Service Manual Access450
Service Manual Access450
GENERAL INFORMATION
GENERAL INFORMATION
SERIAL NUMBER---------------------------------------------------------------1-1
PECIFICATIONS-----------------------------------------------------------------1-2
SERVICE PRECAUTIONS-----------------------------------------------------1-3
TORQUE VALUES--------------------------------------------------------------1-11
SPECIAL TOOLS----------------------------------------------------------------1-12
LUBRICATION POINTS-------------------------------------------------------1-13
CABLE & HARNESS ROUTING--------------------------------------------1-17
WIRING DIAGRAM (ON ROAD)--------------------------------------------1-23
TROUBLESHOOTING---------------------------------------------------------1-24
1-1
1.GENERAL INFORMATION
SERIAL NUMBER
1-2
1.GENERAL INFORMATION
SPECIFICATIONS
Name & model No. SP450 Air cleaner type&No Dry type element
Fuel System
Motorcycle Name & Type SPEED Fuel capacity 14 L
Overall length 1825 mm (71.8 in) Type BDS42
etor
Carbur
Overall width (mm) 1205 mm (47.4in)
Main jet NO. 162.5
Overall height (mm) 1255 mm (49.4 in)
Wheel base (mm) 1270 mm (50 in) Venture dia. ψ42 mm (1.65 in)
Engine type Four-stroke, DOHC, Type Full transistor digital
Electrical equipment
Ignition System
Liquid-cooled ignition
Ignition timing 6˚BTDC/1500rpm
Displacement 248.8 cm³ Spark plug CR8E
Fuel Used 95# nonleaded gasoline Spark plug gap 0.7~0.8mm (0.028~0.032in)
Dry weight Front wheel 109 kg (240 lbs)
Rear wheel 110 kg (242 lbs)
Battery Capacity 12V/10AH
Total 219 kg (482 lbs)
Curb weight Front wheel 111 kg (224 lbs) Clutch Type Wet multi-plate
Rear wheel 118 kg (260 lbs) operation 5-forward and 1-reverse
-sion
Transmis
Total 229 kg (504 lbs) Type
Tires Front wheel 21*7-10
Rear wheel 20*11-9
Power Drive System
Ground clearance 260 mm (10.2 in) Forward 1-down 4-up, foot operated
pattern
Gearshift
type
Rear Linkage-type
1-3
1.GENERAL INFORMATION
SERVICE PRECAUTIONS
1-2
1.GENERAL INFORMATION
1-3
1.GENERAL INFORMATION
1-4
1.GENERAL INFORMATION
1-5
1.GENERAL INFORMATION
1-6
1.GENERAL INFORMATION
1-7
1.GENERAL INFORMATION
1-8
1.GENERAL INFORMATION
Symbols:
the following symbols represent the
servicing methods and cautions included
in this service manual.
Engine oil
Grease
Gear Oil
:Caution
:Warning
1-9
1.GENERAL INFORMATION
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque Item Torque
kgf-m (N-m, lbf-ft) kgf-m (N-m, lbf-
ft)
5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2)
6mm bolt and nut 1 (10, 7.2) 5mm screw 0.4 (4, 2.9)
8mm bolt and nut 2.2 (22, 16) 6mm screw, SH bolt 0.9 (9, 6.5)
10mm bolt and nut 3.5 (35, 25) 6mm flange bolt and nut 1.2 (12, 9)
12mm bolt and nut 5.5 (55, 40) 8mm flange bolt and nut 2.7 (27, 20)
14mm bolt and nut 7 (70, 50) 10mm flange bolt and nut 4 (40, 29)
Torque specifications listed below are for important fasteners.
ENGINE
Item Q’ty Thread dia Torque Remarks
(mm) kgf-m (N-m, lbf ft)
Water temperature switch. 1 10 1.3 (13, 9.4)
Coolant drain bolt. 1 6 1.1~1.4 (11~14, 8~10)
Cooling fan thermo mounting bolt. 1 10 1.3 (13, 9.4)
Magneto rotor nut. 1 12 12 (120, 86.8)
Magneto cover bolt. 8 6 1.0 (10, 7.2)
Cylinder head bolt. 4 10 4.7 (47, 34)
Cylinder head cover bolt. 3 7 1.4 (14, 10)
Cylinder head base bolt. 1 6 1.0 (10, 7.2)
Cylinder base nut. 2 6 1.0 (10, 7.2)
Engine sprocket bolt. 2 6 1.1~1.3(11~13, 8~9.4)
Engine oil check plug. 1 12 1.8(18, 13)
Engine oil drain plug. 1 14 2.1(21, 15) Crankcase
Engine oil drain plug. 1 14 1.2(12, 8.7) Oil tank
Engine oil inlet hose union bolt. 1 12 2.3(23, 16.6)
Spark plug. 1 12 1.1 (11, 8)
Camshaft housing bolt. 8 6 1.0 (10, 7.2)
Cam chain tensioner mounting bolt. 1 6 1.0 (10, 7.2)
Cam chain tension adjuster mounting bolt. 2 6 1.0 (10, 7.2)
Cam chain tension adjuster bolt. 1 6 2.0(20, 14.5)
Crankcase bolt. 10 6&8 1.1 (11, 8)
Clutch sleeve hub nut. 1 20 9.0(90, 65)
Primary drive gear nut. 1 14 14(140, 101)
Gearshift cam stopper. 1 6 3.2(32, 23)
Gear position switch bolt. 1 5 0.65(6.5, 4.7)
FRAME
1-10
1.GENERAL INFORMATION
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Clutch sleeve hub holder 71600-E12-000 4-5,9-5
Valve spring compressor 71605-E12-000 7-12
Rotor remover 71604-E12-000 9-9
Conrod holder 71612-E12-000 9-9,9-30,9-31
Crankshaft installer 71613-E12-000 9-26
Crank case separator 71607-E03-000 9-11,9-13
Bearing puller 71606-E10-000
Ball join remover 71608-A03-000 12-9
Oil seal and bearing install 71620-E10-000 12-6
1-11
1.GENERAL INFORMATION
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part Engine Oil (SAE10W-40)
Cam lobes API SL Engine Oil
Valve rocker arm friction surface
Cam chain -22 -4 14 32 50 68 86 104°F
20W50
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves 15W40 15W50
Piston pin surroundings 10W40 10W50
Cylinder inside wall
10W30
Connecting rod/piston pin hole
5W30
Connecting rod big end
Crankshaft right side oil seal
Oil pump drive chain
Balance gear -30 -20 -10 0 10 20 30 40°C
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip
1-12
1.GENERAL INFORMATION
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
Abnormal noise and rise the durability of the ATV.
1-13
1.GENERAL INFORMATION
Driven Sprocket
Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing
1-14
1.GENERAL INFORMATION
(6) Drive shaft joint spline (5) Rear brake pedal and rod link
1-15
1.GENERAL INFORMATION
Blink Relay
Parking Cable
Throttle Cable
1-16
1.GENERAL INFORMATION
Battery Cable
Main Wire Ass’y
Cable,Manual Choke
1-17
1.GENERAL INFORMATION
Water Hose
Inlet Water Hose
1-18
1.GENERAL INFORMATION
Hose,Foot brake
Hydraulic Pump
1-19
1.GENERAL INFORMATION
Speed Cable
1-20
1.GENERAL INFORMATION
Fuse Box
Starter Relay
Starter Motor
Battery Cable
Ground Wire
1-21
1-22
OPTI ON EQUI PMENT
RH. FR. LEDWI NKER
(12V 0.82W) HAND BRAKE. FOOT BRAKE
FAN MOTOR
COMB. SW. FUSE DC POWER OUTLET ENG.STOP SWI TCH THERMO.SW
C.D.I UNIT
(CDI ) THERMO.UNI T START MAG. SW. START MOTOR BATTERY(MF)
12V 10AH
DG DG
BAT
B B
15A
POSITI ON BULB
(12V 5W)
G /Y
G /Y
M
BR
BR
BR
L /W
B
Lb
Lb
R /W
G /Y
BR
BR
L
O /B
R
BR
B
O /W
L /Y
R
B /Y
Lb
B
B
O
W /L
BR
G /Y
BR
BR
BR
L
G /Y
BR
G /Y
L /W
HEAD LI GHT BULB
O /W
R
BY
RH. RR. LED WINKER
1.GENERAL INFORMATION
(12V 0.82W)
B
DG
R-WIPI LOT
NKER Dg Dg
G /Y
L-WINKER DBr DBr B rB
PI LOT
HI GH Y Y
BEAM LED TAI L/STOP LI GHT
CLOCK R (12V 2.2W/4.2W)
RPM L B /Y
SWI TCH KEY BR Br B
DBr
LH. RR. LED WI NKER
(12V 0.82W)
SENSOR G
SENSOR
+5V
Br
Pr SPEEDOMETER MAGNET
FUEL Y /W Y /W
METER SENSOR
B /Y
BR
Lb L /Y
Y /W
TEMPERATURE
B
PI LOT
Lb
NEUTRAL GY
B
PILOT
Y /W
O
G
REVERSE
ND
PI LOT W /L
GND
WIRING DIAGRAM (ON ROAD)
L
G
Y
Y
Y
O R
B R /W
COMB. METER ASS' Y
DBR
DG
L /W
Br
B
P
L
Y
G
B
P
R /W
B
Y
Y
Y
FUEL UNI T I G. COI L CHANGE SW.
Max.=30A M ACG.
B R /W
Br
a x .= 2 8 0 W
B
B /L
L /W
B R /W
Br
LED
DG
Y
L
G
FLUSHER HORN EARTH REG./REC.
ST SG HO ACC R WR L ACC Hi LO RELAY
COMB.SW.
START
SW. HORN
SW. WI NKER
SW. DI MMER
SW.
LEFT SWI TCH
(12V 0.82W) HORN Br P WI NKER Br/W DBR DG DI MMER L G Y
LH. FR. LED WI NKER PUSH
DBr FREE
B START B/L L/W
WARNI NG Br/W DBR DG
PUSH
FREE
1.GENERAL INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Compression too low
1. Valve clearance out of adjustment. Adjust
2. Worn valve guides or poor seating Repair or replace
of valve.
3. Valves mistiming. Adjust
Replace
4. Piston rings excessively worn.
5. Worn-down cylinder bore. Replace or rebore
6. Poor seating of spark plug. Retighten
7. Starter motor cranks but too slowly. Consult “electrical
Plug not sparking complaints”
1-23
1.GENERAL INFORMATION
Complaint
Noise appears to come from piston
1. Piston cylinder worn down. Replace
2. Weakened or broken valve springs. Replace
3. Worn down piston pin or piston pin Replace
bore.
4. Piston rings or ring groove worn. Replace
Noise seems to come from camshaft
drive chain
1. Stretched camshaft drive chain. Replace
2. Worn camshaft sprockets. Replace
3. Cam chain tensioner adjuster not Repair or replace
Noisy engine working.
Noise seems to come from clutch
1. Worn splines of countershaft or hub. Replace
2. Worn teeth of clutch plates. Replace
3. Distorted clutch plates, driven and Replace
drive.
Noise seems to come from crankshaft
1. Worn or broken bearings.
2. Big-end bearings worn and broken. Replace
3. Thrust clearance too large. Replace
Noise seems to come from Replace
transmission
1. Gears worn or rubbing.
2. Badly worn splines. Replace
3. Primary gears worn or rubbing. Replace
4. Badly worn bearings. Replace
Noise seems to come from water Replace
pump
1. Too much play on pump shaft
bearing. Replace
2. Worn or damaged impeller shaft.
3. Contact between pump case and Replace
impeller. Replace
Complaint
1-24
1.GENERAL INFORMATION
1-25
1.GENERAL INFORMATION
1-26
2.FRAME COVERS/EXHAUST MUFFLER
2-1
2.FRAME COVERS/EXHAUST MUFFLER
2-2
2.FRAME COVERS/EXHAUST MUFFLER
SERVICE INFORMATION
GENERAL INSTRUCTIONS
When removing frame covers, use special care not to pull them by force because the cover joint
claws may be damaged.
Make sure to route cable and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler lock bolt 4.0 kgf-m (40 Nm, 29 lbf-ft)
Exhaust muffler lock nut 2.0 kgf-m (20 Nm, 14.4 lbf-ft)
TROUBLESHOOTING
Noisy exhaust muffler
Damaged exhaust muffler
Exhaust muffler joint air leaks
Lack of power
Caved exhaust muffler
Exhaust muffler air leaks
Clogged exhaust muffler
2-3
2.FRAME COVERS/EXHAUST MUFFLER
FRAME COVERS
SEAT
REMOVAL
Pull the lever rear and pull up the seat at
the rear.
Remove the seat.
Lever
Seat
INSTALLATION
To install the seat, align the tabs on the seat
with the grommets on the frame and press
the seat down until it locks.
RIGHT/LEFT FOOTBOARD
(1) 2-4
2.FRAME COVERS/EXHAUST MUFFLER
REMOVAL/INSTALLATION
Remove the engine under cover (1).
Nylon net
*
During removal, do not pull the joint
Claws forcedly to avoid damage.
Nerfbar
Bolts
Screw
Footrest
Holder, Footrest
Remove 2 Bolts.
2-5
2.FRAME COVERS/EXHAUST MUFFLER
Bolts
Footrest
Plastic Rivet
Bolt Bolt
2-6
2.FRAME COVERS/EXHAUST MUFFLER
Screw Screw
Bolts
2-7
Bolts Bolts
2-8
Fixing bracket
2.FRAME COVERS/EXHAUST MUFFLER
Screws
2-9
2.FRAME COVERS/EXHAUST MUFFLER
EXHAUST MUFFLER
REMOVAL/INSTALLATION
Remove the exhaust pipe joint nuts.
Joint Nuts
Bolts
Spring
2-10
3.INSPECTION/ADJUSTMENT
INSPECTION/ADJUSTMENT
SERVICE INFORMATION 3-1
MAINTENANCE SCHEDULE 3-2
FUEL LINE/THROTTLE OPERATION/AIR CLEANER 3-3
SECONDARY AIR SUPPLY SYSTEM/SPARK PLUG 3-6
VALVE CLEARANCE 3-7
CARBURETOR IDLE SPEED/IGNITION TIMING 3-10
CYLINDER COMPRESSION/ OIL PRESSURE 3-11
ENGINE OIL AND OIL FILTER 3-12
OIL FILTER REPLACEMENT 3-14
BRAKE PADS INSPECTION 3-15
BRAKE FLUID INSPECTION/HEADLIGHT AIM 3-16
STEERING SYSYEM INSPECTION 3-17
TOE-IN ADJUSTMENT 3-18
WHEEL/TIRES 3-19
DRIVE CHAIN SLACK 3-21
CABLE INSPECTION AND LUBRICATION 3-22
REAR SUSPENSION LUBRICATION 3-22
COOLING SYSTEM 3-23
CLUTCH ADJUSTMENT 3-24
FRONT & REAR SUSPENSION 3-25
3-1
3.INSPECTION/ADJUSTMENT
SERVICE INFORMATION
GENERAL
WARNING
Before running the engine, make sure that the working area is well-ventilated. Never run the
engine in a close area. The exhaust contains poisonous carbon monoxide gas which may
cause death to people.
Gasoline is extremely flammable and is explosive under some conditions. The working area
must be well-ventilated and do not smoke or allow flames or sparks near the working area or
fuel storage area.
SPECIFICATIONS
ENGINE
Throttle grip free play: 3~5 mm (0.12~0.20 in)
Spark plug gap : 0.7~0.8 mm (0.028~0.032 in)
Spark plug : Standard : CR8E
Valve clearance : IN: 0.10~0.20 mm (0.004~0.008in)
EX: 0.20~0.30 mm (0.008~0.012in)
Idle speed : 1800± 100rpm
Engine oil capacity:
At disassembly : 2.7 liter
At change : 2.5 liter
TIRE PRESSURE
1 Rider
Front 0.32 kgf/cm² (35 Kpa, 5 psi)
Rear 0.32 kgf/cm² (35 Kpa, 5 psi)
TIRE SIZE:
Front : 21*7-10
Rear : 20*11-9 or 20*11-10
TORQUE VALUES
Front wheel nut 4.5 kgf-m (45 Nm, 32 lbf-ft)
Rear wheel nut 4.5 Kgf-m (45 Nm, 32 lbf-ft)
3-2
3.INSPECTION/ADJUSTMENT
MAINTENANCE SCHEDULE
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if followed, will ensure more reliable
vehicle operation and a longer service life. The need for costly overhaul work will be greatly
reduced. This information applies to vehicles already in service ad well as new vehicles that are
being prepared for sale. All service technicians should be familiar with this entire chapter.
ITEM INITIAL EVERY
WHICHEVER COMES FIRST
mi 100 600 1200
ROUTINE MONTH 1 6 12
Engine oil Replace (Warm engine before draining) ○ ○ ○
3-3
3.INSPECTION/ADJUSTMENT
FUEL LINE
Check the fuel tubes and replace any parts, Fuel Tubes
which show signs of deterioration, damage
or leakage.
* Do not smoke or allow flames or sparks
In your working area.
Oil pump
THROTTLE OPERATION
Check the throttle to swing for smooth Cable adjuster Lock nut
movement.
Measure the throttle to swing free play.
Free Play (A): 3~5 mm (0.12~0.20 in)
(2)
AIR CLEANER
AIR CLEANER REPLACEMENT
Remove the seat. (See page 2-3)
Unlatch the four retainer clips (1) and
Remove the air cleaner cover (2).
(1)
3-4
3.INSPECTION/ADJUSTMENT
3-5
3.INSPECTION/ADJUSTMENT
3-6
3.INSPECTION/ADJUSTMENT
Spark Plug
3-7
3.INSPECTION/ADJUSTMENT
Cracks,Damage
Washer Deformation
VALVE CLEARANCE
* Inspect and adjust valve clearance while
the engine is cold (below 35℃).
The piston must be at top dead center
(TDC) on the compression stroke in order
to check or adjust the valve clearance.
Bolts Bolts
Remove the spark plug.
Disconnect the pressure release hose
3-8
1 2
Remove the valve timing inspection plug 1.
Remove the magneto cover cap 2.
3-9
3.INSPECTION/ADJUSTMENT
If the clearance is out of specification, first remove the cam chain tension adjuster, camshaft housing,
camshaft.
To install the tappet shim at original position, record the shim NO. and clearance to present by
“A”,“B”,“C”,“D” mark on the cylinder head.
Select the tappet that agree with tappet clearance (vertical line) and shim NO. (horizontal line) as
refer to the tappet shim selection chart. (Refer to page 9-38&9-39)
Adjust valve timing; install the camshaft housing and the tension adjuster.
After the crankshaft rotate about 10 times, measure the valve clearance.
If the clearance be not correct, adjust the standard clearance as the same manner above.
In case of valve adjustment which is not the tappet shim selection chart, please follow instructions of
example in the below.
For example, the intake clearance is 0.4 and the shim is 270 (2.70 mm), select 295 (2.95 mm) of the
shim which 270 (2.70 mm) of the shim add up standard 0.15 as the intake standard
clearance0.1~0.2mm
A B
3-10
3.INSPECTION/ADJUSTMENT
C D
IGNITION TIMING
* Before removing the camshaft housing,
(1)
the piston must be at TDC of the
compression storke. (2)
3-11
3.INSPECTION/ADJUSTMENT
CYLINDER COMPRESSION
Warm up the engine before compression
test.
Remove the spark plug.
Insert a compression gauge.
Open the throttle valve fully and push the
starter button to test the compression.
Compression: 16 kg/cm²
If the compression is low, check for the
Following:
- Leaky valves
- Valve clearance too small
- Worn piston rings Compression Gauge
- Worn piston/cylinder
If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.
OIL PRESSURE
Check the engine oil pressure periodically. This will give a good indication of the condition of the
moving parts.
If the oil pressure is lower or higher than the specification, the following causes may be
considered.
Low oil pressure: High oil pressure:
Clogged oil filter Engine oil viscosity is too high
Oil leakage from the oil passage Clogged oil passage
Damaged O-ring Combination of above items
Defective oil pump
Combination of above items
3-12
3.INSPECTION/ADJUSTMENT
3-13
3.INSPECTION/ADJUSTMENT
(A)
(5)
3-14
3.INSPECTION/ADJUSTMENT
3-15
3.INSPECTION/ADJUSTMENT
3-16
3.INSPECTION/ADJUSTMENT
Upper
Lower
adjusting screw
HEADLIGHT AIM
Turn the ignition switch ON and start the
engine.
Turn on the headlight switch.
Adjust the headlight aim by turning the
Headlight aim adjusting screw.
3-17
3.INSPECTION/ADJUSTMENT
STEERING SYSTEM
INSPECTION
Place the machine on a level place.
Check the steering column bushings
Move the handlebar up and down, and/or
back and forth.
Replace the steering column bushings and
if excessive play.
Tie-rod Ends
3-18
3.INSPECTION/ADJUSTMENT
TOE-IN ADJUSTMENT
Place the machine on a level place.
Measure the toe-in
Adjust if out of specification. Front
Toe-in measurement steps:
Mark both front tread centers
Raise the front end of the machine so that
there is no weight on the front ahead.
Measure the width A between the marks.
Rotate the front tires 180 degrees until the
marks come exactly opposite.
Measure the width B between the marks.
Calculate the toe-in using the formula given
below.
Toe-in = B-A
Toe-in : 0~10 mm
If the toe-in is incorrect, adjust the toe-in
Tie-rod
Adjust the toe-in step:
Mark both tie-rods ends.
This reference point will be needed during
adjustment.
Loosen the lock nuts (tie-rod end) of both
tie-rods
The same number of turns should be given
To both tie-rods right and left until the
Specified toe-in is obtained, so that the
lengths of the rods will be kept the same.
Tighten the rod end locknuts of both
Tie-rods
Tie-rod End Nuts
Torque: 3.0 kgf-m (30 Nm, 22 lbf-ft)
3-19
3.INSPECTION/ADJUSTMENT
*
Be sure that both tie-rod are turned the Tie-rod
same amount. If not, the machine will
drift right or left even though the
handlebar is positioned straight which
may lead to mishandling and accident.
After setting the toe-in to specification,
run the machine slowly for some
distance with hands placed lightly on
the handlebar responds correctly. If not,
turn either the right or left tie-rod
within toe-in specification.
TIRE PRESSURE
1 Rider
Front 0.32 kgf/cm² (35 kpa, 5 psi)
Rear 0.32 kgf/cm² (35 kpa, 5psi)
TIRE SIZE
Front : 21*7-10
Rear : 20*11-9 or 20*11-10
Front Axle Nuts
Check the front axle nut for looseness.
3-20
3.INSPECTION/ADJUSTMENT
WHEEL INSPECTION
Inspect the wheel.
Replace if damage.
Always balance the wheel when a tire or
wheel has been changed or replaced.
3-21
3.INSPECTION/ADJUSTMENT
(B)Bolts
Adjust the nut (C) to proper tightness.
Fastening the bolt(B).
Torque:
bolts(B) :7.0kgf-m (70 Nm, 50 lbf-ft)
Nut (C)
3-22
3.INSPECTION/ADJUSTMENT
LEVER LUBRICATION
Lubrication the pivoting parts of each lever.
REAR SUSPENSION
LUBRICATION
Inject grease into the nipples using a grease
gun until slight over flow is observed from Nipple
the thrust covers.
3-23
3.INSPECTION/ADJUSTMENT
CLUTCH ADJUSTMENT
3-24
3.INSPECTION/ADJUSTMENT
3-25
3.INSPECTION/ADJUSTMENT
Rear
3-26
3.INSPECTION/ADJUSTMENT
(2)
To adjuster the tension damping force turn in
the adjuster (2) fully for “S” or “F” direction
(counter –clockwise or clockwise).
Count the number of turns from the fully
turned-in position.
Fully turned-in “F” direction (or clockwise)
provides stiffest tension damping force and
turning “S” direction (or counter –clockwise)
the adjuster will soften compression damping force.
3-25
3.INSPECTION/ADJUSTMENT
REAR (3)
To adjuster the compression damping force
turn in the adjuster (3) fully for “S” or “H”
direction (counter –clockwise or clockwise).
Count the number of turns from the fully
turned-in position.
Fully turned-in “H” direction (or clockwise)
provides stiffest compression damping force
and turning “S” direction (or counter –clockwise)
the adjuster will soften compression damping force.
(4)
To adjuster the tension damping force turn in
the adjuster (4) fully for “S” or “F” direction
(counter –clockwise or clockwise).
Count the number of turns from the fully
turned-in position.
Fully turned-in “F” direction (or clockwise)
provides stiffest tension damping force and
turning “S” direction (or counter –clockwise)
the adjuster will soften compression damping force.
* Unequal front suspension adjustment can cause poor handing and loss of stability.
Be sure to adjust the compression and tension damping force on right and left front shock
absorbers to the same setting.
3-28
4.LUBRICATION SYSTEM
LUBRICATION SYSTEM
SERVICE INFORMATION 4-2
TROUBLESHOOTING 4-2
ENGINE OIL/OIL FILTER 4-3
OIL PUMP 4-3
4-1
4.LUBRICATION SYSTEM
LUBRICATION SYSTEM
4-2
4.LUBRICATION SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Use care when removing and installing the oil pump not to allow dust and foreign matters to
enter the engine and oil line.
Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it
reaches its service limit.
After the oil pump is installed, check each part for oil leaks.
SPECIFICATIONS
Item Standard Note
Oil pressure 1.0~3.0kgf/cm2 -----
(at 60°C, 3,000 rpm)
Oil pump reduction ratio 1.3 (45/34) -----
TROUBLESHOOTING
Oil level too low Poor lubrication pressure
Natural oil consumption Oil level too low
Oil leaks Clogged oil filter or oil passages
Worn or poorly installed piston rings Not use the specified oil
Worn valve guide or seal
SPECIAL TOOLS
Clutch sleeve hub holder 71600-E12-000
4-3
4.LUBRICATION SYSTEM
OIL PUMP
REMOVAL
Remove the magneto cover.
(1)
4-4
4.LUBRICATION SYSTEM
(1)
(3)
4-5
4.LUBRICATION SYSTEM
(3)
(2)
Special
Special
4-6
4.LUBRICATION SYSTEM
4-7
(2)
4.LUBRICATION SYSTEM
(3)
INSPECTION
Remove the outer rotor (1), inner rotor (2) (1)
and pin (3).
Inspect the outer rotor (1) and inner rotor (2)
for any scratches or other damage.
4-8
(3)
(2)
4.LUBRICATION SYSTEM
*
The oil pump case securing screw (4) is (4)
applied with thread lock.
If an attempt is made to overhaul the
oil pump assembly, the screw may be
damaged. only the oil pump unit is
available as a replacement.
(5) (2)
4-9
4.LUBRICATION SYSTEM
(6)
INSTALLATION
Before mounting the oil pump, apply engine oil
to the sliding surface of the oil pump case,
outer rotor, inner rotor, and crankcase.
(1)
4-10
5. FUEL SYSTEM
FUEL SYSTEM
SERVICE INFORMATION-------------------------------------------5-2
TROUBLESHOOTING-----------------------------------------------5-3
FUEL TANK------------------------------------------------------------5-5
FUEL VALVE-----------------------------------------------------------5-5
CARBURETOR -------------------------------------------------------5-6
5-1
5. FUEL SYSTEM
5-2
5. FUEL SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Gasoline is very dangerous. When working with gasoline, keep sparks and flames away
from the working area.
Gasoline is extremely flammable and is explosive under certain conditions. Be sure to
work in a well-ventilated area.
Do not bend or twist control cables. Damaged control cables will not operate smoothly.
When disassembling fuel system parts, note the locations of O-rings. Replace them with new
ones during reassembly.
Before float chamber disassembly, loosen the drain screw to drain residual gasoline into a
clean container.
After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent
foreign matters from entering.
When cleaning the carburetor air and fuel jets, the O-rings and diaphragm must be removed first
to avoid damage. Then, clean with compressed air.
When the ATV is not used for over one month, drain the residual gasoline from the float
chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel.
SERVICE DATA
CARBURETOR
Unit:mm (in)
Item Specification
Type BDS42 TYPE
Bore size ∮42
Idle r.p.m 1800±100 rpm
Float height 13 (0.51)
Main jet 162.5
Main air jet 50
Jet needle 6DFY08-54-3
Needle jet 0-6M
Pilot jet 45
Throttle valve 105
By –pass #1---0.9 #2---0.8 #3---0.8
Valve seat 1.5
Starter jet 42.5
Pilot screw STD
Pilot outlet ∮1.1
PV. Stroke 29.6
Throttle cable play 3~5(0.12~0.20)
5-3
5. FUEL SYSTEM
TROUBLESHOOTING
Engine cranks but won’t start Engine lacks power
No fuel in tank Clogged air cleaner
No fuel to carburetor Faulty carburetor
Cylinder flooded with fuel Faulty ignition system
No spark at plug
Clogged air cleaner Lean mixture
Intake air leak Clogged carburetor fuel jets
Engine idle roughly, stalls or runs poorly Clogged fuel tank cap breather hole
Excessively used choke Kinked or restricted fuel line
Ignition malfunction
Faulty carburetor Rich mixture
Poor quality fuel Float level too high
Lean or rich mixture Clogged air jets
Incorrect idle speed Clogged air cleaner
Faulty carburetor
Backfiring at deceleration
Float level too low
5-4
5. FUEL SYSTEM
CARBURETOR
Complaint Symptom and possible causes Remedy
1. Starter jet is clogged. Clean
Trouble with 2. Starter pipe is clogged. Clean
3. Air leaking from a joint between starter Check starter body and
starting. body and carburetor. carburetor for tightness,
adjust and replace gasket.
4. Starter plunger is not operating properly. Check and adjust
Idling or low-speed 1. Pilot jet, pilot air jet are clogged or Check and clean.
trouble. loose.
2. Pilot outlet or bypass is clogged. Check and clean.
3. Starter plunger is not fully closed. Check and clean.
Medium or high 1. Main jet or main air jet is clogged. Check and clean.
speed trouble. 2. Needle jet is clogged. Check and clean.
3. Throttle valve is not operating properly. Check throttle valve for
operation.
4. Filter is clogged. Check and clean.
Overflow and fuel 1. Needle valve is worn or damaged. Replace
level fluctuations. 2. Spring in needle valve is broken. Replace
3. Float is not working properly. Check and adjust
4. Foreign matter has adhered to needle Clean
valve.
5. Fuel level is too high or low. Adjust float height.
5-5
5. FUEL SYSTEM
INSTALLATION
Reverse the “FUEL TANK REMOVAL”
procedures.
Bolts Bolts
FUEL VALVE
REMOVAL
*Keep sparks and flames away from the
work area.
Drain gasoline into a clean container.
CARBURETOR
5-6
5. FUEL SYSTEM
CONSTRUCTION
REMOVAL
Disconnect the fuel hose (1).
5-7
5. FUEL SYSTEM
(1)
(2)
5-8
O-ring
5. FUEL SYSTEM
DISASSEMBLY
Remove the fuel hose (2) and air vent hoses (3).
(3)
(2)
(5)
5-9
5. FUEL SYSTEM
(1)
(3)
(2)
(5)
(7) (8)
5-10
5. FUEL SYSTEM
(1)
(2)
(1)
(3)
(2)
(4)
(5)
Remove the main jet (1), jet holder (2) and (1),(2)
pilot jet (3).
(3)
5-12
5. FUEL SYSTEM
*
Before removing the pilot air jet (4), its
setting must be determined. Slowly turn
the pilot screw clockwise and count the
number of turns until it is lightly seated.
Make a note of how many turns were made.
When reassembling the pilot screw, you
will want to set it to its original position.
INSPECTION
Check the following parts for damage and
clogging. Check for stopped wear
CLEANING
Clean all jets by using compressed air.
After cleaning, reassemble the carburetor
with new seals and gaskets.
(1)
REASSEMBLY
Carburetor reassembly can be performed in
the reverse order of disassembly. (1)
When reassembling, carefully observe the
following instructions.
5-14
5. FUEL SYSTEM
(3),(4)
(2)
5-15
5. FUEL SYSTEM
REMOUNTING
Remount the carburetor assembly in the reverse
order of removal.
Pay attention to the following points:
Align the lug on the carburetor with intake
pipe’s cutout.
Connect the carburetor hoses properly.
5-16
6. ENGINE REMOVEL
ENGINE REMOVAL
SERVICE INFORMATION 6-1
ENGINE REMOVAL 6-2
6-1
6. ENGINE REMOVEL
SERVICE INFORMATION
GENERAL INSTRUCTIONS
A floor jack or other adjustable support is required to support and maneuver the engine.
Be careful not to damage the machine body, cables and wires during engine removal.
Use shop towels to protect the machine body during engine removal.
6-2
6. ENGINE REMOVEL
Disconnect the breather hose (2) and remove the oil return tank (3) with hose (4).
(3) (4)
(2) (4)
6-3
6. ENGINE REMOVEL
(3)
Disconnect the spark plug cap (1), oil tank
overflow hose (2) and breather hose (3).
(1) (2)
6-4
6. ENGINE REMOVEL
(6)
(7) (8)
6-5
6. ENGINE REMOVEL
(1)
(2)
(3)
6-6
6. ENGINE REMOVEL
(1)
(2)
(5)
6-7
6. ENGINE REMOVEL
(2)
Disconnect the magneto lead wire couplers (1)
and gear position switch lesd wire coupler (2).
(1)
(3)
6-8
6. ENGINE REMOVEL
(1)
(1)
6-9
7.CYLINDER HEAD/VALVES
CYLINDER HEAD/VALVES
SERVICE INFORMATION 7-1
TROUBLESHOOTING 7-3
CYLINDER HEAD COVER 7-4
CYLINDER HEAD /CAMSHAFT 7-8
7-1
7.CYLINDER HEAD/VALVES
7-2
7.CYLINDER HEAD/VALVES
SERVICE INFORMATION
GENERAL INSTRUCTIONS
When assembling, apply engine oil to the valve guide movable parts, valve arm and camshaft
sliding surfaces for initial lubrication.
The camshaft is lubricated by engine oil through the cylinder head engine oil passages. Clean and
unclog oil passages before assembling the cylinder head.
After removal, mark and arrange the removed parts in order. When assembling, install, them in
the reverse order of removal.
SPECIFICATIONS Unit mm(in)
Item Standard Service Limit
Valve IN 0.1~0.2(0.004~0.008) —
clearance(cold) EX 0.2~0.3(0.008~0.012) —
Valve diam IN 36.0 (1.42) —
EX 29.0 (1.14) —
Valve guide to valve IN 0.010~0.037 (0.0004~0.0015) —
stem clearance EX 0.030~0.057 (0.0012~0.0022) —
Valve stem deflection IN&EX ——— 0.35 (0.014)
Valve guide I.D. IN&EX 5.000~5.012 (0.1969~0.1973) —
Valve stem O.D. IN 4.975~4.990 (0.1959~0.1965) —
EX 4.955~4.970 (0.1951~0.1957) —
Valve stem runout IN&EX ——— 0.05 (0.002)
Valve head thickness IN&EX ——— 0.50 (0.02)
Valve seat width 1.25~1.65 (0.049~0.065)
Valve seat angle IN&EX 45°
Valve head radial runout IN&EX ——— 0.35 (0.014)
Cylinder head compression pressure 16 kgf/cm²(at 500 rpm)
Cylinder head warpage ——— 0.05
Camshaft cam height IN 39.98~40.02(1.574~1.576 ) 39.88
EX 39.98~40.02(1.574~1.576 ) 39.88
Camshaft journal oil clearance 0.15
(IN & EX) 0.006 in
Camshaft runout ——— 0.10(0.004 in)
Camshaft O.D. IN&EX 21.959~21.980 (0.8645~0.8654)
Camshaft housing I.D. IN&EX 22.012~22.025 (0.8666~0.8671)
Cam chain pin (arrow 3) 15 th pin
Valve spring free length IN 36.9(1.45 in)
EX 39.6(1.57 in)
Valve spring tension IN 6.5~7.1kgf(14.3~15.7 lbs) —
at length 32.0mm(1.26 in)
EX 12~14kgf(26.5~30.9 lbs) —
at length 35.5mm(1.40 in)
7-3
7.CYLINDER HEAD/VALVES
TORQUE VALUES
Cylinder head cover bolt 1.4kgf-m(14Nm)
Camshaft housing bolts 1.2kgf-m(12Nm) Apply engine oil to threads
Cylinder head bolt 4.7 kgf-m (47 Nm)
Cylinder head base bolt 1.0 kgf-m (10 Nm)
Cam chain tension adjuster bolt 2.0kgf-m (20Nm)
Cam chain tension adjuster mounting bolt 1.0kgf-m (10Nm)
Thermostat cover bolt 1.0kgf-m (10Nm)
SPECIAL TOOLS
Valve spring compressor 71605-E12-000
TROUBLESHOOTING
The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-
end noises.
7-4
7.CYLINDER HEAD/VALVES
REMOVAL (5)
Remove the spark plug (5).
INSTALLATION
Please defer to the opposite order to install
REMOVAL
Remove the cylinder head cover bolts in diagonal
stages, and then remove the cylinder head cover.
7-5
7.CYLINDER HEAD/VALVES
INSTALLATION
Thoroughly wipe off oil from the fitting surfaces
of the cylinder head and cover.
Apply BOND to the end caps of the
cylinder head cover gasket as shown.
BOND
(1)
CAMCHAIN TENSION ADJUSTER
REMOVAL
(2)
INSTALLATION
7-6
7.CYLINDER HEAD/VALVES
(3)
Torque:1 kgf-m(10Nm)
(5)
Torque:2 kgf-m(20Nm)
7-7
7.CYLINDER HEAD/VALVES
CYLINDER HEAD
REMOVAL
Remove the CYLINDER HEAD COVER. (Refer to page 7-4)
7-8
7.CYLINDER HEAD/VALVES
(2)
(3)
(4)
7-9 (2)
7.CYLINDER HEAD/VALVES
7-10
7.CYLINDER HEAD/VALVES
CAMSHAFT RUNOUT
Support the valve using a V-blocks and measure the
camshaft runout using the dial guage. If the runout
exceeds the service limit, replace the camshaft
with a new one.
7-11
7.CYLINDER HEAD/VALVES
CAMSHAFT
The camshaft should be checked for runout and
also for wear of cams and journals if the engine
has been noted to produce abnormal noise or
vibration or a lack of output power. Any of these
abnormality could be caused by a worn camshaft.
CAMSHAFT WEAR
Worn-down cams are often the cause of mistimed
valve operation resulting in reduced output power.
The limit of cam wear is specified for both intake
and exhaust cams in terms of cam height H,
which is to be measured with a micrometer.
Replace camshafts if found it worn-down to the limit.
H
7-12
7.CYLINDER HEAD/VALVES
CYLINDER HEAD
DISASSEMBLY
(2)
(2)
Special
Special
7-13
7.CYLINDER HEAD/VALVES
(4)
7-14
7.CYLINDER HEAD/VALVES
7-15
7.CYLINDER HEAD/VALVES
SHIM KIND
There are 49 kinds of shim which thickness is
increased by each 0.025 mm from 2.30 mm to 3.50 mm.
7-16
7.CYLINDER HEAD/VALVES
REASSEMBLY
Install each valve spring seat (1).
7-17
7.CYLINDER HEAD/VALVES
(2)
* (1)
Be sure to install new oil seal.
*
When inserting each valve into the valve
guides, make sure not to damage the lip
of the oil seal.
Head direction
7-18
7.CYLINDER HEAD/VALVES
Special
Special
Valve Spring Compressor 71605-E12-000
Valve springs compressor attachment
CYLINDER HEAD
INSTALLATION
Install the cam chain guide (4). (5)
Install the dowel pins (5) and new gasket (6).
(6)
(4)
Torque:
Cylinder head bolt:4.7 kgf-m (47 Nm)
Torque:
Cylinder head base bolt:1 kgf-m (10 Nm)
7-19
7.CYLINDER HEAD/VALVES
With the “T” line on the magneto rotor is aligned with the triangle mark on the crankcase, hold the
camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain
sprocket and exhaust camshaft sprocket.
The exhaust camshaft sprocket has an arrow marked “ 1 ” . Turn the exhaust camshaft so that the
7-20
7.CYLINDER HEAD/VALVES
arrow is aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust
camshaft sprocket.
The other arrow marked “ 2 ” should now be pointing straight up. Starting from the roller pin that is
directly above the arrow marked “ 2 ” , count out 15 roller pins (from the exhaust camshaft side
going towards the intake camshaft side).
Engage the 15 th roller pin on the cam chain with the arrow marked “ 3 ” on the intake sprocket.
Refer to the following illustrations.
15 Pins
3
2
1
7-21
7.CYLINDER HEAD/VALVES
INSTALLATION
Installation the 2 nd pipe. (Refer to page 7-7)
Installation the thermostat & thermostat cover. (Refer to page 7-7)
Installation the cam chain tension adjuster. (Refer to page 7-6)
Installation the cylinder head cover. (Refer to page 7-5)
7-22
8.CYLINDER/PISTON
CYLINDER/PISTON
8-1
8.CYLINDER/PISTON
8-2
8.CYLINDER/PISTON
SERVICE INFORMATION
GENERFAL INSTRUCTIONS
After disassembly, clean the removed parts and dry them with compressed air before inspection.
TROUBLESHOOTING
When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
SPECIFICATIONS
8-3
8.CYLINDER/PISTON
8-4
8.CYLINDER/PISTON
CYLINDER/PISTON
REMOVAL
Remove the cylinder head.(Refer to the Dowel Pins Gasket
chapter 7)
Nut
Cylinder base nut
Torque:1.0gf-m (10Nm)
*
Be careful not to drop foreign matters
into the crankcase. Dowel Pins
If the cylinder dose not come off easily,
lightly tap it using a plastic hammer.
8-5
8.CYLINDER/PISTON
Piston
Remove the piston pin clip.
8-6
8.CYLINDER/PISTON
18mm
PISTON-TO-CYLINDER CLEARANCE
To determine the piston-to-cylinder clearance,
calculate the difference between the cylinder
bore and outside diameter of the piston.
Service Limit:0.120mm
Service Limit:19.030mm
8-7
8.CYLINDER/PISTON
8-8
8.CYLINDER/PISTON
PISTON RING-TO-GROOVE
CLEARANCE INSPECTION
Remove carbon deposit both from the piston
ring and its groove.
Fit the piston ring into the groove. With the ring
compressed and lifted up, measure the clearance
on the bottom side of the ring using a thickness
gauge.
If any clearance reading exceeds the service
limit, replace both the piston and piston rings.
8-9
8.CYLINDER/PISTON
8-10
8.CYLINDER/PISTON
8-11
8.CYLINDER/PISTON
Standard:0.10~0.65mm
Service limit:1.0mm
PISTON INSTALLATION
Remove any gasket material from the
crankcase surface.
* Be careful not to drop foreign matters
into the crankcases. 8-12
8.CYLINDER/PISTON
8-13
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
SERVICE INFORMATION
9-1
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
SPECIFICATIONS Unit:mm
Item Standard Service Limit
Width between webs 71.0±0.1 -----
Clutch drive plate thickness No.1 2.92~3.08 2.62
No.2 3.42~3.58 3.12
Clutch drive plate claw width No.1 15.9~16.0 15.1
No.2 15.9~16.0 15.1
Clutch drive plate distortion ----- 0.1
Clutch cable play 10~15 -----
Clutch spring free length ----- 51.6
Shift fork to groove clearance 0.10~0.30 0.50
Shift fork groove width (No.1/No.2/No.3) 4.85~5.00 -----
Shift fork thickness (No.1/No.2/No.3) 5.3~5.4 -----
Conrod big end width 24.95~25.00 -----
Crank web to web width 71±1 -----
Crankshaft runout ----- 0.05
Primary reduction ratio 2.500 (75/30) -----
Secondary reduction ratio 3.143 (44/14) -----
Gear ratio 1 st 2.538 -----
2 nd 1.684 -----
3 rd 1.261 -----
4 th 1.040 -----
5 th 0.885 -----
Reverse 2.231 -----
Drive chain Type RK 520EXW -----
Links 102 -----
20-pitch length 317.5 319.4
Drive chain slack 30~40 -----
Reverse cable play 1~2 -----
TORQUE VALUES
Item TORQUE
Starter clutch bolts 2.3~2.8kgf-m(23~28 Nm)
9-2
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
SPECIAL TOOLS
Clutch sleeve hub holder 71600-E12-000
Conrod holder 71612-E12-000
Rotor remover 71615-E12-000
Crankcase separator 71607-E03-000
Crankcase installer 71613-E12-000
TROUBLESHOOTING
Refer to the chapter 1 (page 1-24)
REMOVAL
9-3
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(1)
9-4
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(1)
(3)
9-5
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(3)
(2)
Special
Special
(5)
(6)
9-6
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
9-7
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(2)
(4)
(2) (1)
(2)
9-8
(3)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Special
Special (1)
Conrod holder:71612-E12-000
(2)
* The primary drive gear nut has left-hand
threads.
If turning it counter-clockwise, it may
cause damage.
Pay attention at the primary drive gear nut
with a washer, and water pump drive gear
9-9with a washer
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Special
Special
Conrod holder:71612-E12-000
Special
Special
Rotor remover:71604-E12-000
*
Do not hit the magneto rotor with a
hammer, otherwise the rotor may be
damaged.
Remove the cam chain (3) and cam chain (6) (5)
tensioner (4).
Remove the starter idle shaft (5) and starter (4)
idle gear (6).
9-10
(3)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(9)
(8)
9-11
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Special
Special
Crankcase separator:71607-E03-000
(4) (3)
(2)
(1)
(3)
9-12
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(6)
(5)
(8)
Special
Special
Crankcase separator:71607-E03-000
CRANKSHAFT
9-13
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Service limit:0.05mm
9-14
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
REASSEMBLY
Reassemble the crank balancer and balancer drive gear in the reverse order of disassembly.
STARTER CLUTCH
Install the starter driven gear onto the starter
clutch and turn the starter driven gear by hand
(the gear turns in only one direction).
The starter driven gear should turn smoothly.
If excessive resistance is felt while turning the
starter driven gear, inspect the starter clutch.
Also, inspect the surface of the starter driven
gear which contacts the starter clutch, for wear
or damage. If any wear or damage is found,
replace the defective parts.
DISASSEMBLY
With the magneto rotor held immovable,
remove the starter clutch bolts.
9-15
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
REASSEMBLY
Apply a small quantity of THREAD LOCK
to the starter clutch bolts and tighten
them to the specified torque with the magneto
rotor held immovable.
CLUTCH
CLUTCH DRIVE PLATES
Measure the thickness and claw width of
the clutch plates using a vernier calipers.
If a clutch drive plate is not within the
service limit, replace the clutch plates as a set.
Thickness standard:
NO.12.92~3.08 mm(0.115~0.121 in)
NO.23.42~3.58 mm(0.135~0.141 in)
Thickness service limit:
NO.12.62 mm(0.103 in)
NO.23.12 mm(0.123 in)
Claw width standard:
NO.115.9~16.0 mm(0.626~0.630 in)
NO.215.9~16.0 mm(0.626~0.630 in)
Claw width service limit:
NO.115.1 mm(0.595 in)
NO.215.1 mm(0.595 in)
9-16
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
OIL PUMP
Remove the oil pump.(Refer to the chapter 4)
9-17
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
TRANSMISSION
DISASSEMBLY
Disassemble the transmission gears as show.
9-18
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
INSPECTION
GEAR-SHIFTING FORK
Using a thickness gauge, check the clearance
between the groove of its gear and shifting fork.
The clearance for each of the three shifting forks
plays an important role in the smoothness and
positiveness of shifting action.
If the clearance checked is noted to exceed the
limit specified, replace the fork or its gear,
or both.
9-19
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
REASSEMBLY
Reassemble the transmission in the reverse
order of disassembly.
Pay attention to following points:
* Thrust
Before installing the gears, coat lightly
engine oil to the inner surface of each
gear and bushing.
Never reuse a circlip. After a circlip has
been removed from a shaft, it should be
discarded and new circlip must be Sharp edge
installed.
When installing a new circlip, care must
be taken not to expand the end gap larger
than required to slip the circlip over the
shaft.
After installing a circlip, always ensure
that it is completely seated in its groove
and securely fitted.
9-20
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
oil hole.
9-21
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
CRANKCASE
OIL STRAINER CAP
Remove the oil strainer cap.
9-22
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(1)
BEARING INSPECTION
Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection.
Rotate the inner race and check to see that it turns smoothly.
If it dose not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is
defective and must be replaced with a new one as follows.
play play
9-23
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
9-24
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
GREASE
(1)
CLUTCH COVER
OIL FILTER
Refer to page 3-14
9-25
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
WATER PUMP
Refer to page 10-11
REASSEMBLY
Reassemble the engine in the reverse order of disassembly.
Pay special attention to the following points:
*
Apply engine oil to each running and sliding part before reassembling the engine.
CRANKSHAFT
Crankshaft installer:71613-E12-000
(1)
(5)
(2)
(4)
(3)
(5)
9-27
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
CRANKCASE
Thoroughly remove the sealant material and oil
stains on the mating surface of the right and (1)
left crankcases.
Install the dowel pins (1) to the crankcase.
Apply engine oil to the conrod big end and to
the transmission gears.
Apply BOND “1215” to the mating surface
of the crankcase.
(1)
9-28
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
(3)
(1) , (2)
CAM CHAIN
(7) (6)
Install the cam chain (4) onto the sprocket.
(5)
Tighten the cam chain tensioner mounting
bolt (5) to the specified torque.
Install the starter idle shaft (6) and starter idle
gear (7).
9-29
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
(2)
TRANSMISSION/CRANKCASE/CLUTCH COVER
(1)
Special
Special
Conrod holder:71612-E12-000
9-30
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Special (2)
Special
Conrod holder:71612-E12-000
(3)
9-31
(1)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
OIL PUMP
Before mounting the oil pump, apply engine oil
to the sliding surface of the oil pump case,
outer rotor, inner rotor, and crankcase.
(1)
9-32
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
OIL PIPE
Apply engine oil to the O-rings.
Tighten the oil pipe bolt securely.
CLUTCH
9-33
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
Install the clutch sleeve hub (1), lock washer (2). (1)
(2)
(3)
(1)
(2)
9-34
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
E A
D
(A) NO.2 (E) NO.1
C B
(2)
(1)
Install the dowel pins (1) and new gasket (2).
9-35
(1)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
9-36
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER
9-37
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/ TRANSMISSION/CRANKCASE
/CLUTCH COVER
SHIM NO. 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
MEASURING SHIM THICKNESS 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
TAPPET AT PRESENT
0.00~0.04 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40
0.05~0.09 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45
0.10~0.20 Specified clearance--Adjustment unnecessary
0.21~0.25 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.26~0.30 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.31~0.35 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.36~0.40 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.41~0.45 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.46~0.50 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.51~0.55 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.56~0.60 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.61~0.65 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.66~0.70 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 HOW TO USE THE CHART
0.71~0.75 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 1. Measure the tappet clearance . (When cold)
0.76~0.80 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 2. Measure the shim thickness at present .
0.81~0.85 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3. Look for meeting space in that horizontal line
0.86~0.90 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 for thickness and vertical line for clearance .
0.91~0.95 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.96~0.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 (EXAMPLE)
1.01~1.05 3.20 3.25 3.30 3.35 3.40 3.45 3.50 When the tappet clearance is 0.38mm and the
1.06~1.10 3.25 3.30 3.35 3.40 3.45 3.50 shim thickness at present is 2.70mm , the shim
1.11~1.15 3.30 3.35 3.40 3.45 3.50 thickness should be used 2.95mm .
9-38
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/ TRANSMISSION/CRANKCASE
/CLUTCH COVER
SHIM NO. 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
MEASURING SHIM THICKNESS 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
TAPPET AT PRESENT
0.10~0.14 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40
0.15~0.19 2.30 2.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45
0.20~0.30 Specified clearance
0.31~0.35 2.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.36~0.40 2.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.41~0.45 2.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.46~0.50 2.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.51~0.55 2.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.56~0.60 2.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.61~0.65 2.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.66~0.70 2.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.71~0.75 2.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
0.76~0.80 2.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 HOW TO USE THE CHART
0.81~0.85 2.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 1. Measure the tappet clearance . (When cold)
0.86~0.90 2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 2. Measure the shim thickness at present .
0.91~0.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3. Look for meeting space in that horizontal line
0.96~1.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 for thickness and vertical line for clearance .
1.01~1.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50
1.06~1.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 (EXAMPLE)
1.11~1.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 When the tappet clearance is 0.48mm and the
1.16~1.20 3.25 3.30 3.35 3.40 3.45 3.50 shim thickness at present is 2.70mm , the shim
1.21~1.25 3.30 3.35 3.40 3.45 3.50 thickness should be used 2.95mm .
9-39
10.COOLING SYSTEM
COOLING SYSTEM
SERVICE INFORMATION-------------------------------------------10-1
TROUBLESHOOTING------------------------------------------------10-1
SPECIFICATIONS------------------------------------------------------------10-2
COOLING SYSTEM TESTING--------------------------------------10-3
ENGINE COOLANT/COOLING CIRCUIT------------------------------10-4
RADIATOR--------------------------------------------------------------10-5
COOLANT REPLACEMENT----------------------------------------10-9
WATER PUMP----------------------------------------------------------10-11
OIL TANK AND HOSE------------------------------------------------10-16
THERMOSTAT---------------------------------------------------------10-19
10-1
10.COOLING SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The cooling system service can be done with the engine installed in the frame.
The engine must be cool before servicing the cooling system.
When the coolant temperature is over 100℃, never remove the radiator cap to release the
pressure because the boiling coolant may cause danger.
Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces.
Wash off any spilled coolant with fresh water as soon as possible.
After servicing the system, check for leaks with a cooling system tester.
TORQUE VALUES
Thermostat case bolt torque:1.0 kgf-m (10 Nm)
Engine oil inlet hose union bolt torque:2.3 kgf-m (23 Nm)
Radiator mounting bolt torque:0.8~1.2 kgf-m (8~12 Nm)
TROUBLESHOOTING
Temperature gauge pointer does not register the correct coolant temperature.
Faulty temperature gauge or thermo sensor
Faulty thermostat
10-2
10.COOLING SYSTEM
SPECIFICATIONS
Radiator cap relief pressure 0.75~1.05 kgf/cm2
(75~105 kPa,10.65~14.91 psi)
Standard Limit
Thermostat valve Lift Over 8mm/90°C
Valve opening 76°C
Thermostat valve operating temperature
Valve closing 71°C
OFFON Approx.95
Water temperature switch operating
temperature Approx.105
ONOFF
OFFON Approx.85°C
Cooling fan thermo-switch operating
temperature ONOFF Approx.75°C
10-3
10.COOLING SYSTEM
10-4
10.COOLING SYSTEM
ENGINE COOLANT
At the time of manufacture, the cooling system is filled with 1:1 mixture of distilled water and
ethylene glycol anti-freeze.
This 1:1 mixture will provide the optimum corrosion protection and excellent heat protection, and
will protect the cooling system from freezing at temperatures above -31°C (-24°F).
*
You can be injured by scalding fluid or steam if you open the radiator cap when the engine is
hot. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by
turning it a quarter turn to allow pressure to escape and then turn the cap all the way off.
The engine must be cool before servicing the cooling system.
Coolant is harmful ;
If it comes in contact with skin or eyes, flush with water.
If swallowed accidentally, induce vomiting and call physician immediately.
Keep it away from children.
COOLING CIRCUIT
(2)
(1) Impeller
(2) Radiator cap
(3) Radiator (3)
(4) Thermostat
(5) Cooling fan thermo-switch (6)
(6) Water temperature switch (5)
(4)
(1)
RADIATOR
RADIATOR INSPECTION
10-5
10.COOLING SYSTEM
Radiator
Radiator Cap
RADIATOR REMOVAL
Remove the radiator cap.
Remove the drain bolt and drain the coolant
from the system.
(2)
Disconnect the radiator hose (1).
Disconnect the Aux. Liquid Bottle hose (2).
(1)
(2)
10-6
10.COOLING SYSTEM
(2)
(1)
10-7
10.COOLING SYSTEM
Bolts
RADIATOR DISASSEMBLY
Remove the fore bolts and then remove the
fan shroud from the radiator.
Check fan motor by battery.
Bolts
10-8
10.COOLING SYSTEM
RADIATOR ASSEMBLY
Install the fan shroud on the radiator with
the three bolts.
RADIATOR INSTALLATION
Reverse the“RADIATOR REMOVAL”
procedures.
10-9
10.COOLING SYSTEM
COOLANT REPLACEMENT
PREPARATION
The effectiveness of coolant decreases
with the accumulation of rust or if there is
a change in the mixing proportion during
usage. Therefore, for best performance
change the coolant regularly as specified in
the maintenance schedule.
Mix only distilled, low mineral water with
the antifreeze.
Recommended mixture:
1:1 ( Distilled water and antifreeze )
Radiator Cap
REPLACEMENT/AIR BLEEDING
* When filling the system or reserve tank
with coolant (checking the coolant
level), place the vehicle in a vertical
position on a flat, level surface.
10-10
10.COOLING SYSTEM
Maximum Mark
Filler Neck
Fill the system with the recommended
coolant through the filler opening up to the
filler neck.
10-11
10.COOLING SYSTEM
WATER PUMP
REMOVAL AND DISASSEMBLY
Drain engine coolant.
Drain engine oil.
Disconnect the water hoses.
(1)
(2)
(4) (3)
(5)
(4)
(4)
(1),(2),(3)
10-12
10.COOLING SYSTEM
(1)
(2)
Remove the pin (2) and washer (3).
(3)
10-13
10.COOLING SYSTEM
clutch cover.
(1)
(2)
(3)
10-14
10.COOLING SYSTEM
(1)
INSPECTION
BEARING
Inspect the play of the bearing by hand while it
is in the water pump case.
Rotate the inner race by hand to inspect
abnormal noise and smooth rotation.
Replace the bearing if there is anything unusual.
BEARING CASE
Visually inspect the bearing case for damage.
Replace the water pump body if necessary.
10-15
10.COOLING SYSTEM
IMPELLER
Visually inspect the impeller and its shaft
for damage.
10-16
10.COOLING SYSTEM
REMOVAL
Drain engine coolant. (Refer to page 10-5).
Remove the radiator. (Refer to page 10-6~10-8).
Drain engine oil. (Refer to page 3-12).
10-17
10.COOLING SYSTEM
(1)
Remove the oil hoses.
10-18
10.COOLING SYSTEM
Oil tank
REMOUNTING
Remount the oil tank and hoses in the reverse order of removal.
*
Use the new O-ring to prevent engine
coolant leakage.
Engine oil inlet hose union bolt torque:2.3 kgf-m (23 Nm)
10-19
10.COOLING SYSTEM
THERMOSTAT
THERMOSTAT REMOVAL
Disconnect the radiator hose.
(Refer to page 10-5)
Drain engine coolant.
(Refer to page 10-5)
Place a rag under the thermostat case.
Remove the thermostat case cap.
10-20
10.COOLING SYSTEM
THERMOSTAT INSPECTION
Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to
check its operation.
Technical Data
Thermostat valve operation temperature Standard
Valve opening 76°C (169°F)
Valve closing 71°C (160°F)
10-21
11.BRAKE SYSTEM
BRAKE SYSTEM
SERVICE INFORMATION----------------------------------------------11-2
TROUBLESHOOTING---------------------------------------------------11-2
FRONT HYDRAULIC BRAKE-----------------------------------------11-3
FRONT BRAKE FLUID CHANGE/AIR BLEED--------------------11-4
BRAKE MASTER CYLINDER-----------------------------------------11-6
FRONT BRAKE CALIPER----------------------------------------------11-9
REAR HYDRAULIC BRAKE-------------------------------------------11-12
FOOT BRAKE MASTER CYLINDER--------------------------------------11-15
REAR BRAKE CALIPER---------------------------------------------------11-18
11-1
11.BRAKE SYSTEM
11-2
11.BRAKE SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
During servicing, keep oil or grease off the brake pads and brake disk.
Drain the brake fluid from the hydraulic brake system before disassembly.
Contaminated brake disk or brake pads reduce stopping power. Clean the contaminated brake
disk with high-performance brake degreaser and replace the brake pads.
Do not use brake fluid for cleaning.
Bleed air form he brake system if the brake system is removed or the brake is soft.
Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir
with brake fluid.
Brake fluid will damage painted, coated surfaces and plastic parts. When working with brake
fluid, use shop towels to cover and protect painted, rubber and plastic parts. Wipe off any splash
of brake fluid with a clean tower. Do not wipe the machine with a towel contaminated by brake
fluid.
Make sure to use recommended brake fluid. Use of other unspecified brake fluids may cause
brake failure.
Inspect the brake operation before riding.
SPECIFICATIONS Unit: mm (in)
Item Standrad Service Limit
Brake disk thickness front 3.3~3.6(0.129~0.141) 2.7(0.0106)
rear 3.9~4.1(0.153~0.161) 3(0.12)
Brake disk runout — 0.3(0.012)
TROUBLESHOOTING
Loose brake lever Tight brake lever
Air in hydraulic brake system Seized piston
Brake fluid level too low Clogged hydraulic brake system
Hydraulic brake system leakage Smooth or worn brake pad
11-3
11.BRAKE SYSTEM
Bolts
11-4
11.BRAKE SYSTEM
Bleed Valve
11-5
11.BRAKE SYSTEM
11-6
11.BRAKE SYSTEM
Remove fluid tube bolt and then disconnect Stop Light Switch Wire
.
Bolts
* When removing the brake fluid tube
bolt, be sure to place towels under the
tube and plug the tube end to avoid brake
fluid leakage and contamination.
Disconnect the stop light switch wires.
Snap Ring
Remove the brake lever bolt and the brake
lever.
Remove the piston rubber cover and snap
ring from the brake master cylinder.
11-7
11.BRAKE SYSTEM
INSPECTION
Check the cylinder inside wall, and spring
for scratch, corrosion or other abnormal
condition.
If any abnormal condition is found, replace
the inner parts or master cylinder.
11-8
11.BRAKE SYSTEM
ASSEMBLY
Before assembly, apply brake fluid to all
removed parts.
“UP”Mark
Place the brake master cylinder on the
handlebar and install the holder with the
“UP” mark facing up .
First tighten the upper bolt and then tighten
the lower bolt.
Torque: 1.0 kgf-m (10Nm, 7.2 lbf-ft)
11-9
11.BRAKE SYSTEM
DISASSEMBLY
Remove the brake pads. (11-3)
Remover the brake pad spring plate.
Spring Plate
11-10
11.BRAKE SYSTEM
Dust Seal
INSPECTION
Inspect the caliper cylinder wall and piston
surface for scratch, corrosion or other
damages.
If any abnormal condition is noted, replace
the caliper.
11-11
11.BRAKE SYSTEM
ASSEMBLY
Clean all removed parts.
Apply silicon grease to the piston and oil
seals. Lubricate the brake caliper cylinder
inside wall with brake fluid.
INSTALLATION
Reverse the “FRONT BRAKE CALIPER
REMOVAL” procedures.
11-12
11.BRAKE SYSTEM
Bolts
INSTALLATION
Reverse the “REAR BRAKE PADS
REMOVAL” procedures.
11-13
11.BRAKE SYSTEM
11-14
11.BRAKE SYSTEM
Bleed Valve
* When bleeding air from the brake
system, the brake fluid level(pedal)
should be kept over 1/2 of the brake.
11-15
11.BRAKE SYSTEM
ASSEMBLY
Refer to the “FRONT BRAKE MASTER
CYLINDER ASSEMBLY” section in the
chapter 11.
Lower nut
Bolts
11-16
11.BRAKE SYSTEM
Circlip
Seal Boot
Nuts
Push Rod
Circlip Washer
11-17
11.BRAKE SYSTEM
INSPECTION
Check the cylinder inside wall, and spring
for scratch, corrosion or other abnormal
condition.
If any abnormal condition is found, replace
the inner parts or master cylinder.
Before assembly, inspect the 1st and 2nd
rubber cups for wear.
ASSEMBLY
Before assembly, apply brake fluid to all
removed parts.
11-18
11.BRAKE SYSTEM
Bolts
11-19
11.BRAKE SYSTEM
Seal Piston
INSPECTION
Inspect the caliper cylinder wall and piston
surface for scratch, corrosion or other
damages.
If any abnormal condition is noted, replace
the caliper.
BRAKE DISK
Measure the brake disk thickness.
Service Limit:3.0 mm (0.12in)
Measure the brake disk run out.
Service Limit:0.3 mm (0.012in)
11-20
11.BRAKE SYSTEM
ASSEMBLY
Reassemble the caliper in the reverse order
of disassembly procedures and observe the
following points.
INSTALLATION
Install the rear caliper and tighten the two
mounting bolts.
With the tube ends contacted to the caliper
and install the washers and tighten the fluid
tube bolts.
Torque: 3.4 kgf-m(34Nm, 25 lbf-ft)
11-21
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
FRONT WHEEL/
FRONT SUSPENSION\STEERING SYSTEM
SERVICE IMFORMATION----------------------------------------12-2
TROUBLESHOOTING---------------------------------------------12-2
FRONT WHEEL-----------------------------------------------------12-3
FRONT WHEEL HUB----------------------------------------------12-4
FRONT SUSPENSION---------------------------------------------12-8
TIE-ROD--------------------------------------------------------------12-15
HANDLEBAR-------------------------------------------------------12-18
STEERING COLUMN----------------------------------------------12-24
12-1
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Jack the machine front wheel off the ground be careful to prevent the machine from falling
down
During servicing, keep oil or grease off the brake disk
Inspect the brake system before riding.
SPECIFICATIONS Unit: mm( in)
Item Standard Service Limit
Front wheel rim run out Radial - 2(0.08)
Axial - 2(0.08)
Tie rod length 430±1 (11.98±0.02) -
TORQUE VALUES
Steering stem nut 7.0kgf-m (70Nm, 50 lbf-ft)
Front swing arm nut 4.5kgf-m (45Nm, 32 lbf-ft)
Front wheel nut 4.5kgf-m (45Nm, 32 lbf-ft)
Front wheel hub nut 7.0kgf-m (70Nm, 50 lbf-ft)
Steering knuckle nut 3.5kgf-m (35Nm, 25 lbf-ft)
Front shock absorber upper
mount bolt 4.0kgf-m (40Nm, 29 lbf-ft)
Front shock absorber lower
mount bolt 4.0kgf-m (40Nm, 29 lbf-ft)
SPECIAL TOOLS
Oil seal and bearing install 71620-E10-000
Ball join remover 71608-A03-000
TROUBLESHOOTING
Hard steering (heavy) Front wheel wobbling
Insufficient tire pressure Bent rim
Excessive wheel bearing play
Bent spoke plate
Faulty tire
Steers to one side or does not track straight Improperly tightened axle nut
Uneven front shock absorbers Soft front shock absorber
Bent front arm Weak shock springs
Bent steering knuckle Insufficient damper oil
Front shock absorber noise
Slider bending
Loose arm fasteners
Lack of lubrication
12-2
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
FRONT WHELL
CONSTRUCTION
12-3
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
FRONT WHEEL
REMOVAL AND INSPECTION
Place the machine on a level place.
Remove four nuts attaching the front wheel
hub and front wheel.
Elevate the front wheels by placing a
suitable stand under the frame.
* Support the machine securely so
there is no danger of it falling over. Nuts
INSTALLATION
12-4
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
When reinstalling a wheel, tighten the
wheel nuts in a crisscross (rather than a
circular) pattern.
Torque: 4.5kgf-m (45Nm,32lbf-ft)
DISASSEMBLY
Remove the outside collars.
Inspect the dust seals for wear or damage.
If any defects are found, replace the dust
seal with a new one.
Remove the dust seals by a flat-head screw
driver.
* Place a wood block against the outer
12-5 edge to protect this edge.
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Bearing
Bearing
If any defects are found, replace the
bearings
12-6
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Distance Collar
ASSEMBLY
12-7
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Install the left new bearing and dust seal
into the front wheel hub.
Special
Special
Distance Collar
12-8
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Install the right new bearing and dust seal
into the front wheel hub.
*Apply the grease onto the oil seal lips,
bearing.
Special
Special
INSTALLATION
Reverse the “FRONT WHEEL HUB
REMOVAL AND INSPECTION’’
FRONT SUSPENSION
CONSTRUCTION
12-10
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
FRONT SUSPENSION
REMOVAL AND INSPECTION
Elevate the front wheels by placing a
suitable stand under the frame.
*Support the machine securely so there is
no danger of it falling over.
Tie-rod
Remove the cotter pins, washer and nuts
from tie-rod, upper and lower front arm.
Disconnect the tie-rob ball from the steering
knuckle.
12-11
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
lower arms off the knuckle, using the
special tool according to the following
instructions.
Special
Special
Bolts
12-12
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Shock Absorber
12-13
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Torque: 4.5 kgf-m (45 Nm, 32 lbf-ft)
Bolts
Inspect bearings.
Wear/damage→ Replace.
12-15
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Bolts
Inspect bearings.
Wear/damage → Replace.
12-16
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
INSTALLATION
Reverse the “FRONT SUSPENSION
REMOVAL AND INSPECTION’’
procedures.
12-17
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Nut Nut
TIE-ROD
REMOVAL/INSPECTION
Remove the cotter pin and nut attaching the
tie-rod and steering column.
Remove the cotter pin, and nut
attaching the tie-rod and steering knuckle.
Then remove tie-rod.
Cotter pin
Cotter pin
12-18
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
roughly → Replace.
Check the tapered surface of the tie-rod end.’
Pitting/wear/damage → Replace.
12-19
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Adjust the tie-rod length
Adjustment steps:
(The following procedures are done on both
tie-rods, right and left.)
Loosen the tock nuts.
Adjust the tie-rod length by tuning both tie-
rod ends.
Tie rod length: 430±1 mm
12-20
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
INSTALLATION
Reverse the “REMOVAL/INSPECTION”
procedures.
Install the tie-rod onto the steering knuckle
and steering column, then tighten the nuts.
Torque:
Steering knuckle side:
2.1 kgf-m (21Nm, 15 lbf-ft)
Steering column side:
3.5 kgf-m (35Nm, 25lbf-ft)
*Be sure that the rod-end on the
indentation surface side is connected to
the steering knuckle.
12-21
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
HANDLEBAR
CONSTRUCTION
12-22
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
12-23
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
HANDLEBAR
REMOVAL/INSPECTION
Remove the following parts:
Seat, cover Fender , front fender and
handlebar cover.
Handlebar cover
Screws
12-24
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Screws
Screws
Bolts
12-25
Handlebar Holder
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
holder.
12-26
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
INSPECTION
Inspect the handlebar.
Cracks/bends/ damage → Replace.
INSTALLATION
Install handlebar and handlebar holder, then
tighten the four bolts.
Torque: 2.2 kgf-m (22Nm, 16 lbf-ft)
*Align the mark on the handlebar with the
lower handlebar holder surface.
*
Be sure the upper handlebar holder
mark face to front.
First tighten the bolts on the front side
of the handlebar holder, and then
tighten the bolts on the rear side.
12-27
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
12-28
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Install the handlebar switch by aligning the
Pin Hole
pin on the handlebar switch with the hole in
the handlebar and then tighten the two
screws.
Master cylinder
“UP” Mark
Place the right brake master cylinder on the
handlebar and install the master cylinder holder
with the “UP” mark facing up.
First tighten the upper bolt and then tighten
the lower blot.
Torque: 1.0 kgf-m (10 Nm, 7.2 lbf-ft)
12-29
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Screws
12-30
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
STEERING COLUMN
REMOVAL AND INSPECTION
Remove handlebar. (12-19)
12-31
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
the tie-rods, then disconnect the tie-rods
from the steering column.
12-32
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
INSTALLATION
Reverse the “REMOVAL” procedures.
12-33
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
12-34
13.REAR WHEEL/AXLE/SUSPENSION
13-1
13.REAR WHEEL/AXLE/SUSPENSION
13-2
13.REAR WHEEL/AXLE/SUSPENSION
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Jack the machine rear wheel off the ground be careful to prevent the machine from falling
down.
During servicing, keep oil or grease off the brake disk
Inspect the brake system before riding.
SPECIFICATIONS Unit: mm( in)
Item Standard Service Limit
Rear wheel Rim run out Radial - 2(0.08)
Axial - 2(0.08)
TORQUE VALUES
Rear wheel nut 4.5kgf-m (45 Nm, 32 lbf-ft)
Real shock absorber upper mount bolt 4.0kgf-m (40 Nm, 29 lbf-ft)
Real shock absorber lower mount bolt 4.0kgf-m (40 Nm, 29 lbf-ft)
Rear fork axie 9.0kgf-m (90 Nm, 65 lbf-ft)
Rear wheel hub nut 10.0kgf-m (100 Nm,72 lbf-ft)
Rear wheel shaft nut 12.0 kgf-m (120 Nm, 86 lbf-ft)
Caliper holder bolt 2.2 kgf-m (22Nm, 16 lbf-ft)
SPECIAL TOOLS
Nut wrench 71601-E10-000
TROUBLESHOOTING
Rear wheel wobbling
Bent rim
Faulty tire
Axle not tightened properly
13-3
13.REAR WHEEL/AXLE/SUSPENSION
REAR WHEEL/AXLE/AXLE
HUB
REMOVAL AND INSPECTION
Place the machine on a level place.
Remove the rear caliper. (Refer to the
“REAR BRAKE CALIPER
REMOVAL”section in chapter 11)
Nut
Special
Special
Nut wrench 71601-E10-000
*
Elevate the rear wheels by placing a
suitable stand under the rear of frame.
Support the machine securely so there is
no danger of it falling over.
Wheel Nuts
Nut
Rear Wheel Hub
13-4
13.REAR WHEEL/AXLE/SUSPENSION
Splines
Nut
13-5
13.REAR WHEEL/AXLE/SUSPENSION
Bolts
13-6
13.REAR WHEEL/AXLE/SUSPENSION
Rear sprocket
Remove the bolt、washer and nut.
Bolts
13-7
13.REAR WHEEL/AXLE/SUSPENSION
Washer
Remove the rear axle nut and washer.
Splines
13-8
13.REAR WHEEL/AXLE/SUSPENSION
Bolts
13-9
13.REAR WHEEL/AXLE/SUSPENSION
13-10
13.REAR WHEEL/AXLE/SUSPENSION
13-11
13.REAR WHEEL/AXLE/SUSPENSION
INSTALLATION
Reverse the “REAR SHEEL/AXLE/AXLE
HUB REMOVAL AND INSPECTION”
procedures.
*Apply grease onto the dust seal lips and
bearings,
Install the rear axle hub.
*
At this time, the rear axle hub should not
be tightened completely.
Final tightening is done after the chain
slack adjustment.
13-12
13.REAR WHEEL/AXLE/SUSPENSION
Special
Special
Nut wrench 71601-E10-000
Torque: 12.0 kgf-m (120 Nm, 86 lbf-ft)
13-13
13.REAR WHEEL/AXLE/SUSPENSION
Pivot Shaft
Check the tightening torque of the pivot
shaft (rear fork)securing nut.
Torque: 9.0 kgf-m (90 Nm, 65 lbf-ft)
13-14
13.REAR WHEEL/AXLE/SUSPENSION
Band
Packing cable
13-15
13.REAR WHEEL/AXLE/SUSPENSION
Lower guard
Bolts
Thrust Covers
Remove the thrust covers.
13-16
13.REAR WHEEL/AXLE/SUSPENSION
Collar
Spacer
Oil seal Shock link, rear
Needle bearing
Oil seal
Needle bearing
Bolts
.threaded.
13-17
13.REAR WHEEL/AXLE/SUSPENSION
Grease valve
INSTALLATION
Reverse the “REAR FORK/SHOCK
ABSORBER REMOVAL AND
INSPECTION”
procedure.
Apply grease onto the collar, bush, pivot
shaft and thrust cover.
Pivot Shaft
Install the rear fork and drive chain.
Install the pivot shaft and tightening the nut
and pivot shaft.
Torque: 9.0 kgf-m (90 Nm, 65 lbf-ft)
13-18
14.BATTERY/CHARGING SYSTEM/MAGNETO
BATTER/CHARGING SYSTEM/MAGNETO
14-1
14.BATTERY/CHARGING SYSTEM/MAGNETO
Fuse/Battery
Magneto
Regulator/Rectifier
CHARGING SYSTEM
BATTERY(MF)
FUSE START MAG. SW. START MOTOR 12V 10AH
15A
R
R
M
R
Y
Y
Y
R /W
B
Y
Y
Y
REG./REC. ACG.
M a x .= 3 0 A M a x .= 2 8 0 W
14-2
14.BATTERY/CHARGING SYSTEM/MAGNETO
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and
Eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get
prompt medical attention
The battery can be charged and discharged repeatedly. If a discharged battery is not used for a
long time, its service life will be shortened. Generally, the capacity of a battery will decrease after
it is used for ~ 3years. A capacity-decreased battery will resume its voltage after it is recharged
but its voltage decreases suddenly and then increases when a load is added.
When a battery is overcharged, some symptoms can be found. If there is a short circuit inside the
battery, no voltage is produced on the battery terminals. If the rectifier won’t operate, the voltage
will become too high and shorten the battery service life.
If a battery is not used for a long time, it will discharge by itself and should be recharged every 3
months.
A new battery filled with electrolyte will generate voltage within a certain time and it should be
recharged when the capacity is insufficient. Recharging a new battery will prolong its service life.
Inspect the charging system according to the sequence specified in the Troubleshooting.
Do not disconnect and soon reconnect the power of any electrical equipment because the electronic
parts in the regulator/rectifier will be damaged. Turn off the ignition switch before operation.
It is not necessary to check the GS battery electrolyte or fill with distilled water.
Check the load of the whole charging system.
Do not quick charge the battery. Quick charging should only be done in an emergency.
Remove the battery from the machine for charging.
When replacing the battery, do not use a traditional battery.
When charging, check the voltage with a voltmeter.
SPECIFICATIONS
Item Standard
Battery Capacity/ Model 12V-10AH
Voltage Fully charged 13.1V
( 20℃ ) Undercharged 12.3V
Charging current STD:1.2A Quick: 12A
Charging time STD: 5~ 10hr Quick: 30 min
Magneto coil Pick-up coil 90~110 Ω G-L
resistance Charging coil 0.3~0.8 Ω Y-Y
Limit voltage Lighting 12.0~14.0V
Regulator/Rectifier 10~ 13.0V
Charging 13.5~ 15.5V
14-3
14.BATTERY/CHARGING SYSTEM/MAGNETO
TESTING INSTRUMENTS
Pocket tester
TROUBLESHOOTING
No power Intermittent power
Dead battery Loose battery cable connection
Disconnected battery cable Loose charging system connection
Fuse burned out Loose connection of short circuit in
Faulty ignition switch lighting system
14-4
14.BATTERY/CHARGING SYSTEM/MAGNETO
BATTERY
REMOVAL/INSTALLATION
1. Make sure the ignition switch is OFF.
2. Pull right the lock lever and pull up the
seat at the rear.
Lever
14-5
14.BATTERY/CHARGING SYSTEM/MAGNETO
INSTALLATION
1. Installation is in the reserve order of
removal
First connect the positive (+) cable and then
negative (-) cable to avoid short circuit.
2. Make sure the battery is installed upright
as shown
3. Check all bolts and other fasteners are
secure.
4. After installing the battery, check to see if
the battery cables are routed correctly.
14-6
14.BATTERY/CHARGING SYSTEM/MAGNETO
CHARGING
Connecting the charger positive (+) cable to the
battery positive (+) terminal.
Connecting the charger negative (-) cable to the
battery negative (-) terminal.
*
Keep flames and sparks away from a
charging battery.
Turn power ON/ OFF at the charger, not
at the battery terminals to prevent
sparks near the battery to avoid
explosion.
Charge the battery according to the
current specified on the battery.
14-7
14.BATTERY/CHARGING SYSTEM/MAGNETO
CHARGING SYSTEM
CURRENT LEAKAGE TEST
Remove the seat (see p2-3).
Turn the ignition switch “OFF”, and
disconnect the negative(-) cable from the
battery.
Connect the ammeter (+) probe to the
negative (-) cable and the ammeter (-) probe
to the battery(-) terminal.
With the ignition switch “OFF”, check for
current leakage.
* When measuring current using a tester,
set it to a high range, and then bring
the range down to an appropriate level.
Current flow higher than the range
selected may blow out the fuse in the
tester.
While measuring current, do not turn
the ignition switch “ON”. A sudden
surge of current may blow out the fuse
in the tester.
14-9
14.BATTERY/CHARGING SYSTEM/MAGNETO
Unit :MΩ
(+) Tester probe
(-) Tester probe
14-10
14.BATTERY/CHARGING SYSTEM/MAGNETO
MAGNETO
Using the pocket tester, measure the resistance
between the lead wires in the following table.
If the resistance is not within the specified value,
replace the stator coil, with a new one.
*
When mounting the stator on the magneto cover,
apply a small quantity of “THREAD LOCK” to the
threaded parts of screws.
14-11
14.BATTERY/CHARGING SYSTEM/MAGNETO
14-12
15.IGNITION SYSTEM
IGNITION SYSTEM
SERVICE INFORMATION 15- 2
TROUBLESHOOTING 15- 3
IGNITION UNIT /CHANGE GEAR CINTRIL INSPECTION 15- 4
IGNITION COIL INSPECTION 15- 4
15-1
15.IGNITION SYSTEM
Igntion coil
Magneto
Ignition Unit
IGNTION CIRCUIT
C. D. I UNIT START BATTERY(MF)
( CDI) SW. HAND BRAKE. COMB. SW
. FUSE . START MOTOR
START MAG. SW 12V 10AH
BAT
ST SG
G /Y
BR
L /W
R
G /Y
BR
R
B /L
L /W
M
B /Y
Lb
B
BR
O
W /L
G /Y
BR
BR
L /W
G /Y
L /W
B
R
B /Y
BR
Lb
B
L
G
START
W/L
D
N B/L L/W
PUSH
O R FREE
ACG. LEFT SW
ITCH
CHANGE SW
.
IG. COIL Max. =280W
15-2
15.IGNITION SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
Check the ignition system according to the sequence specified in the Troubleshooting.
The ignition system adopts ignition unit, ignition timing cannot be adjusted.
If the timing is incorrect, inspect the ignition unit, A.C. generator, and replace any faulty parts.
Inspect the ignition unit with a ignition unit tester.
Loose connector and poor wire connection are the main causes of faulty ignition system. Check
each connector before operation.
Use of spark plug with improper heat range is the main cause of poor engine performance.
The inspections in this section are focused on maximum voltage. The inspection of ignition coil
resistance is also described in this section.
Inspect the spark plug referring to chapter 3.
SPECIFICATIONS
Item Standard
Spark plug Standard type CR8E
Spark plug gap 0.7 ~ 0.8 mm
Ignition timing “T” Line 6∘± 1∘ B T D C /
Full advance 1500RPM
Ignition coil resistance(20℃) Primary coil 3.8~5.2Ω
Secondary 12~18 KΩ
Coil(With plug cap)
Pulser coil resistance (20℃) 90 ~ 110Ω
Ignition coil primary side max. voltage 12V
Exciter coil max. voltage 19KV
TESTING INSTRUMRNT
Commercially available electric tester with resistance over 10MΩ/CDV
15-3
15.IGNITION SYSTEM
TROUBKESHOOTING
High voltage too low No high voltage
Weak battery or low engine speed Faulty ignition switch
Loose ignition system connection Faulty ignition unit
Faulty ignition unit Poorly connected or broken ignition unit
ground wire
Faulty ignition coil Dead battery or faulty regulator/ rectifier
Faulty pulser coil Faulty ignition coil connector
Normal high voltage but no spark at plug Faulty pulser coil
Faulty spark plug
Electric leakage in ignition secondary circuit
Faulty ignition coil
Good spark at plug but engine won’t start
Faulty ignition unit or incorrect ignition timing
Improperly tightened A.C. generator flywheel
15-4
15.IGNITION SYSTEM
Plastic Rivet
15-5
15.IGNITION SYSTEM
PULSER COIL
INSPECTION
Remove the front fender. (Refer to the
chapter 2)
Disconnect the pulser coil wire coupler and
measure the resistance between the blue
and green wire terminals.
Resistance: 90~110Ω 20℃
15-6
16.STARTING SYSTEM
STARTING SYSTEM
SERVICE INFORMATION 16- 2
TROUBLESHOOTING 16- 2
STARTER MOTOR 16- 3
STARTER RELAY 16- 4
STARTER CLUTCH 16- 4
16-1
16.STARTING SYSTEM
Starter Motor
15A
ST SG
G/Y
BR
L /W
G/ Y
R
BR
L /W
B /L
M
G/Y
BR
BR
L /W
R
G/ Y
L /W
B
START
B/L L/ W
PUSH
FREE
L E F T S WIT C H
This ATV can only start the engine with pulling the clutch lever.
16-2
16.STARTING SYSTEM
SERVICE INFORMATION
GENERAL INSTRUCTIONS
The removal of starter motor can be accomplished with the engine installed.
TROUBLESHOOTING
Starter motor won’t turn Lack of power
Fuse burned out Weak battery
Weak battery Loose wire or connection
Faulty ignition switch Foreign matter stuck in starter motor
Faulty starter clutch of gear
Faulty front or rear stop switch
Faulty starter relay Starter motor rotates but engine does
Poorly connected, broken or shorted wire not start
Faulty starter motor Faulty starter clutch
Weak battery
16-3
16.STARTING SYSTEM
STARTER MOTOR
REMOVAL Rubber Jacket
*
Before removing the starter motor, turn
the ignition switch OFF and remove the
battery ground. Then, turn on the
ignition switch and push the starter
button to see if the starter motor operates
properly.
Remove the waterproof rubber jacket and
remove nut to disconnect the starter motor
cable connector.
Remove the two starter motor mounting
bolts and the motor.
Bolts
Small Gear
Remove the starting motor then connect to
Battery to check if the rotation is abnormal
noise, Change to new parts, if it is abnormal.
16-4
16.STARTING SYSTEM
STARTER CLUTCH
REMOVAL / INSTALLATION
Refer to the chapter 9
16-5
17.LIGHTS/SWITCHES
LIGHTS/SWITCHES
SERVICE INFORMATION 17- 1
BULB REMOVAL 17- 2
HORN (ON ROAD) 17- 7
IGNITION SWITCH 17- 8
HANDLEBAR SWITCH 17- 9
GEAR POSITION SWITCH 17- 10
17-1
17.LIGHTS/SWITCHES
SERVICE INFORMATION
A continuity test can be made with the switches installed on the vehicle.
All plastic connectors have locking tabs that must be released before disconnecting, and
must be aligned when reconnecting.
To isolate an electrical failure, check the continuity of the electrical path through the part. A
continuity check can usually be made without removing the pat from the vehicle. Simply
disconnect the connectors and connect a continuity tester to the terminals or connections.
ITEM SPECIFICATION
HI 12V/35W
Head lamp LO 12V/35W
POSITION 12V/5W
Brake / Tail lamp 4.2W/2.2W(LED)
Signal lamp 0.82W(LED)
17-2
17.LIGHTS/SWITCHES
BULBS REMOVAL
HEADLIGHT
Remove the front fender cover.
POSITION LIGHT
Remove the bulb socket by pulling it out.
Remove the bulb.
Install the bulb in the reverse order of
Removal
17-3
17.LIGHTS/SWITCHES
TAIL/BRAKE LIGHT
This ATV’s tail/brake light is LED type.
Lever
Screw Screw
Bolts
17-4
17.LIGHTS/SWITCHES
Bolts Bolts
17-5
17.LIGHTS/SWITCHES
Battery wire
Fixing bracket
Tail/brake light
Screws
Nuts
17-6
17.LIGHTS/SWITCHES
INSTALLATION
The installation sequence is the reverse of
removal.
INSTALLATION
The installation sequence is the reverse of
removal.
Nut
17-7
17.LIGHTS/SWITCHES
REAR
Signal light wire leads
Disconnect the signal light wire leads.
Remove the nut.
Remove the signal light assembly.
INSTALLATION
The installation sequence is the reverse of
removal.
Nut
INSTALLATION
The installation sequence is the reverse of
removal.
Horn Wire Leads Horn
17-8
17.LIGHTS/SWITCHES
IGNTTION SWTTCH
INSPECTION
Disconnect the ignition switch connectors.
REPLACEMENT
Remove the ignition switch clips.
Remove the ignition switch from the cover.
17-9
17.LIGHTS/SWITCHES
HANDLEBAR SWTTCH
INSPECTION
Remove fender cover.
Disconnect the connectors.
Winker Switch
Start Switch
17-10
17.LIGHTS/SWITCHES
17-11
TAPPET SHIM SELECTION CHART (IN.)
SHIM NO.
230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
MEASURING SHIM THICKNESS 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
TAPPET AT PRESENT
0.00~0.04 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40
0.05~0.09 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45
0.10~0.20 Specified clearance--Adjustment unnecessary
0.21~0.25 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.26~0.30 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.31~0.35 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.36~0.40 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.41~0.45 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.46~0.50 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.51~0.55 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.56~0.60 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.61~0.65 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.66~0.70 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 HOW TO USE THE CHART
0.71~0.75 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 1. Measure the tappet clearance . (When cold)
0.76~0.80 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 2. Measure the shim thickness at present .
0.81~0.85 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 3. Look for meeting space in that horizontal line
0.86~0.90 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 for thickness and vertical line for clearance .
0.91~0.95 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.96~0.10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 (EXAMPLE)
1.01~1.05 3,20 3,25 3,30 3,35 3,40 3,45 3,50 When the tappet clearance is 0.38mm and the
1.06~1.10 3,25 3,30 3,35 3,40 3,45 3,50 shim thickness at present is 2.70mm , the shim
1.11~1.15 3,30 3,35 3,40 3,45 3,50 thickness should be used 2.95mm .
TAPPET SHIM SELECTION CHART (EX.)
SHIM NO.
230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
MEASURING SHIM THICKNESS 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
TAPPET AT PRESENT
0.10~0.14 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40
0.15~0.19 2,30 2,35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45
0.20~0.30 Specified clearance
0.31~0.35 2,40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.36~0.40 2,45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.41~0.45 2,50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.46~0.50 2,55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.51~0.55 2,60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.56~0.60 2,65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.61~0.65 2,70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.66~0.70 2,75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.71~0.75 2,80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
0.76~0.80 2,85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 HOW TO USE THE CHART
0.81~0.85 2,90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 1. Measure the tappet clearance . (When cold)
0.86~0.90 2,95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 2. Measure the shim thickness at present .
0.91~0.95 3,00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 3. Look for meeting space in that horizontal line
0.96~1.00 3,05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 for thickness and vertical line for clearance .
1.01~1.05 3,10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50
1.06~1.10 3,15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 (EXAMPLE)
1.11~1.15 3,20 3,25 3,30 3,35 3,40 3,45 3,50 When the tappet clearance is 0.48mm and the
1.16~1.20 3,25 3,30 3,35 3,40 3,45 3,50 shim thickness at present is 2.70mm , the shim
1.21~1.25 3,30 3,35 3,40 3,45 3,50 thickness should be used 2.95mm .