TOP RING
SECOND RING
SIDE RAIL
OIL
SPACER
RING
20mm SIDE RAIL
PISTON
TOP RING
SECOND RING
CRANK
CRANK SHAFT
CRANKSHAFT CONNECTING
SHAFTCONNECTING ROD
CONNECTINGROD
ROD
11-5
CYLINDER / PISTON
CYLINDERGASKET
CYLINDER
CYLINDER GASKET
GASKET
PISTON
PISTON
PISTON
DOWEL
DOWEL
DOWELPIN
PIN
PIN
PIN
PIN
PINCLIP
CLIP
CLIP
CYLINDER
CYLINDER
CYLINDER
( 10-12)
( 10-13)
( 10-5)
( 3-9)
( 7-3)
11-6
MEMO

TRANSMISSION/CRANKSHAFT/CRANK CASE
12-0
TRANSMISSION/CRANKSHAFT/CRANKCASE
12
12-1 12-7
12-2 12-8
12-3 12-9
12-6 12-10
( SECTION 4-4)
( SECTION 7)
( SECTION 10 AND 11)
( SECTION 9)
( SECTION 8)
( SECTION 8)
( SECTION 12)
12
12-1
TORQUE VALUE
CRANK CASE BOLT 1.0kg-m
TOOLS
-UNIVERSAL BEARING PULLER
-BEARING REMOVER SET
-REMOVER ASSEMBLY
-REMOVER SHAFT
-REMOVER HEAD
-SLIDING WEIGHT
-ASSEMBLY SHAFT
TROUBLESHOOTING
Engine Noise
Connecting rod big and small ends loose.
Crank pin bearing loose.
Engine started but unable to move out

Transmission damage.
Transmission seized.
Noise during operation

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

OUTER DRIVER
CRANK
CRANK
CRANKASSEMBLY
CRANK ASSEMBLY SHAFT
ASSEMBLYSHAFT
SHAFT DRIVER PILOT
FINAL
FINALSHAFT
FINAL SHAFT
SHAFT
COUNTERSHAFT
COUNTER
COUNTER SHAFT
SHAFT
12-5
Replace the new oil seal on the transmission

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

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

Install the engine on the frame. ( 7-3)
12-10
MEMO

FRONT WHEEL/FRONT FORK/STEERING
STEERING HANDLE
STEERING STEM
FRONT FORK
FRONT DISK
FRONT WHEEL
FRONT TIRE
13-0
13. FRONT WHEEL/FRONT FORK/STEERING
SERVICE INFORMATION13-1 SPEEDOMETER GEAR13-6

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

AXLE SHAFIT DEFLECTION - 0.2
RADICAL - 2.0
FRONT WHEEL RIM DEFLECTION
AXIAL - 2.0
FRONT CUSHION SPRING FREE LENGTH 266.3
13
TORQUE VALUES
STEERING STEM LOCK NUT 7.84~11.76 fm
STEERING TOP CONE RACE 0.49~1.27 fm
FRONT CUSHION BOLT 1.98~2.45 fm
FRONT AXLE NUT 4.41~4.9 fm
BRAKE CALIPER BOLT 2.45~3.43 fm
13-1
TROUBLESHOOTING
Hard steering
Steering top cornice too tight.
Damaged steering stem steel ball.
Faulty steering ball race, cone race.
Insufficient tire pressure.
Tire is worn.
Steers to one side or does not track straight

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

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

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

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

HANDLE
HANDLE
HANDLEGRIP
GRIP
GRIP
HEX
HEX
HEXSOCKET
SOCKET
SOCKETBOLTS
BOLTS
BOLTS Remove the cap on the handle upper holder.
Loosen the hexbolt securing handle bar and remove the
steering handle comp.
HANDLE
HANDLE UPPER
HANDLE UPPER HOLDER
UPPER HOLDER
HOLDER
13-3
INSTALLATION
STEERING
STEERING
STEERINGHANDLE
STEERING HANDLE
HANDLE
Align the line of the steering handle to the handle under
holder.
Install the handle upper holder using the hexbolt, to the
specified torgue.
TORQUE : 3.92 - 4.9fm
HANDLE
HANDLEUNDER
HANDLE UNDERHOLDER
UNDER HOLDER
HOLDER
! NOTE
Adjust the throttle grip free play to the
specified range of 2-6mm.
HANDLE
HANDLE UPPER
HANDLE UPPER HOLDER
UPPER HOLDER
HOLDER
FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT
FRONT
FRONT
FRONTCALIPER
CALIPER
CALIPER FRONT WHEEL
REMOVAL
Jack the motorcycle front wheel off the ground.
Loosen the flange bolt securing the front caliper to
remove the caliper.
Loosen the axle nut, speedometer cable setting screw
and remove the wheel.
DIAL
DIAL GAUGE
DIALGAUGE
GAUGE FRONT
FRONTAXLE
FRONT AXLE
AXLE INSPECTION
AXLE RUNOUT
Set the axle in V blocks and measure the runout using a
dial gauge.
The actual runout is 1/2 of the total indicator reading.
SERVICE LIMIT : 0.2mm replace if over
13-4
ROTATION
ROTATION
ROTATION
BEARING
BEARING REMOVER
BEARINGREMOVER HEAD
REMOVERHEAD
HEAD
DRIVER
DRIVER
DRIVERHANDLE
DRIVER HANDLE
HANDLEAAA
13-5
SPEEDOMETER GEAR
GEAR
GEARWASHER
WASHER
INSPECTION
Remove the speedometer gear from the speedometer
gear box.
Apply grease to the speedometer gear unit and install.
SPEEDOMETERGEAR
SPEEDOMETER
SPEEDOMETER GEARBOX
GEAR BOX
BOX SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETERGEAR
SPEEDOMETER GEAR
GEAR
ASSEMBLY
DUST
DUST SEAL
DUSTSEAL
DUST SEAL
SEAL
Apply grease to left side dust seal rim.
Install the left side dust seal.
Install the brake disk.
Install disk bolts.
TORQUE VALUE : 4.0 ~4.5 kgfm
BEARING
BEARING
BEARING
BEARING
Install the front wheel side collar.
FRONT
FRONT
FRONTWHEEL
WHEEL
WHEELSIDE
SIDE
SIDECOLLAR
COLLAR
COLLAR
Install the speedometer gear unit by aligning its

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

GEAR
GEARBOX
GEAR BOXRETAINER
BOX RETAINER
RETAINER Install the dust seal, and align the tangs of the
speedometer gear retainer with the gear groove to
assemble the speedometer gear box.
SPEEDOMETER
SPEEDOMETERGEAR
SPEEDOMETER GEARBOX
GEAR BOX
BOX
PART
PART FRONT WHEEL INSTALLATION
Insert the front wheel between the front forks.
Insert the disk, taking precautions not to damage the
pad, and assemble the wheel.
Align the slots of the speedometer gear with the tangs
of the RH. fork slider.
Insert the front axle into the speedometer gear box and
the wheel hub.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER GEAR
SPEEDOMETERGEAR BOX
GEARBOX
GEAR BOX
BOX
Install the axle nut.

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

lightly.
STEERING
STEERING
STEERING STEM
STEERINGSTEM
STEM COMP
STEMCOMP
COMP
COMP ! NOTE
Support the vehicle securely under the engine not
to turn over it.
Loosen the flange bolt, but do not remove it.
Loosen the 4 setting bolts securing the RH./LH. front

fork, remove the RH./LH. front fork.
After removal of RH. front fork, loosen the flange bolt
FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT and remove the front brake hose clamp A.
FRONT
FRONTFORK
FRONT FORKBOLT
FORK BOLT
BOLT DISASSEMBLY
Remove the fork pipe bolt.
! NOTE
FRONT
FRONT
FRONTFORK
FORK
FORKPIPE
PIPE
PIPE If the screw is completely loosened, the fork tube
cap bolt may spring out by the force fo the spring.
Take due precautions.
Remove the fork spring, and expand and release
the fork pipe several times to drain fork oil.
Wrap the bottom case with a piece of cloth, and

SOCKET
SOCKET BOLT
SOCKETBOLT
BOLT remove the socket bolt.
! NOTE
If the socket bolt turns idle, but cannot be
removed, temporarily assemble the spring and
the fork tube cap bolt first.
Hold the bottom case firmly with a vise, taking
precautions not to distort or damage it.
13-8
Remove the dust seal.
DUST
DUST SEAL
DUSTSEAL
DUST SEAL
SEAL
OILSEAL
OIL
OIL SEALSTOP
SEAL STOPRING
STOP RING
RING
Remove the oil seal stop ring.
! NOTE
Take precaution not to damage the interior and

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

Remove the cution spring, pipe seat and oil lock piece
from the fork pipe.
BOTTOM
BOTTOM
BOTTOMCASE
CASE
CASE
FRONT
FRONT
FRONT CUSHION
FRONTCUSHION SPRING
CUSHIONSPRING
SPRING FORK
FORK BOLT
FORK BOLT
BOLT Check and inspect the each parts.
PIPE
PIPE SEAT
PIPE SEAT
SEAT FORK
FORK
FORKPIPE
PIPE
PIPE
BOTTOM
BOTTOM
BOTTOMCASE
CASE
CASE RESOUND
RESOUND SPRING
RESOUNDSPRING
SPRING
SOCKET
SOCKET BOLT
BOLT
OIL
OIL LOCK
OIL LOCK PIECE
LOCK PIECE
PIECE
13-9
FRONT FORK INSPECTION
Place the fork spring on a level place, and measure the

free length.
If the free length deviates from the service limit,
replace the springs with new ones.
Check components for damage or abnormal wear.
Replace defective parts with new ones.
SERVICE LIMIT : FORK SPRING : 266.3mm

FRONT
FRONT FORK
FRONTFORK SPRING
FORKSPRING
SPRING
Set the fork pipe on a V-blocks, and measure fork pipe

FORK
FORK PIPE
FORKPIPE
FORK PIPE
PIPE
deflection by rotating with a dial gauge.
SERVICE LIMIT : Replace if the deflection is greater

than 0.2mm
Check the slider bush contact face.

If the slider bush is extensively damaged, replace the
bottom case.
OIL
OIL SEAL
OILSEAL STOP
SEALSTOP RING
STOPRING
RING
FRONT FORK ASSEMBLY
OIL SEAL STOP RING
Wash parts with clean oil prior to assembling.

Assemble the rebound spring and the fork piston to the
fork tube.
Assemble the fork pipe to the bottom case.
Wrap the bottom case with a piece of cloth, and fix it to

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

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

FORK SEAL DRIVER BODY
Install the oil seal stopper ring.

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

Fill a prescribed amount of automatic transmission
fluid(ATF) into the fork tube.
CAPACITY : 90cc
FORK OIL OIL LEVEL Slowly press the fork tube 2-3 times to discharge air.
Assemble the springs to the fork pipe.
! NOTE
Install the spring with the smaller pitch side facing
downward.
13-11
Assemble the fork bolt to the fork pipe.

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

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

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

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

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

STEERING STEM SOCKET
Install the following parts

-Front fork
-Front wheel
-Steering handle
-Inner box
13-13
REAR WHEEL/SUSPENSION/REAR SWING ARM
14-0
14. REAR WHEEL / SUSPENSION / REAR SWING ARM
SERVICE INFORMATION 14-1 REAR CUSHION

14-5
TROUBLESHOOTING 14-2 14-6
REAR SWING ARM
REAR WHEEL 14-3
SERVICE INFORMATION
! CAUTION
Use the specified tire lever and rim protector to remove or assemble tires to protect the rim from being damage.
SPECIFICATIONS

REAR WHEEL RIM RUN OUT - 2.0 mm
REAR CUSHION SPRING FREE LENGTH 219 mm 215 mm
TORQUE VALUES :
REAR CUSHION UPPER BOLT 3.5~4.5fm

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

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

REAR
REAR WHEEL
REARWHEEL
REAR WHEEL
WHEEL
REARBRAKE
REAR
REAR BRAKEDISK
BRAKE DISK
DISK
14-3
DIAL
DIAL
DIALGAUGE
GAUGE
GAUGE
FINAL
FINALSHAFT
FINAL SHAFT
SHAFT
REARWHEEL
REAR
REAR WHEEL
WHEEL
( 14-6)
REAR
REARSWING
REAR SWINGARM
SWING ARM
ARM
REAR
REARWHEEL
REAR WHEELINSIDE
WHEEL INSIDECOLLAR
INSIDE COLLAR
COLLAR
Install the EX. muffler.
14-4
REAR
REAR
REARCUSHION
CUSHION
CUSHION
REAR CUSHION
REMOVAL
Remove the upper bolt.
Remove the lower bolt.
UNDER
UNDER
UNDER Remove the rear cushion.
BOLTS
BOLTS
BOLTS
ATTACHMENT
ATTACHMENT
ATTACHMENT
DISASSEMBLY
Install the compressor attachment as shown in the
figure.
Install the cushion on the cushion compressor, and
compress the spring.
TOOL : REAR CHUSION COMPRESSOR

ATTACHMENT
REAR CHUSION COMPRESSOR
REAR
REAR
REARCUSHION
CUSHION
CUSHIONCOMPRESSOR
COMPRESSOR
COMPRESSOR
Fix the upper metal and loosen the hex nut.

ATTACHMENT
ATTACHMENT
ATTACHMENT Remove the upper metal.
Remove the hex nut, upper metal, stopper rubber and
the spring from the rear damper comp.
UPPER
UPPER METAL
UPPERMETAL
UPPER METAL
METAL
INSPECTION
REAR
REAR
REARCUSHION
CUSHION
CUSHIONSPRING
SPRING
SPRING Measure the rear cushion spring free length.
Check the damper rod for deflection or damage.
SERVICE LIMIT : 215mm
FREE
FREE
FREELENGTH
LENGTH
LENGTH
14-5
INSTALLATION
Install the spring, stopper rubber to the damper comp.
Apply thread locking agent to the hex nut, and install
the rear cushion compressor attachment on the damper
rod.
Fix the upper metal, and tighten the hex nut.
TORQUE VALVE : 3.0~4.5kgf m

TOOLS : REAR CHUSION COMPRESSOR ATTACHMENT
REAR CHUSION COMPRESSOR
! NOTE
Install the spring with the smaller pitch side
facing downward.
Install the rear cushion.
Tighten the top and bottom of the cushion with bolts.
TORQUE VALVE : UPPER SIDE : 3.5~4.5kgf m

LOWER SIDE : 3.5~4.5kgf m
REAR
REAR BRAKE
REARBRAKE
REAR CALIPER
BRAKECALIPER
BRAKE CALIPER
CALIPER REAR SWING ARM
REMOVAL
Remove the EX. Muffler.
REAR
REAR
REAR SWING
REARSWING ARM
SWINGARM
SWING ARM
ARM
Remove the rear brake caliper.

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

Install the muffler.
14-7
MEMO

MEMO

BRAKE SYSTEM
15-0
BRAKE SYSTEM
15. BRAKE SYSTEM

SERVICE INFORMATION15-1 FRONT BRAKE CALIPER 15-6
TROUBLESHOOTING15-2 REAR BRAKE CALIPER 15-8
BRAKE FLUID 15-3 MASTER CYLINDER15-11
FRONTBRAKEPADREPLACEMENT15-5 BRAKE DISK 15-13
REAR BRAKE PAD 15-6
SERVICE INFORMATION
GENERAL SAFETY
Do not allow foreign material to enter the system when replenishing brake fluid.
To prevent chemical changes, do not mix different types of brake fluid.
Do not use the old brake fluid again.
Brake fluid can cause damage to painted, plastic, and rubber surfaces. Take precaution not to allow parts to be
contaminated by the brake fluid.
Do not reuse sealing washers.
Clean the disassembled parts with brake fluid, and check for any clogged passage with compressed air.
Bleed the brake hose after removing it.
Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking
performance, if contaminated, replace the pad with a new one and clean the disk.
SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT
FRONT BRAKE CALIPER PISTON A O.D 33.928-33.878mm 33.848mm
FRONT BRAKE CALIPER CYLINDER A I.D 33.96-34.01mm 34.01mm
FRONT BRAKE CALIPER PISTON B O.D 25.33-25.37mm 25.30mm
FRONT BRAKE CALIPER CYLINDER B I.D 25.41-25.46mm 25.46mm
REAR BRAKE DISK THICKNESS 4.0mm 3.0mm
REAR BRAKE DISK RUNOUT - 3.0mm 15
REAR BRAKE MASTER CYLINDER I.D 13.5mm 13.543mm
REAR BRAKE MASTER CYLINDER PISTON O.D 13.5mm 13.378mm
REAR CALIPER CYLINDER I.D 34.0mm 34.039mm
REAR CALIPER PISTON O.D 34.0mm 33.914mm
15-1
BRAKE SYSTEM
TROUBLESHOOTING
Brake lever / pedal soft or spongy Brake lever / pedal hard

Air bubbles in the hydraulic system. Clogged / restricted brake system.
Leaking hydraulic system. Sticking / worn caliper piston.
Contaminated brake pad / disk . Caliper not sliding properly.
Worn caliper piston seal. Clogged / restricted fluid passage.
Worn master cylinder piston seal. Worn caliper piston seal.
Worn brake pad. Sticking / worn master cylinder piston.
Contaminated caliper. Bent brake lever / pedal.
Caliper not sliding properly.
Worn brake pad / disk. Brakes grab or pull to one side
Low fluid level. Contaminated brake pad / disk.
Clogged fluid passage. Misaligned wheel.
Warped / deformed brake disk. Clogged / restricted brake hose.
Sticking / worn caliper piston. Warped / deformed brake disk.
Sticking / worn master cylinder piston. Caliper not sliding properly.
Worn brake disk. Clogged / restricted brake hose joint.
Contaminated master cylinder.
Bent brake lever / pedal. Brakes drag
Contaminated brake pad / disk.
Misaligned wheel.
Worn brake pad / disk
Warped / deformed brake disk.
Caliper not sliding properly.
Hydraulic system contaminated with dust.
15-2
BRAKE SYSTEM
MASTER
MASTER CYLINDER
MASTERCYLINDER
MASTER CYLINDER
CYLINDER BRAKE FLUID

! CAUTION
A contaminate disk or pad reduces braking

power. Do not allow the disk or pad to be
contaminated by oil.
Replace contaminated pads, and remove
pollutants from the disk completely.
Check the brake fluid level often and replenish
new fluid as required.
Do not spill fluid on painted, plastic or rubber
parts.
FR.
FR.BRAKE
FR. BRAKEBREEDER
BRAKE BREEDERVALVE
BREEDER VALVE
VALVE Remover the fluid maintenance lid.
FR.
FR.BRAKE
FR. BRAKEMASTER
BRAKE MASTERCYLINDER
MASTER CYLINDER
CYLINDER
Remove the oil cup cap, diaphragm plate, and
diaphragm from the master cylinder.
Connect the bleeder hose to the bleeder valve. Loosen
the bleeder valve, and pump the brake lever repeatedly.
When there is no more fluid flowing out of the bleeder
valve. Stop pumping the brake lever.
CALIPER
CALIPER
CALIPER
BREEDER
BREEDER
BREEDERVALVE
VALVE
VALVE
FRONT
FRONTBRAKE
FRONT BRAKELEVER
BRAKE LEVER
LEVER FRONT BRAKE AIR BLEEDING
<When the brake bleeder is available>
Fill the reservoir with DOT 3 or 4 brake fluid up to the
BRAKE BREEDER upper level.

! CAUTION
To prevent chemical changed.Do not use

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

if the amount of fluid is reduced to the lower
level.
Read the users manual carefully prior to
disassembling or using the brake bleeder.
Protect the bleeder valve with tape to prevent
air from entering the bleeder valve.
Repeat the above procedures until no air bubbles
appear in the bleeder hose.
Squeeze the bleeder valve and operate the brake lever
to check the ingress of air.
15-3
BRAKE SYSTEM
BREEDER
BREEDER
BREEDERHOSE
HOSE
HOSE
<When the brake bleeder is not available>
BREEDERVALVE
BREEDER
BREEDER VALVE
VALVE
Fill the brake fluid up to the upper limit line.
Connect the transparent bleeder hose to the bleeder
valve and place the other end of the hose in a container.
Squeeze the brake lever, then open the bleeder

valve 1/2 turn, and close the valve.

! NOTE
Do not release the brake lever until the bleeder valve

has been closed.
Release the brake lever slowly and wait several

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

DIAPHRAGMPLATE
DIAPHRAGM
DIAPHRAGM PLATE
PLATE the master cylinder and refill if necessary
Reinstall the diaphragm, diaphragm plate and oil cup
cap.
TORQUE VALUE : 1.0 kgfm
REAR BRAKE BLEEDLING (INTERLOCK)

RR.
RR.BRAKE
RR. BRAKEBREEDER
BRAKE BREEDERVALVE
BREEDER VALVE
VALVE
The rear brake is apply to interlocking system, when
REAR
REAR CALIPER
REARCALIPER
REAR CALIPER
CALIPER squeezing the right side brake lever, the front and rear
brake works at once.
Fill the brake fluid up to the upper limit line.

Connect the breeder hose to the breeder valve on
the rear caliper and bleed air.
BREEDER
BREEDER
BREEDERHOSE
HOSE
HOSE
15-4
BRAKE SYSTEM
If no air leaks out of the breeder hose after operate
RR.
RR. BRAKE
RR.BRAKE LEVER
BRAKELEVER
LEVER the brake lever, stop pumping it.
FR.
FR.BREEDER
BREEDERVALVE
VALVE FR.
FR.BRAKE
FR. BRAKEHOSE
BRAKE HOSE
HOSE Connect the breeder hose to the breeder valve on
FR. BREEDER VALVE
the front caliper and bleed air.
Fill the brake fluid up to the upper limit line and
install the diaphragm, plate and oil cup cap.
Install the fluid maintenance lid.
HANGER
HANGERPIN
HANGER PIN
PIN
FRONT BRAKE PAD
REPLACEMENT
FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT Loosen the hanger pin on the front caliper.

! NOTE
When replacing brake pads, replace whole set.

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

Loosen the hanger pin from the brake pad.
BRAKE
BRAKE
BRAKE PAD
BRAKEPAD
PAD
PAD Install the hanger pin to the new brake pads.
Install the brake caliper to the front fork.
15-5
BRAKE SYSTEM
RR.
RR. CALIPER
RR.CALIPER
CALIPER LOCK
LOCK PLATE
LOCKPLATE
PLATE
REAR BRAKE PAD
REPLACEMENT
Flatten the lock plate pawl and loosen the hanger pin.

! NOTE
When replacing brake pads, replace whole set.

Do not remove the brake hose when replacing brake
HANGERPIN
HANGER
HANGER PIN
PIN pads.
Loosen the rear brake bolt and remove the brake

RR.
RR.
RR.BRAKE
BRAKE
BRAKEPAD
PAD
PAD PAD
PAD
PADSPRING
SPRING
SPRING caliper.
Loosen the new brake pad, lock plate, hanger pin and
replace the pads.
Install in the revers order of removal.
FR.
FR.
FR.CALIPER
CALIPER
CALIPER FRONT BRAKE CALIPER
REMOVAL
Drain the brake fluid.
Loosen the oil bolt securing the brake hose.
Loosen the 2 bolts securing the caliper.

! NOTE
Avoid spilling fluid on painted, plastic or rubber parts.

! CAUTION
Keep oil off the brake disk or pad, because the

contaminated brake disk or pads reduce the braking
performance if contaminated. Replace the pad with a
new one and clean the disk.
15-6
BRAKE SYSTEM
DISASSEMBLY
AIR
AIR
AIRGUN
GUN
GUN
Remove the pad spring, pad comp, caliper bracket,
boot from the caliper body.
Wrap the caliper with a piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
Remove the piston from the caliper while blowing the
low-pressure air in the opening of the brake hose.
PISTON
PISTON
PISTON
PISTON

! CAUTION
PISTON
PISTON
PISTONSEAL
PISTON SEAL
SEAL
DUST
DUSTSEAL
DUST SEAL
SEAL Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.
Disassemble the piston seal and the dust seal.

! NOTE
Pay attention not to damage the inner sunface of the

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

CYLINDER I.D.B : 25.46mm
Check the caliper piston outer diameter part for

scratches or other damage.
Measure the piston outer diameter.
SERVICE LIMIT : PISTON O.D.A : 33.848MM

PISTON I.D.B : 25.30MM
PISTON
PISTON
PISTON
PISTON
15-7
BRAKE SYSTEM
LH
LH CALIPER
LHCALIPER
LH BODY
CALIPERBODY
CALIPER BODY
BODY HANGER
HANGER
HANGERPIN
PIN
PIN RH
RH
RHCALIPER
CALIPER
CALIPERBODY
BODY
BODY ASSEMBLY
PISTON
PISTON AA
PISTONAA
PISTON PISTON
PISTONAA
PISTON A
Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper.
Install the piston in the caliper with the groove side of
the piston facing the pad.
BRAKE
BRAKE PAD
BRAKE PAD
PAD
PISTON
PISTONBBB
PISTON
PADSPRING
PAD
PAD SPRING
SPRING
SOCKET
SOCKETBOLT
SOCKET BOLT
BOLT
Install the RH./LH. caliper body.
Install the socket bolt.
Install pad spring to the caliper.
Install caliper hanger pin bolt to the pad comp and
caliper bracket to the caliper body.
Install the brake pad to the caliper.
INSTALLATION
FR.
FR.
FR.CALIPER
CALIPER
CALIPER
Install the brake caliper to the from fork, and front axle.
Install the caliper to the specified torgue.
Install the brake hose to the caliper body with the new
2 oil bolts washer and oil bolts.
Install the oil bolt to the specified torgue.
Fill the brake fluid, and bleed air.
RR.
RR.
RR.BRAKE
BRAKE
BRAKEHOSE
HOSE
HOSE REAR BRAKE CALIPER
REMOVAL
Loosen the rear brake hose bolt and remove the brake
hose.
Loosen the 2 bolts and remove the rear brake caliper.
RR.
RR.CALIPER
RR. CALIPER
CALIPER
15-8
BRAKE SYSTEM
AIR
AIR
AIR GUN
AIRGUN
GUN
DISASSEMBLY
Remove the rear brake caliper.
Check the caliper assembly.
Remove the pad spring, slide pin, caliper bracket and
boot from the caliper body.
If there is any wear or damage in the boot, replace it
with a new one.
PISTON
PISTON
PISTON
Wrap the caliper with a piece cloth to avoid piston and

brake fluid leakage and facing the piston downward.
DUST
DUST
DUSTSEAL
SEAL
SEAL Remove the piston from the caliper, while blowing the
low-pressure air in the opening of the brake hose.

! CAUTION
Never use the high-pressure air or bring the air gun too
close.
Never touch the inside of the caliper.
Disassemble the piston seal and the dust seal.

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

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

Connect the boot to the piston of the caliper.
DUST
DUST PLUG
DUSTPLUG
DUST PLUG
PLUG
INSTALLATION
Tighten the caliper hanger pin bolt, and install the
caliper bracket in the caliper.
Install the rear brake hose in the caliper.
RR.
RR.
RR.BRAKE
BRAKE
BRAKEHOSE
HOSE
HOSE
15-10
BRAKE SYSTEM
MASTER CYLINDER
MASTER
MASTER
MASTERCYLINDER
CYLINDER
CYLINDER
REMOVAL
Drain the front rear brake fluid.
Remove the front rear stop switch.
Loosen the brake hose oil bolt.
Loosen the master cylinder holder bolt.
Remove the master cylinder.

! CAUTION
PIVOT
PIVOT
PIVOTBOLT
BOLT
BOLT BRAKE
BRAKELEVER
BRAKE LEVER
LEVER
Brake fluid causes damage to the painted, plastic or
rubber parts. Do not spill fluid on these parts.
If contaminated, gently wipe off the fluid with a piece
of cloth or wash in water. Close hose joints properly to
prevent leakage of brake fluid.
Clean the disassembled parts with brake fluid, and use
compressed air to verify each passage is not clogged.
Do not allow the disassembled parts to be
contaminated by waste material or dust.
MASTER
MASTER CYLINDER
MASTER CYLINDER
CYLINDER
DISASSEMBLY
Remove the front / rear stop switches.
Remove the piston boot, cir clip from the master
cylinder.
TOOL : SNAP RING PLIERS
MASTER
MASTERCYLINDER
MASTER CYLINDERSET
CYLINDER SET
SET Remove the washer piston spring from the master
cylinder.
STOP
STOPSW
STOP SW
SW Clean the master cylinder, reserve, master piston with
the recommended brake fluid.
LEVER
LEVER
LEVER
LEVER
BOOT
BOOT
BOOT CIRCLIP
CIR
CIR CLIP
CLIP MASTER
MASTER
MASTERCYLINDER
CYLINDER
CYLINDERBODY
BODY
BODY
15-11
BRAKE SYSTEM
INSPECTION
PISTON
PISTON
PISTON
Check the piston periphery for scores, scratches or
nicks replace if necessary.
Check the primary and secondary cups for wear.
SECONDARY
SECONDARY
SECONDARYCUP
CUP
CUP PRIMARY
PRIMARY
PRIMARY CUP
PRIMARYCUP
CUP
CUP

! NOTE
If there is any leak of fluid, when installing

new piston, it may indicate the side wear of the
cylinder by the direction of the piston
contacting face. In this case, the master
cylinder must be replaced also.
Check the master cylinder for scores, scratches or nicks

and replace if necessary.
OIL CUP CAP DIAPHRAGM ASSEMBLY

PLATE
BOOT
CIR CLIP

! CAUTION
DIAPHRAGM
SPRING Replace the piston, spring, cups and snap ring
as a set.
Be sure that each part is free from dust or dirt
WASHER
MASTER before reassembly.
CYLINDER BODY When cleaning with the brake fluid, use the
specified brake fluid.
LEVER STOP SW
Apply the recommendatory brake fluid to the cup,
cylinder and inside of cylinder, and install the spring,
primary cup, piston.

! CAUTION
When installing the cups, do not allow to close

the cup ends.
Install the spring with its smaller direction of
coil ends toward the piston.
Install the side of primary cup toward the
spring.
Install the cir clip to the master cylinder groove firmly.
TOOL : SNAP RING PLIERS
Install the boot to the master cylinder.
15-12
BRAKE SYSTEM
INSTALLATION
Install the front rear master cylinder to the handle.

! NOTE
Install the holder with its UP mark facing

upwards, and align the holder joint with the
BRAKE
BRAKEHOSE
BRAKE HOSEOIL
HOSE OILBOLT
OIL BOLT
BOLT punch mark on the handle bar.
Tighten the holder upper bolt first.
Install the brake hose to the master cylinder with 2 new

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

diaphragm plate and diaphragm.
Fill the brake fluid, and bleed air.
Install the diaphragm, diaphragm plate and the oil cup
cap, tighten the 2 flat screws.
BRAKE DISK
INSPECTION
Measure the brake disk for the thickness.

TOOL : MICRO METER
RR.
RR.
RR. BRAKE
RR.BRAKE DISK
BRAKEDISK
BRAKE DISK
DISK
FR.
FR.
FR. BRAKE
FR.BRAKE DISK
BRAKEDISK
DISK
Check the brake disk for wobbles.

FR.
FR.BRAKE
FR. BRAKEDISK
BRAKE DISK
DISK
SERVICE LIMIT : 0.02MM
TOOL : DIAL GAUGE
RR.
RR.
RR. BRAKE
RR.BRAKE DISK
BRAKEDISK
DISK
15-13
CHARGING SYSTEM
15A
16-0
CHARGING SYSTEM
16. CHARGING SYSTEM
SERVICE INFORMATION16-1 CHARGING SYSTEM INSPECTION 16-4

TROUBLESHOOTING 16-2 A.C. GENERATOR INSPECTION16-5
BATTERY 16-3 REGULATOR RECTIFIER INSPECTION 16-5
SERVICE INFORMATION

! WARNING
Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
during charging battery.
Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss of
eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with water and see a doctor.
If battery acid gets on clothing, as it can seep through or make a hole through the clothing and make its way to the skin,
make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes.

! CAUTION
This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take special
care when performing maintenance and especially when replacing parts. Not all regular battery equipment is
compatible with MF batteries.
When charging the battery, remove the battery from the frame and do not open stopper.
There is the possibility of damaging the regulator/rectifier, etc. if the terminal or coupler is separated/connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged state,
the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note here that the
battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced, leading to a loss in
battery strength.
It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited and
if a state develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develops where voltage is not created between the terminals, the regulator will not operate and excessive
voltage will develop in the battery and normal cell electrolytes will decrease.
If the vehicle is not used for a long period, make sure to chage the battery every three months. If not so, the battery
ability to store electricity is reduced.
For information on generator disassembly, refer to section 9.
16
SPECIFICATIONS
ITEM STANDARD VALUES
Capacity 12V - 10AH (MF)
BATTERY
Terminal-to-terminal voltage (When fully charged) 13.0 - 13.2V
Charging coil resistance value ( 20
C) 0.1 - 1.0
A.C.GENERATOR
rpm at charging start 1,500rpm
REGULATOR /
Regulator voltage 14.5 0.5V
RECTIFIER
TOOLS
DIGITAL TESTER, PVA MULTI-TESTER, RPM TESTER, BATTERY TESTER
16-1
CHARGING SYSTEM
TROUBLESHOOTING
No power (Key turned on) Low power (Engine running)

Dead battery. Battery undercharged.
-Low fluid level. Battery is failing.
-Low specific gravity. Charging system failure.
-Charging system failure.
Disconnected battery cable. Intermittent power
Main fuse burned out. Loose battery connection.
Faulty ignition switch. Loose charging system connection.
Loose starting system connection.
Low power (Key turned on) Loose connection or short circuit in ignition system.
Battery undercharged. Loose connection or short circuit in lighting system.
-Low fluid level.
-Low specific gravity. Charging system failure
Charging system failure. Loose, broken or shorted wire or connection.
Loose battery connection. Faulty regulator rectifier.
Faulty A.C generator.
CHARGING SYSTEM
Measure battery current leakage. INCORRECT

Check the regulator rectifier.
CORRECT CORRECT
Shorted harness wire.
Faulty ignition switch.
INCORRECT
Inspect the charging voltage. OVER 15V Faulty regulator rectifier.
UNDER 14V
14~15V Battery is failing
Check the voltage between the battery line and Open circuit in wire harness.
ABNORMAL
ground wire of regulator rectifier. Poorly connected coupler.
NORMAL
Check the resistance of the charging coil at INCORRECT Check the charging coil of theA.C
the charging coil line of regulator rectifier generator.
coupler.
NORMAL
Poorly connected A.C generator coupler.
CORRECT ABNORMAL
Faulty charging coil.
Check the regulator rectifier. ABNORMAL Faulty regulator rectifier.
NORMAL
Faulty battery.
16-2
CHARGING SYSTEM
BATTERY
BATTERY COVER
BATTERYCOVER
COVER
BATTERY
BATTERY COVER
REMOVAL
Loosen the screws securing the battery cover and
remove the battery cover.
SCREW
SCREW
SCREW
Remove the battery.

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

Remove the battery cable.
Disconnect the battery terminals from the battery.
Measure the voltage between the battery terminals.
FULLY CHARGED : 13.0-13.2V

INSUFFICIENTLY CHARGED : UNDER 12.3V
TOOL : DIGITAL TESTER

! NOTE
Use a voltmeter that will accurately indicate 0.1V

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

! NOTE
The rapid charging could be possible to reduce the

battery life and cause of damage.
Avoid the rapid charging except emergency.
Be sure to the battery charging is not allow to exceed
the specified changing time and current.
16-3
CHARGING SYSTEM
CHARGING SYSTEM INSPECTION

LEAK TEST
Trun off the ignition switch, and disconnect the ground
(-) cable from the battery.
Connect an ampere meter between negative (-) terminal
and ground cable.
With the ignition switch off, measure the leakage current.
LEAK CURRENT : Not to allow to exceed 0.5A

TOOL : DIGITAL TESTER

! NOTE
When measuring current using a tester, set it to a large

AMPERE METER range, and then bring it down the range to an
appropriate level.
Current flow larger than the range selected may blow
BATTERY TERMINAL
out the fuse in the tester.
While measuring current, do not turn the ignition on. A
sudden surge of current may blow out the fuse in the
tester.
EARTH CABLE
CHARGING VOLTAGE INSPECTION

! NOTE
Be sure that the battery is fully charged before

performing this test.
The amount of current flow may change abruptly if not
sufficiently charged. Use a battery whose voltage
between its terminals is 13.0 13.2V
If the brobes are connected in reverse order, the

registered current flow direction when charging and
discharging the battery will be reversed as well.
After warming up the engine, replace the battery with a
fully charged battery.
Connect a tester between the battery terminals.
Connect a RPM tester to the high-tension cord.
Start the engine, gradually increase the engine speed
and measure the charging voltage and charging current.
CHARGING CURRENT : 0~0.5A / 5,000rpm
CONTROL VOLTAGE : 14.50.5V / 5,000rpm
TOOLS : RPM TESTER, DIGITAL TESTER
MAIN FUSE
TERMINAL
! NOTE
Take precaution not to control the tester or wiring

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

AC
AC
ACGENERATOR
GENERATOR
GENERATORCOUPLER
COUPLER
COUPLER

! NOTE
This test can be made without removing the stator

from the engine. Disconnect the wellow wire from the
auto bystarter.
Release the rear under cover.

Disconnect the A.C generator connector.
Measure the resistance between the yellow wires.

AC
AC
AC GENERATOR
ACGENERATOR COUPLER
GENERATORCOUPLER
COUPLER Replace the stator if resistance value is high or there is
continuity between each yellow wire and ground.
Resistance : yellow~yellow 0.6~1.6
MAGNETIC
MAGNETIC
MAGNETICSW.
SW.
SW. WINKER
WINKER
WINKERRELAY
RELAY
RELAY REGULATOR RECTIFIER
INSPECTION
Remove the regulator rectifier coupler.
Measure each terminal.
EURO 2 Unit :
IGNITION
IGNITION
IGNITIONCOIL
IGNITION COIL
COIL R B Y Y Y G
R 0-5 1-3 1-3 1-3 1-4
B 25-40k
CDIUNIT
CDI
CDI UNIT
UNIT REGULATOR
REGULATOR
REGULATORRECTIFIER
RECTIFIER
RECTIFIER Y 1-4 1-4
Y 1-4 1-4
Y 1-4 1-4
REGULATOR
REGULATOR
REGULATORRECTIFIER
REGULATOR RECTIFIER
RECTIFIER
G 25-40k
EURO 3 Unit : , (20)

Tester
Tester
R G Y Y Y
R 28~36
G 28~36
Y
Y
Y
Replace the regulator rectifier unit if the resistance
value between the terminals is abnormal.
16-5

IGNITION SYSTEM
IGNITION SYSYTEM
SIDE STAND
SWITCH IGNITION
COIL SPARK
PLUG
MAIN
B/Y SW G
AC. G FUSE
GENERATOR (15A) G
HEADLIGHT RELAY
B/W
G/B
B/Y
B/Y
G
B
P
+ _
BATTERY
PULSE UNIT
(12V 10AH)
GENERATOR
17-0
IGNITION SYSTEM
17. IGNITION SYSTEM

SERVICE INFORMATION 17-1 IGNITION COIL INSPECTION 17-4
TROUBLESHOOTING 17-2 IGNITION TIMING INSPECTION 17-5
CDI UNIT 17-3 SIDE STAND IGNITION CUT-OFF
PULSE GENERATOR INSPECTION 17-3 SWITCH 17-5
SERVICE INFORMATION
GENERAL SAFETY
Follow the steps described in the troubleshooting flow chart when servicing the ignition system.
The CDI unit may be damage if dropped. Also, if the connector is disconnected when current is flowing, the excessive
voltage may damage the unit. Always turn off the ignition switch before servicing.
The CDI unit use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing.
Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine.
Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding.
This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are also
included, it may be difficult to make a correct determination.
Conduct inspection on the main switch by referring to the wiring diagram continuity chart. (SECTION 20)
SPECIFICATIONS
ITEM STANDARD VALUE
PRIMARY COIL 0.1 ~ 0.2
IGNITION COIL WITH PLUG CAP 7.3 ~ 11.0

RESISTANCE VALUE 20 SECONDARY COIL
WITHOUT PLUG CAP 3.6 ~ 4.6
PULSE GENERATOR COIL RESISTANCE VALUE 90 ~150

SPARK PLUG NGK CR8EH-9
SPARK PLUG GAP 0.8~0.9mm
TOOLS 17
DIGITAL TESTER
PVA MULTI-TESTER
DC-CDI TESTER
17-1
IGNITION SYSTEM
TROUBLESHOOTING
No spark at plug.
UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER)
1. The multitester impedance is too low.
2. Cranking speed is too slow.
- Battery is undercharged (or operating force of the kick starter is
weak).
3. The sample timing of the tester and measured pulse were not
IGNITION COIL PRIMARY VOLTAGE
Low peak voltage. synchronized. (System is normal if measured voltage is over the
standard voltage at least once.)
4. Poorly connected connectors or an open circuit in ignition system.
5. Faulty ignition system control circuit such as side stand switch.
6. Faulty ignition coil.
7. Faulty CDI unit (in case when above No. 1~6 are normal).
1. Incorrect peak voltage adaptor connections.

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

PULSE GENERATOR

Low peak voltage. weak).
synchronized.(System is normal if measured voltage is over the
No peak voltage. 1. Faulty peak voltage adaptor.

EXCITE COIL
Low peak voltage. weak).

synchronized.(System is normal if measured voltage is over the
No peak voltage. 1. Faulty peak voltage adaptor.
17-2
IGNITION SYSTEM
CDI
CDI
CDIUNIT
UNIT
UNIT CDI UNIT INSPECTION (EURO2)
CDI IGNITION CIRCUIT INSPECTION

! NOTE
Follow the steps described in the troubleshooting flow

chart when servicing the ignition system.
Release the seat lock with the main key.
Remove the rear under cover.
Disconnect the coupler from the CDI unit, and check the
ignition system circuits from the wiring coupler side.
Inspection Items
ITEM INSPECTION
CDI
CDI
CDIUNIT
UNIT
UNIT Check that there is battery voltage between
MAIN
main switch wire (black) and ground wire
SWITCH
when the ignition is ON
Check that the resistance of coil (between blue /
PULSE
yellow and green) is within the specified range.
GENERATOR
( 90~150) (20)
Check that the resistance of coil (between black
IGNITION COIL
(PRIMARY COIL) / yellow and green) is within the specified range.
( 0.1~0.2) (20)
GROUND WIRE Check continuity between ground and frame.
If there are a normality in the diagonosis above, and if
there is no spark at plug, check the CDI unit and
ignition coil by using a CDI tester.
TOOLS : CDI TESTER
DIGITAL TESTER

! NOTE
Read tester manual carefully prior to using the tester.

Replace the CDI unit if faulty.
PULSE GENERATOR INSPECTION

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

Remove the primary wire.

! NOTE
Since the resistance value of the primary coil is

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

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

between the primary coil terminal and the spark plug
cap.
If the resistance value is within the specified range,
IGNITION
IGNITION COIL
IGNITION COIL
COIL then the coil is good.
If the resistance is (open wire), disconnect the spark
plug cap and measure the secondary coil resistance.
STANDARD VALUE : 7.3~11.0
Without the spark plug cap, measure the resistance

between the primary coil terminal and high-tension
code.
If the resistance value is within the specified range,
then the coil is good.
If the resistance is (infinite), replace the coil with
new one.
IGNITION
IGNITIONCOIL
IGNITION COIL
COIL STANDARD VALUE : 3.6~4.6
FAN
FANSCREW
FAN SCREW
SCREW REPLACEMENT
Remove the high-tension cord from the plug, remove
IGNITION
IGNITION
the plug cap.
IGNITION COIL
IGNITIONCOIL
COIL
Remove the wire from the ignition coil.
Remove the primary wire from the ignition coil.
Loosen the ignition coil fixing bolt securing the frame,
Remove the ignition coil.
17-4
IGNITION SYSTEM
RH
RH
RHSHROUD
SHROUD
SHROUD IGNITION TIMING INSPECTION

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

need not be adjusted, Check the ignition system if the
ignition timing is incorrect.
Warm up the engine.
TIMING
TIMING
TIMINGHOLE
HOLE
HOLE

! NOTE
Read the instruction for timing light operation.

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

with the index mark on the case.
Increase the engine speed by turning the throttle stop
screw and make sure the F mark begins to move
counterclockwise when the engine speed at
approximately 4,000 rpm.
SIDE
SIDE
SIDESTAND
SIDE STAND SWITCH
STANDSWITCH
SWITCH SIDE STAND IGNITION CUT-
OFF SWITCH
INSPECTION
Remove the coupler of the side stand switch linked to
the wire.
SIDE
SIDE
SIDE STAND
SIDESTAND DOWN
STANDDOWN
STAND DOWN
DOWN
Check for continuity between the terminal as shown

SIDE
SIDESTAND
SIDE STANDSWITCH
STAND SWITCH
SWITCH
below;
ITEM TERMINAL SPECIFICATION

ON
GREEN AND NO
(Side stand is
BLACK/WHITE CONTINUITY
lowered)
SIDE
SIDE STAND
SIDE STAND UP
STAND UP
UP
OFF
GREEN AND
(Side stand is CONTINUITY
BLACK/WHITE
retracted)
17-5
STARTER SYSTEM
STARTER SYSTEM
STARTER
CABLE RELAY
CABLE
G/Y
STOP LAMP
G/Y
STARTER
Y/R M MOTOR
FRONT REAR STARTER
STOP STOP SWITCH
SWITCH SWITCH
G
MAIN
SWITCH FUSE
B
BATTERY
(12V 10AH
18-0
STARTER SYSTEM
18. STARTER SYSTEM
SERVICE INFORMATION 18-1 STARTER MOTOR 18-3

TROUBLESHOOTING 18-2 STARTER MAGNETIC SWITCH 18-6
SERVICE INFORMATION
GENERAL SAFETY

! WARNING
Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing
serious injury.
The starter motor can be maintained without removing the engine from the vehicle.
A weak battery may be unable to turn the starter motor quickly enough, or, supply adequate ignition current.
The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over.
The engine may not be turned over if the stop switch is faulty.
SPECIFICATION

STARTER MOTOR BRUSH LENGTH 10.2 mm 5 mm
TOOLS
DIGITAL TESTER
VERNIER CALIPER
18
18-1
STARTER SYSTEM
TROUBLESHOOTING
Starter motor will not turn.
Check for a blown main fuse before servicing.

Check that the stop light is correctly adjusted.
Check that the side stand is positioned in the condition under which the engine can be started.
Connect the starter motor (+) terminal to the

With the ignition switchONand squeeze battery positive terminal. (Because a large
the brake lever, check for a click sound CLICKS amount of current flows, do not use thin
from starter magnetic switch. (17-6) wires). (17-3)
Starter motor does not turn.

NO CLICK.
Starter motor turns.
Faulty starter motor.
Loose or disconnected
Disconnect starter magnetic switch coupler, wire or cable.
and check the starter magnetic switch coil
NO CONTINUITY. Faulty starter switch.
ground wire. (17-6)
Faulty side stand switch.
Loose or poor contact at connector.
CONTINUITY. Open circuit in wire harness.
Connect the starter magnetic switch coupler.

Measure the starter magnetic voltage at the NO VOLTAGE. Faulty ignition switch or starter switch.
starter magnetic switch coupler. (17-6) Loose or poor contact at connector.
Open circuit in wire harness.
VOLTAGE MEASURED.
Faulty brake stop switch.
Check the starter magnetic switch operation. NORMAL Loose or poor contact at starter magnetic
(17-7) switch coupler.
ABNORMAL Faulty starter magnetic switch.
Starter motor turns slowly.

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

Starter motor is running backwards.
-Brushes assembled improperly.
-Case assembled improperly.
-Terminals connected improperly.
Faulty starter clutch.
Damaged starter gear.
18-2
STARTER SYSTEM
STARTER
STARTER MOTOR
STARTERMOTOR
MOTOR STARTER MOTOR
STARTER
STARTER
STARTERMOTOR
MOTOR
MOTORCABLE
CABLE
CABLE
REMOVAL
Remove the starter motor cable from the starter

magnetic switch.
Loosen the 2 flange bolts securing the engine case,
remove the battery earth cable and starter motor.
FLANGE
FLANGE
FLANGEBOLT
BOLT
BOLT

! NOTE
Always turn the ignition switch OFF before servicing

the starter motor. The motor could suddenly start,
STARTERMOTOR
STARTER
STARTER MOTOR
MOTOR causing serious injury.
SETTING
SETTING
SETTINGBOLT
BOLT
BOLT Accurately tighten the battery earth cable.
DISASSEMBLY
Remove the starter motor cable.
Before disassembling the starter motor mark the
position of the case and cover so the starter can be
assembled correctly later.
Loosen the starter motor case bolts and remove the
motor cover.
ASSEMBLY
ASSEMBLY
ASSEMBLYMARK
MARK
MARK
INSPECTION
RR.
RR. BRACKET
RR.BRACKET
RR. BRACKET
BRACKET
Check for continuity of the starter motor case.
CORD
CORDTERMINAL
CORD TERMINAL
TERMINAL
-Between cord terminal and bracket: normal
if no continuity.
-Between cord terminal and brush : normal if there is
continuity.
If abnormal, replace with a new one.
BRUSH
BRUSH
BRUSH
BRUSH
BRUSH
BRUSH HODER
BRUSHHODER SET
HODERSET
SET
Loosen the brush terminal setting nut, remove the
BRUSH
BRUSH
BRUSHHODER
HODER
HODER brush holder set.
BRUSH
BRUSH
BRUSHHODER
HODER
HODER Check for continuity between and terminals
of the brush holder.
If there is continuity, replace with a new one.
18-3
STARTER SYSTEM
Remove the brush spring, and then remove the brush.
Measure the brush length. Replace the brush if it is
BRUSH
BRUSH
BRUSH
BRUSH worn beyond the service limit.
SERVICE LIMIT : 5 mm
TOOL : VERNIER CALIPER

! NOTE
If replacement, replace with a brush holder set.
Check the commutator for :

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

bars.
Make a continuity check between individual
commutator bars and the armature shaft.
There should be no continuity.
Check the needle bearing and oil seal.

OILSEAL
OIL
OIL SEAL
SEAL -Do not rotate smoothly. Replace with a new one.
-Damage oil seal. Replace with a new one.
NEEDLE
NEEDLE
NEEDLEBEARING
BEARING
BEARING
18-4
STARTER SYSTEM
STARTER MOTOR ASSEMBLY
BRUSH
BRUSH
BRUSH HOLDER
BRUSHHOLDER SET
HOLDERSET
HOLDER SET
SET Install the brush and brush spring to the brush hold set.
Insert the brush terminal into the rear bracket, and
install the terminal set and flange nut.
Align the brush holder set with the rear bracket
groove, and install the brush holder set.
Apply grease to both ends of the armature shaft, and
install the 2 washers.
Push and hold the brush inside the rear bracket, and
insert the armature into the rear bracket groove.
RR.
RR. BRACKET
RR. BRACKET
BRACKET
Align the yoke with the rear bracket mark, and install
the yoke to the amature.

! CAUTION
The sliding surfaces of the brushes can be damaged if

they are not installed properly.
When inserting the armature into the case, hold the
armature tightly to keep the magnet from pulling the
RR.
RR.BRACKET
RR. BRACKET
BRACKET armature against the case.
Align the front bracket with the yoke mark, and install
the front bracket.
Tighten the 2 set bolts.
MARK
MARK
MARK
FR.
FR.
FR.BRACKET
BRACKET
BRACKET YOKE
YOKE
YOKE RR.
RR.
RR.BRACKET
BRACKET
BRACKET

! CAUTION
When installing the cover, take care to prevent

damaging the oil seal lip with the shaft.
Overtightening the starter motor cable terminal nuts
may cause the inside the starter motor, resulting in
serious damage to the inner connectors.
SETTING
SETTING BOLT
SETTING BOLT
SETTING BOLT
BOLT
18-5
STARTER SYSTEM
STARTER
STARTER
STARTERMAGNETIC
MAGNETIC
MAGNETICSWITCH
SWITCH
SWITCH
STARTER MAGNETIC SWITCH
REMOVAL
Remove the center cover and battery cover.
Remove the battery (+) cable from the starter magnetic
switch terminal.
Remove the starter motor cable from the starter
magnetic switch terminal.
Disconnect the yellow / red connector and green /
yellow connector from the wire harness.
Remove the starter magnetic switch from the switch
setting bracket securing the frame.
STARTER
STARTERMAGNETIC
STARTER MAGNETICSWITCH
MAGNETIC SWITCH
SWITCH
INSPECTION
Check if the starter magnetic switch clicks when it is
turned ON.
-Clicks Poorly connected battery terminal and
motor terminal of the switch. (Check
the starter magnetic switch)
-No clicks No starter magnetic switch input
voltage. (Faulty relay ground line and
starter magnetic switch)
STARTER
STARTER
STARTERMAGNETIC
MAGNETIC
MAGNETICSWITCH
SWITCH
SWITCH
Starter magnetic switch voltage
Measure the voltage between the yellow / red wire (+)
and ground at the starter magnetic switch connector.
If battery voltage appears only when the starter switch

is pressed, it is normal.
Starter magnetic switch ground line

Disconnect the wire connector from the starter
magnetic switch and check for continuity between the
ground wire (green / yellow) and ground.
18-6
STARTER SYSTEM
OPERATION CHECK
Disconnect the magnetic switch wire connector.
Apply battery voltage between terminals, when the
yellow / red wire is connected to the positive (+)
battery terminal and the green / yellow wire to the
negative (-) battery terminal.
If there is continuity between battery and motor

terminal, it is normal.
18-7
MEMO

LIGHTS/SWITCHES/HORN
19. LIGHTS/SWITCHES/HORN
SERVICE INFORMATION 19-1 SPEEDOMETER 19-3

TROUBLESHOOTING19-1 MAIN SWITCH 19-4
HEADLIGHT 19-2 HANDLE BAR SWITCH 19-4
FRONT WINKER 19-2 HORN SWITCH 19-5
REAR TAIL LIGHT 19-3 FRONT/REAR STOP SWITCH 19-5
REAR WINKER 19-3 FUEL GAUGE19-6
SERVICE INFORMATION
GENERAL SAFETY
Connect the same color wires together. Connect couplers carrying the same color and the same number of pins together.
All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert these
tabs all the way until locked when assembling.
Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester or
an ohmmeter to the coupler terminals or connectors.
The continuity test is conducted to check if electric power is connected between 2 terminals. If there is coil resistance
within circuits, or to check the large resistance resulting form the connector corrosion, an ohmmeter is required to check
the circuit resistance value.
TROUBLESHOOTING
Light not turned on when the main switch is ON Fuel meter indicator malfunctioning
Faulty light bulb Coupler separated.
Faulty switch Harness disconnected.
Faulty or disconnected wiring Float operation malfuction.
Fuse cut Fuel unit damaged.
Battery discharged
Fuel meter needle unstable
Dim headlight Coupler loose.
Battery discharged Fuel unit damaged.
Wiring and switch resistance high Meter damaged.
Headlight Hi-Low bean cannot be charged

Faulty light bulb
Faulty dimmer switch
19
19-1
HEADLIGHT BULB
REMOVAL
Loosen the washer screw securing the headlight.
HEAD
HEAD
HEADLIGHT
LIGHT
LIGHT Disconnect the headlight wiring.
BULB REPLACEMENT
WASHER
WASHER
WASHERSCREW
SCREW
SCREW
Pull off the headlight socket.
Replace with a new bulb.
HEAD
HEAD LIGHT
HEAD LIGHT SOCKET
LIGHT SOCKET
SOCKET

! NOTE
When replacing the bulb, be sure not to put

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

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

! NOTE
TAIL
TAIL&&&STOP
TAIL STOPBULB
STOP BULB
BULB Pay attention not to damage the lens.
Do not apply excessive force when removing
the lens.
REAR
REAR
REAR WINKER
REARWINKER
WINKER Check the installation of the tail light and lens
seal accurately.
REAR WINKER
BULB REPLACEMENT
Press the lock on the side of the winker base and
remove the rear winker cover.
Remove the winker lens.
Remove the bulb from the socket and replace with a
new bulb.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER SPEEDOMETER
REMOVAL
Remove the headlight.
Remove the wiring coupler and speedometer cable.
Loosen the flange bolt securing the pilot box on the
inner box and remove the speedometer set.
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER Loosen the bolt securing the pilot box from the
PILOT
PILOT
PILOTBOX
BOX
BOX speedometer set and remove the speedometer assembly.
19-3
MAIN
MAIN SWITCH
MAINSWITCH
MAIN SWITCH
SWITCH
MAIN SWITCH
REMOVAL
Remove the front cover.
Disconnect the ignition switch wire couplers.
Check for continuity between the wire terminal.

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

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

FUEL
FUEL
FUELGAUGE
FUEL GAUGE
GAUGE Check the base packing for damage.
BASE
BASE
BASEPACKING
PACKING
PACKING
Inspect the fuel gauge.
FUEL GAUGE
FUEL E ETC
THERMISTER
OFF
FUEL CHECK 1.2 L
COLOR YELLOW/WHITE GREEN
19-6
MEMO

MEMO

WIRING DIAGRAM
0-1. WIRING DIAGRAM (EURO-2)

WIRING DIAGRAM
0-2. WIRING DIAGRAM (EURO-3)

SERVICE MANUAL
2009. 02 PRINTED
COPY PROHIBIT
2009. 02 PUBLICATION


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com manuals search engine

Rear Wheel / Suspension /

Lights / Switches / Horn 19

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SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

"( )" MARKED CONTENTS APPLY TO EURO 2 ONLY

TYPE / VENTURI BORE CV type ( vacuum ) / '24.2 mm

CLUTCH TYPE Automatic Transmission

IGNITION SYSTEM ECU (C.D.I)

OPEN TYPE MANUFACTURERS NAME, BEARING No.

CAUTION WHEN WIRING

WHITE / RED CORD

Insert the lock of the coupler until the lock is fully

DRAINING HOLE WIRING DRIVER GROOVE SIDE

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Check the element, if it is dirty or damaged replace it.

The air cleaner element made of dry process paper

CHECK GAP, Remove the spark plug maintenance cover.

- Floor panel ass'y.

spark plug maintenance.

Make sure that the oil sealing washer is good

TAPPET ADJUSTING HOLE CAP

DRIVE FACE DRIVE

If the brake pad is worn severely brake fluid level

BRAKE PAD BRAKE PAD

CONTROL CABLE LUBRICATION

RR. BRAKE LEVER PIVOT

STEERING HEAD BEARING

WHEEL BEARING / SPEDOMETER GEAR WHEEL BEARING

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SERVICE INFORMATION 3-1 SEAT SUPPORT PIPE 3-6

This chart shows arrows connected in the order of disassembling covers.

INNER BOX SEAT CENTER COVER UNDER COVER

FR. COVER RR. FENDER TRUSS PIPE RR. WHEEL MUDGUARD

FR. FENDER RR. UPPER COVER FLOOR SIDE COVER

FR. WHEEL RR. UNDER COVER BATTERY COVER

FR. UNDER COVER SEAT SUPPORT PIPE FLOOR PANEL

Release the lock by turning the cap securing the

Remove the speedometer cable, headlight

Remove the speedometer cable and

Loosen the 3 special screw securing the front

Remove the front under cover.

FLOOR SIDE COVER

Remove the center cover.

REAR WHEEL MUD GUARD

Remove the inner box.

Remove the speedometer cable.

Replace the packing when assemblying the muffler

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Low or no oil pressure

Close oil valve relief.

TORQUE VALVE : 1.4kgf m

5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS 5-2

1. CAUTION WHEN REPAIRING THE EMS PARTS.

While engine operating, do not disassembly the battery terminal.