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Service Manual Access450

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100% found this document useful (1 vote)
4K views305 pages

Service Manual Access450

Uploaded by

filipe
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 305

1.

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) Location of Frame Serial Number


(Vehicle Identification Number)

(2) Location of Engine 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

Starting system Electric starter


Type 4-stroke, DOHC Reverse Foot / hand operated
Cylinder arrangement Single cylinder
Valve arrangement O.H.C., 4 valve
1st 2.538
Bore × stroke (mm) 96 × 62 mm
2st 1.684
Gear ratio

(3.78 × 2.44 in)


Compression ratio 11.8:1 3st 1.261
Compression pressure 16 kgf/cm²(at 500 rpm) 4st 1.040
5st 0.885
Valve clearance Intake 0.1~0.2 mm reverse 2.231
Engine

(cold) (0.004~0.008 in) Final reduction 3.143


Exhaust 0.2~0.3 mm
(0.008 ~0.012 in) Drive chain 520 O-Ring Chain
Idle speed (rpm) 1800 rpm FR/RR tire rolling 1676/1596 mm(66/62.8 in)
Moving Device

Lubrication type Wet sump circumference


system
Lubrication

Tire pressure Front 0.32 kg/cm²


Oil change 2.5 L (35 Kpa,5 psi)
Rear
Oil and filter 2.6L
Turning Left 40˚
change
angle Right 40˚
Engine overhaul 2.7L
Cooling Type Liquid cooled Brake system Rear Disk brake
type Front Disk brake
Suspension Front Independent, double A-arm
Device
Damping

type
Rear Linkage-type

1-3
1.GENERAL INFORMATION

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,


circlips, cotter pins, etc. when
reassembling.

 When tightening bolts or nuts, begin with


larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

 Use genuine parts and lubricants.

 When servicing the machine, be sure to


use special tools for removal and
installation.

After disassembly, clean removed parts.


Lubricate sliding surface with engine oil
before reassembly.

1-2
1.GENERAL INFORMATION

 Apply or add designated greases and


Lubricants to the specified lubrication
points.

 After reassembly, check all parts for


Proper tightening and operation.

 When two persons work together, pay


Attention to the mutual working safety.

 Disconnect the battery negative (-)


terminal before operation.
 When using a spanner or other tools,
make sure not to damage the motorcycle
surface.

 After operation, check all connecting


points, fasteners, and lines for proper
connection and installation.
 When connecting the battery, the positive
(+) terminal must be connected first.
 After connecting, apply grease to the
battery terminals.
 Terminal caps shall be installed securely.

1-3
1.GENERAL INFORMATION

If the fuse is burned out, find the cause


and repair it. Replace it with a new one
according to the specified capacity.

 After operation, terminal caps shall be


Installed securely.

 When taking out the connector, the lock


on the connector shall be released before
operation.

 Hold the connector body when connecting


or disconnecting it.
 Do not pull the connector wire.

 Check if any connector terminal is


Bending, protruding or loose.

1-4
1.GENERAL INFORMATION

 The connector shall be inserted


completely.
 If the double connector has a lock, lock
it at the correct position.
 Check if there is any loose wire.

Before connecting a terminal, check


for damaged terminal cover or loose
negative terminal.

 Check the double connector cover for


proper coverage and installation.

 Insert the terminal completely.


 Check the terminal cover for proper
coverage.
 Do not make the terminal cover opening
face up.

 Secure wire harnesses to the frame with


their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

1-5
1.GENERAL INFORMATION

 After clamping, check each wire to make


sure it is secure.

 Do not squeeze wires against the weld or


its clamp.

 After clamping, check each harness to


make sure that it is not interfering with
any moving or sliding parts.

 When fixing the wire harnesses, do not


make it contact the parts which will
generate high heat.

 Route wire harnesses to avoid sharp edges


or corners. Avoid the projected ends of
bolts and screws.
 Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.

1-6
1.GENERAL INFORMATION

 Route harnesses so they are neither


pulled tight nor have excessive slack.

 Protect wire and harnesses with


electrical tape or tube if they contact a
sharp edge or corner.

 When rubber protecting cover is used to


protect the wire harnesses, it shall be
installed securely.

Do not break the sheath of wire.


If a wire or harnesses is with a broken
Sheath, repair by wrapping it with
Protective tape or replace it.

 When installing other parts, do not press


or squeeze the wires.

1-7
1.GENERAL INFORMATION

 After routing check that the wire


harnesses are twisted or kinked.

 Wire harnesses routed along with


handlebar should not to be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

 When a testing device is used, make sure


to understand the operating methods
thoroughly and operate according to the
operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove


the rust with sand paper or equivalent
before connecting.

1-8
1.GENERAL INFORMATION

 Symbols:
the following symbols represent the
servicing methods and cautions included
in this service manual.

:Apply engine oil to the specified points。


(Use designated engine oil for lubrication。)

Engine oil

:Apply grease for lubrication。

Grease

:Transmission Gear Oil。


(SAE80W90)

Gear Oil

Special :Use special tool。


Special

: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

Item Q`ty Thread dia Torque Remarks


(mm) kgf-m (N-m, lbf ft)

Steering stem nut 1 14 7 (70, 50)


Front swing arm nut 8 10 4.5 (45, 32)
Front wheel nut 8 10 4.5 (45, 32)
Rear wheel nut 8 10 4.5 (45, 32)
Front wheel hub nut 2 14 7 (70, 50)
Rear wheel hub nut 2 18 10 (100, 72)
Front shock absorber upper mount bolt 2 10 4 (40, 29)
Front shock absorber lower mount bolt 2 10 4 (40, 29)
Rear shock absorber upper mount bolt 1 10 4 (40, 29)
Rear shock absorber lower mount bolt 1 10 4 (40, 29)
Rear swing arm axle 1 16 9 (90, 66)
Rear hub nut 4 12 6 (60, 43)
Rear wheel shaft nut 2 38 12 (120, 86)
Front engine bracket upper bolt 1 10 4.5 (45, 32)
Rear engine bracket lower bolt 1 10 4.5 (45, 32)
Engine hanger bracket bolt 1 10 4.5 (45, 32)
Engine hanger bracket bolt 1 14 7 (70, 50)
Exhaust muffler lock bolt (frame) 1 10 4.5 (45, 32)
Exhaust muffler lock nut (engine) 2 8 2 (20, 14.4)

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.

Throttle Cable Steering Column Upper

Front Swing Arm Bush Front Swing Arm Bush

Steering Column Lower

1-13
1.GENERAL INFORMATION

Rear Swing Arm Axle

Driven Sprocket

Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing

1-14
1.GENERAL INFORMATION

(1) Clutch lever holder

(2) Steering shaft holder

(3) Throttle lever (4) Front brake lever holder


holder

(6) Drive shaft joint spline (5) Rear brake pedal and rod link

1-15
1.GENERAL INFORMATION

CABLE & HARNESS ROUTING


Speedometer Cable

Blink Relay
Parking Cable
Throttle Cable

Hand Brake Hose Clutch Cable

Front Brake Cable


Reverse Cable
Handlebar,Switch Wire

Hose, Pressure Release Power Supplier Wire

CDI Unit Main Wire Ass’y


Horn (ON ROAD)

Left Front Brake Fluid Hose

Right Front Brake Fluid Hose

Head Light Cable


Main Switch

Front Right Turn Signal Light


(ON ROAD)

1-16
1.GENERAL INFORMATION

Battery Cable
Main Wire Ass’y

Cable,Manual Choke

Gear Position Switch

Hose Comp, Oil

Outlet Water Hose

Rectifier & Regulator

Rear Left Turn Signal Light


(ON ROAD)

1-17
1.GENERAL INFORMATION

Rear Right Turn Signal Light


(ON ROAD)

Hose Comp, Oil

Start Motor Cable

Water Hose
Inlet Water Hose

1-18
1.GENERAL INFORMATION

Footbrake Switch Wire

Hose,Foot brake
Hydraulic Pump

1-19
1.GENERAL INFORMATION

Hose, Pressure Release


For Cylinder Head Cover
Hose, Pressure Release
For Air Cleaner
Oil Filter,Box
Left Front Brake

Cable , Rear Disk


Brake
Hose , Rear
brake

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

(HS1 12V 35/35W)


G

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”

Engine will not start, 1. Fouled spark plug. Clean or replace


or is hard to start. Clean and dry
2. Wet spark plug.
Replace
3. Defective ignition coil.
Replace
4. Open or short circuit in high tension
cord. Replace
5. Defective magneto. Replace
6. Defective igniter.
No fuel reaching the carburetor Clean.
1. Clogged hole in the fuel tank cap. Clean or replace
2. Clogged or defective fuel cock. Replace
3. Defective carburetor float valve. Clean or replace.
4. Clogged fuel pipe.
1. Fouled spark plug. Clean
2. Clogged fuel hose. Clean
Engine stalls easily 3. Clogged jets in carburetor. Clean
4. Valve clearance out of adjustment. Adjust
5. Defective CDI unit. Replace

Excessive valve chatter


1. Valve clearance too large. Adjust
Noisy engine 2. Weakened or broken valve springs. Replace
3. Worn down camshaft. Replace

Symptom and possible causes Remedy

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

Slipping clutch 1. Clutch control out of adjustment or Adjust


too much play.
2. Weakened clutch springs. Replace
3. Worn or distorted pressure plate. Replace
4. Distorted clutch plates, driven and Replace
drive.

Complaint

1-24
1.GENERAL INFORMATION

Symptom and possible causes Remedy


1. Clutch control out of adjustment or Adjust
too much play.
Dragging clutch 2. Weakened clutch springs. Replace
3. Distorted clutch plates, driven and Replace
drive.
1. Broken gearshift cam. Replace
Transmission will not 2. Distorted gearshift forks. Replace
shift 3. Worn gearshift pawl. Replace
1. Broken return spring on shift shaft. Replace
Transmission will not 2. Shift shaft are rubbing or sticky. Repair
shift back 3. Distorted or worn gearshift forks. Replace
1. Worn shifting gears on driveshaft or Replace
countershaft.
Transmission jumps 2. Distorted or worn gearshift forks. Replace
out of gear 3. Weakened stopper pawl spring on Replace
gearshift cam.
4. Worn gearshift pawl. Replace
1. Valve clearance out of adjustment. Adjust
2. Poor seating of valves. Replace
3. Defective valve guides. Replace
Engine idles poorly 4. Defective pick-up coil. Replace
5. Spark plug gap too wide. Adjust or replace
6. Defective ignition coil resulting in Replace
weak sparking.
7. Float-chamber fuel level out of Adjust
adjustment in carburetor.
8. Clogged jets. clean
1. Valve spring weakened. Replace
2. Valve timing out of adjustment. Adjust
Engine runs poorly in 3. Worn cams. Replace
high speed range 4. Spark plug gap too narrow. Repair
5. Defective ignition coil. Replace
6. Float-chamber fuel level too low. Adjust
7. Clogged air cleaner element. Clean
8. Clogged fuel hose, resulting in Clean or replace
inadequate fuel supply to carburetor
1. Too much engine oil in the engine. Check with inspection
window, drain out excess oil.
2. Worn piston rings or cylinder. Replace
Dirty or heavy exhaust 3. Worn valve guides. Replace
smoke 4. Cylinder wall scored or scuffed. Replace
5. Worn valve stems. Replace
6. Defective stem seals. Replace
7. Worn side rails. Replace

Complaint Symptom and possible causes Remedy

1-25
1.GENERAL INFORMATION

1. Loosen of valve clearance. Adjust


2. Weakened valve springs. Replace
3. Valve timing out of adjustment. Adjust
4. Worn piston rings or cylinder. Replace
5. Poor seating of valve. Repair or replace
6. Fouled spark plug. Clean or replace
Engine lacks power 7. Worn camshaft. Replace
8. Spark plug gap incorrect. Adjust or replace
9. Clogged jets in carburetor. Clean
10. Float-chamber fuel level out of Adjust
adjustment.
11. Clogged air cleaner element. Clean
12. Too much engine oil. Drain out excess oil
13. Defective air intake pipe. Retighten or replace
1. Heavy carbon deposit on piston head. Clean
2. Not enough oil in the engine. Add oil
3. Defective oil pump or clogged oil Repair or replace
Engine overheats circuit.
4. Fuel level too low in float chamber. Adjust
5. Air leak from intake pipe. Retighten or replace
6. Use of incorrect engine oil. Change
7. Defective cooling system. See “cooling system”
section.
No sparking or poor 1. Defective ignition coil. Replace
sparking. 2. Defective spark plug. Replace
3. Defective igniter. Replace
1. Mixture too rich. Adjust carburetor
Spark plug soon 2. Idling speed set too high. Adjust carburetor
becomes fouled with 3. Incorrect gasoline. Change
carbon. 4. Dirty element in air cleaner. Clean or replace
5. Spark plug too cold. Replace by hot type plug
1. Worn piston rings. Replace
Spark plug become 2. Pistons or cylinder worn. Replace
fouled too soon. 3. Excessive clearance of valve stems in Replace
valve guides.
4. Worn stem oil seal. Replace
1. Spark plug too hot. Replace by cold type plug.
Spark plug electrodes 2. The engine overheats. Tune up.
overheat or bum. 3. Spark plug loose. Retighten
4. Mixture too lean. Adjust carburetor.

1-26
2.FRAME COVERS/EXHAUST MUFFLER

FRAME COVERS/EXHAUST MUFFLER

SERVICE INFORMATION 2-2


TROUBLESHOOTING 2-2
FRAME COVERS 2-3
EXHAUST MUFFLER REMOVAL 2-9

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

Remove 3 mounting bolts and nylon net.


Remove the right (left) nerfbar.


During removal, do not pull the joint
Claws forcedly to avoid damage.

Installation is in the reverse order of


removal.

Nerfbar
Bolts

Remove 4 screws, and the right (left) footrest.

Screw

Footrest
Holder, Footrest
Remove 2 Bolts.

2-5
2.FRAME COVERS/EXHAUST MUFFLER

Remove the right (left) Holder, Footrest.


Bolts
Remove 2 Bolts.
Remove the right (left) Footrest

Bolts

Footrest

Remove the 4 plastic rivets and headlight


connector.

Plastic Rivet

Bolt Bolt

Remove the bolts from the support bracket,

2-6
2.FRAME COVERS/EXHAUST MUFFLER

And remove the right & left Signal Light


connector, main switch connector.

Remove the screws from the 2 side fenders.

Screw Screw

Remove the 2 bolts.

Bolts

Remove the plastic rivet from

2-7

Plastic Rivet Plastic Rivet


2.FRAME COVERS/EXHAUST MUFFLER

the rear fender.

Remove the 2 bolts from support under rear


Fender and right & left signal light, tail light
connector.

Bolts Bolts

Nuts and Washer


Remove the 2 nuts and washer. band
Remove the fixing bracket.

Fuse Box Starter Relay

Remove the battery wire.


Remove the battery.
Battery wire

2-8

Fixing bracket
2.FRAME COVERS/EXHAUST MUFFLER

Remove the 2 screws from rear cover fender.

Screws

2-9
2.FRAME COVERS/EXHAUST MUFFLER

EXHAUST MUFFLER
REMOVAL/INSTALLATION
Remove the exhaust pipe joint nuts.

Exhaust muffler lock nut:


2 kgf-m (20 Nm, 14.4 lbf-ft)

Joint Nuts

Remove the muffler mounting bolt, spring and


exhaust muffler.

Bolts

Spring

Inspect the gasket.


If the exhaust gas leaks, the gasket should
be replaced. Bolts
Installation is in the reverse order of
removal.
Torque Spring
Exhaust muffler lock bolt:
4.5 kgf-m (45 Nm, 32 lbf-ft)

* Be sure to install a new exhaust gasket.

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

Cylinder compression : 16± 2 kg/cm² at 500rpm


Ignition timing : 6° B.T.D.C. at 1500rpm

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

km 150 1000 2000

ROUTINE MONTH 1 6 12
Engine oil  Replace (Warm engine before draining) ○ ○ ○

Oil strainer  Clean. ○ ○ ○


 Replace if necessary.
Clutch  Check operation ○ ○
 Adjust if necessary.
Air filter element  Clean. Every 20~40 hours
(for engine )  Replace if necessary. (150~300km, 100~200 mi)
(More often in wet or dusty areas.)
Carburetor  Check idle speed/starter operation. ○ ○ ○
 Adjust if necessary.
Cylinder head cover  Check breather hose for cracks or damage. ○ ○
breather system  Replace if necessary.
Spark plug  Check condition. ○ ○ ○
 Adjust gap and clean.
 Replace if necessary.
Fuel line  Check fuel hose for cracks or damage. ○ ○
 Replace if necessary.
Valves  Check valve clearance. ○ ○ ○
 Adjust if necessary.
Brake  Check operation and brake fluid. ○ ○ ○
 Replace brake pad if necessary.
Coolant  Check coolant leakage. ○ ○ ○
 Replace if necessary.
 Replace coolant every 24 months.
Battery  Check specific gravity. ○ ○ ○
 Check breather hose for proper operation.
 Correct if necessary.
Exhaust system  Check leakage. ○ ○
 Retighten if necessary.
 Replace gasket if necessary.
Drive chain  Check and adjust slack/alignment/clean/lube. ○ ○ ○

Wheels  Check balance/damage/runout. ○ ○ ○


 Replace if necessary.
Wheel bearings  Check bearing assembly for looseness/damage. ○ ○ ○
 Replace if damaged.
Steering system  Check operation. ○ ○ ○
 Replace if damaged.
 Check toe-in.
 Adjust if necessary.
Knuckle shafts/  Lubricate every 6 months. ○ ○
Steering shaft
Fittings and Fasteners  Check all chassis fittings and fasteners. ○ ○ ○
 Correct if necessary.
 In the interest of safety, we recommend these items should be serviced only by an authorized
Access Motor dealer.

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)

To adjust throttle free play:


Slide the rubber sleeve back to expose the
Throttle cable adjuster.
Loosen the lock nut, then turn the adjuster (A)
To obtain the correct free play. (3~5 mm or
0.12~0.20 in)
Tighten the lock nut and reinstall sleeve. Rubber Sleeve

(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

Unscrew (3) screw and remove the


air cleaner assembly (4) from the air cleaner
box.

Remove the screw.


Remove the air cleaner and air cleaner
screen from the air cleaner body.
remove the air cleaner net from the air
cleaner.

Reassemble by reversing the disassembly


sequence.

Screw Air Cleaner net Air Cleaner Screen

3-5
3.INSPECTION/ADJUSTMENT

CLEAN AIR FILTER ELEMENT


Wash the element gently, but thoroughly in
solvent.
* Use parts cleaning solvent only. Never
use gasoline or low flash point solvents
which may lead to a fire or explosion.
Squeeze the excess solvent out of the
element and let dry.

* Do not twist or wring out the foam


element. This could damage the foam
material.

More frequent replacement is required when


riding in unusually dusty or rainy areas. Air Cleaner Box

AIR CLEANER BOX DRAIN


Remove the drain tube (under air cleaner
case) by removing the clip.
Drain the deposits.
Reinstall the drain tube, securing it with the
clip.

Drain Tube Clip

3-6
3.INSPECTION/ADJUSTMENT

SECONDARY AIR SUPPLY


SYSTEM
This model is equipped with a built-in
secondary air supply system. The pulse
secondary air supply system is near the radiator.
The secondary air supply system introduces
air cleaner air into exhaust gases in the exhaust
port. The secondary air is drawn into the
exhaust port whenever there is negative
pressure pulse in the exhaust system. This
charged secondary air promotes burning of
the unburned exhaust gases and changes a
considerable amount of hydrocarbons and
carbon monoxide into relatively harmless
carbon dioxide and water.
Secondary Air Valve

SPARK PLUG Ignition Coil Cap


Remove ignition coil cap and spark plug.
Check the spark plug for wear and fouling
Deposits.
Clean any fouling deposits with a spark
Plug cleaner or a wire brush.

Specified Spark Plug: CR8E

Spark Plug

3-7
3.INSPECTION/ADJUSTMENT

Measure the spark plug gap.


Spark Plug Gap: 0.7~0.8 mm
(0.028~0.032 in)

* When installing, first screw in the spark Cap,Wear,


and Fouling Deposits
plug by hand and then tighten it with a
spark plug wrench

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.

Remove the seat.


Remove the fender, front.
Remove the cover fender, front.
(See chapter 7)

Remove the four bolts,


then remove the fuel tank.

Bolts Bolts
Remove the spark plug.
Disconnect the pressure release hose

3-8

Pressure release hose breather hose


3.INSPECTION/ADJUSTMENT

and breather hose.

Remove the screw and cylinder head cover.


The valve clearance specification is different
for both intake and exhaust valves.
Valve clearance adjustment must be checked
and adjusted:
1. at the time of periodic inspection,
2. when the valve mechanism is serviced, and
3. when the camshafts are removed for servicing.

cylinder head cover

1 2
Remove the valve timing inspection plug 1.
Remove the magneto cover cap 2.

Rotate the magneto rotor counter-clockwise


with a socket wrench to set the piston at
TDC on the compression stroke.
(rotate the rotor until the “T” line on the

3-9
3.INSPECTION/ADJUSTMENT

magneto rotor is aligned with the triangle


mark on the crankcase.)

To inspect the valve clearance, insert a


thickness gauge between the tappet and camshaft.

Valve clearance Standard (when cold)


IN. 0.10~0.20mm(0.004~0.008 in)
EX. 0.20~0.30mm(0.008~0.012 in)

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

CARBURETOR IDLE SPEED


*The engine must be warm for accurate Throttle Stop Screw air screw
idle speed inspection and adjustment.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed: 1800±100rpm

When the engine misses or run erratic,


Adjust the air screw.

IGNITION TIMING
* Before removing the camshaft housing,
(1)
the piston must be at TDC of the
compression storke. (2)

Remove the valve timing inspection plug.


(1).
Remove the magneto cover cap (2) using
the tool.
Turn the magneto rotor until the “T” line on
the magneto rotor is aligned with the triangle
mark on the crankcase.

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.

Oil pressure:1.0~3.0 kg/cm² (at 60°c , 3000rpm)

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

Oil pressure test procedure


Remove the oil check plug and install the adapter of oil pressure gauge at removed position.
Connect an engine tachometer.
Warm up the engine as follows:
Summer:10 min. at 2000rpm. Winter:20 min. at 2000rpm.
After warming up the engine, increase the engine speed to 3000rpm. (with the engine tachometer),
and read the oil pressure gauge.

ENGINE OIL AND OIL FILTER


The oil should be changed while the engine is warm.
oil filter replacement at the above intervals, should
be done together with the engine oil change.
Engine oil replacement
Place an oil pan under the drain plug(2) on the
crankcase and drain plug(3) on the oil tank.
Then drain out the engine oil by removing the engine
oil drain plug(2) ,(3) and engine oil level gauge(4)
and outer cover oil filler cap(5). (3)
Reinstall the drain plug(2) ,(3) and gasket.
Tighten the engine oil drain plug(2) and(3) to the
specified torque, and then pour the new oil through
the oil filler hole of oil tank and filler hole of outer
cover.
When performing an oil change (without oil filter
replacement ), the engine will hold about 2,500
Lof oil.
Use an engine oil that meets the API service
classifications of over SL and that has a viscosity
rating of SAE 10W/40.
Engine oil drain plug:2.10 kgf-m(21 Nm)…. (2) (2)
1.20 kgf-m(12 Nm) …. (3)

Install the oil lever gauge(4).

3-13
3.INSPECTION/ADJUSTMENT

Install the outer cover oil filler cap(5).


Start the engine and allow it to run for a few
minutes at idling speed.
Turn off the engine and wait about three minutes,
and the check the oil level on the dipstick(6).
(Remove the oil level gauge(4). Wipe the oil
from the oil level gauge using a clean rag.
Reinsert the oil level gauge until the threads
touch filler neck, but do not screw the oil level
gauge in. (4)

If the level is below upper limit line, add oil to


that level.
The vehicle must be in a level position for
accurate measurement.

(A)

(5)

* Necessarily, confirm and clean the oil


strainer (A) when replace the engine oil
(specially, when first replacement). (6)

3-14
3.INSPECTION/ADJUSTMENT

OIL FILTER REPLACEMENT


Drain the engine oil as described in the
engine oil replacement procedure.
Replace the oil filter (1) with a new one.
Add new engine oil and check the oil level
as described in the engine oil replacement
procedure.

Necessary amount of engine oil


Oil change 2,500cc
Oil and filter change 2,600cc
Engine overhaul 2,700cc
Engine oil type SAE 10W/40
API OVER SL
(1)

3-15
3.INSPECTION/ADJUSTMENT

BRAKE PADS INSPECTION


A wear indicator is provided on each brake.
The indicators allows checking of brake
pads wear. Check the position of the
indicator. If the indicator reaches the wear
limit line, to replace the pads.

3-16
3.INSPECTION/ADJUSTMENT

BRAKE FLUID INSPECTION


Check if the fluid level is below the lower
level mark through the inspection window.

Inspection Window (R Brake Lever)

Upper

Lower

Inspection Window (Rear Brake Pedal)

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.

Check the tie-rod ends


Turn the handlebar to the left and/or right
until it stops completely, then slightly move
the handlebar from left to right.
Replace the tie-rod ends if tie-rod end has
any vertical play.

Tie-rod Ends

Raise the front end of the machine so that


there is no weight on the front wheels.
Check ball joints and/or wheel bearings.
Move the wheels lately back and froth.
Replace the front arms and/or wheel
Bearings if excessive free play.

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.

WHEELS/TIRES Tie-rod End Nuts


Check the tires for cuts, imbedded nails or
Other damages.
Check the tire pressure.
* Tire pressure should be checked when
tires are cold.

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

Check the rear axle nut for looseness.


If the axle nuts are loose, tighten them to the
Specified torque.
Torque:
Front : 7.0 kgf-m (70 Nm, 50 lbf-ft)
Rear :10.0 kgf-m (100 Nm, 72 lbf-ft)

Rear Axle Nut

Inspect the tire surfaces.


Replace if wear or damage.
Tire wear limit: 3 mm (0.12 in)

*It is dangerous to ride with a worn out


tire. When a tire wear is out of
specification, replace the tire
immediately.

WHEEL INSPECTION
Inspect the wheel.
Replace if damage.
Always balance the wheel when a tire or
wheel has been changed or replaced.

* Never attempt even small repairs to


the wheel.
Ride conservatively after installing a
tire to allow it to seat itself properly
on the rim.

3-21
3.INSPECTION/ADJUSTMENT

DRIVE CHAIN SLACK


ADJUSTMENT
Before checking and/or adjusting, rotate the
Rear wheels several revolutions and check
slack at several points to find the tightest
point. Check and/or adjust the chain slack
with the rear wheels in this “tightest”
position.
*Too little of chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.

Place the machine on a level place. (B)Bolts


* Wheels should be on the ground without
the rider on it.

Check drive chain slack.


Adjust if out of specification.
Drive chain slack (A):
30~40 mm (1.2~1.6 in)

Adjust drive chain slack:


Loosen the bolts(B).

(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

CABLE INSPECTION AND


LUBRICATION
* Damaged cable sheath may cause
corrosion and interfere with the cable
movement. An unsafe condition may
result so replace such cable as soon as
possible.
Inspect the cable sheath.
Replace if damage.
Check the cable operation.
Lubricate or replace if unsmooth operation.
* Be careful not to drop foreign matters
into the crankcases.

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.

* Wipe off the excess grease.

3-23
3.INSPECTION/ADJUSTMENT

COOLING SYSTEM Coolant Reservoir Cap Minimum Mark


COOLANT LEVEL INSPECTION
Place the machine on the level ground.
Check the coolant level in the coolant
Reservoir when the engine is cold as the
Coolant level will vary with engine
temperature. The coolant level should be
between the maximum and minimum
marks.
If the level is low, remove the coolant
reservoir cap, and then add coolant or
distilled water to raise it to the specified
level.
Recommended Coolant: SIGMA Coolant Maximum Mark
(Standard Concentration 30%)
*The coolant level does not change no
Matter the engine is warm or cold. Fill to
the maximum mark.
COOLANT REPLACEMENT
* Perform this operation when the engine
is cold.

Remove the radiator cap.


Remove the drain bolt to drain the coolant.
Drain the coolant in the reserve tank.
Reinstall the drain bolt.
*The coolant freezing point should be 5℃
lower than the temperature of the riding
area.
Coolant capacity:
1000 cc
Reserve tank capacity: Drain Bolt
400 cc
Start the engine and check if there are no
Bubbles in the coolant and the coolant level
is stable. Reinstall the radiator cap.
If there are bubbles in the coolant, bleed air
from the system.
Fill the reserve tank with the recommended
Coolant up to the maximum mark.

CLUTCH ADJUSTMENT

3-24
3.INSPECTION/ADJUSTMENT

At each maintenance interval, adjust the


clutch cable play by means of clutch cable
adjuster. (3) (2)

The cable play should be 10~15 mm


(0.4~0.6 in) as measured at the clutch lever
holder before the clutch begins to disengage.
If you find the play of the clutch incorrect,
adjust it in the following way:
1. A basis adjustment be allowed by the clutch
lever adjuster (3). (1)
2. Loosen the clutch lever adjuster lock nut (2)
and turn the clutch lever adjuster (3) in or out
to provide the specified play.
3. After adjustment, tighten the lock nut (2).
4. If can’t adjust by the adjuster (3), Loosen the
clutch cable adjuster lock nut (6).
5. Turn the clutch cable adjuster (5) in or out to
provide the specified play.
6. After adjustment, tighten the clutch cable
adjuster lock nut (6).
7. The clutch cable should be lubricated with
a light weight oil whenever it is adjusted.

(1). The clutch lever play


(2). The clutch lever adjuster lock nut
(3). The clutch lever adjuster
(4). The clutch cable adjuster (4) (5)
(5). The clutch cable adjuster lock nut
.

3-25
3.INSPECTION/ADJUSTMENT

Front & Rear suspension Front


Spring PRE-LOAD adjustment
This adjustment can be performed by
changing the adjuster ring position.

To ensure riding comfort, the travel of rear


shock absorber is adjustable.

How to adjust it:


1. Using a wrench to loosen the retaining
nut and adjust the absorber travel.
2. Turning counterclockwise the retaining
nut is to increase the travel, and turning
clockwise is to reduce the travel.
3. Tighten the retaining nut again after a proper
travel is obtained.

Rear

Damping force adjustment

3-26
3.INSPECTION/ADJUSTMENT

The compression and tension damping force


can be individually adjusted by turning the
respective adjusters.
The compression damping force adjusters
(1), (3) is located at the top of the front and
rear suspension.
The tension damping force adjusters (2), (4)
is located at the bottom of the front and rear
suspension.
(1)
FRONT
To adjuster the compression damping force
turn in the adjuster (1) 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.

(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

ENGINE OIL/OIL FILTER


OIL LEVEL AND OIL CHANGE
Refer to the “ENGINE OIL” section in the
chapter 3 to check the oil level and
replacement and oil filter cleaning.

OIL PUMP
REMOVAL
Remove the magneto cover.

Remove the dowel pins and gasket.

Remove the clutch cover (1).


A

(1)

4-4
4.LUBRICATION SYSTEM

* When remove or inspect the clutch drive


and driven plate, remove only the clutch
pressure cover A.

Remove the dowel pins (1) and gasket (2).


(2)
(1)

(1)

Loosen the clutch spring mounting bolts


working in diagonal stages.
Remove the bolts and spring.
Remove the clutch pressure disk (3).

(3)

Remove the clutch drive plates No. 1

4-5
4.LUBRICATION SYSTEM

and driven plates.


Remove the spring washer and spring washer
seat.
Remove the clutch drive plate No. 2.

Remove the clutch push piece (1) and


push rod (2).
Flatten the clutch sleeve hub washer (3). (1) , (2)
(3)
(1)

(3)

(2)

Hold the clutch sleeve hub using the special tool,


(4)
and then remove the clutch sleeve hub nut (4).

Special
Special

Clutch sleeve hub holder:71600-E12-000

Remove the clutch sleeve hub (5). (5)

4-6
4.LUBRICATION SYSTEM

Remove the primary driven gear assembly (6)


(6)
and washer.

Remove the oil pump driven gear (1) (1)


by removing the circlip (2).

4-7
(2)
4.LUBRICATION SYSTEM

Remove the oil pin (3)and oil pump assembly.

(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

If any damages are found, replace them with


new ones.


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.

Apply engine oil to the sliding surfaces of the


oil pump inner rotor, outer rotor and shaft.

When installing the inner rotor (2),


align the pin (3) with the groove (5).
(3)

(5) (2)

When installing the outer rotor, face the


punched mark (6) on the outer rotor to
the outside.

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.

Apply a small quantity of THREAD LOCK


to the oil pump mounting screws,
and then tighten them securely.

When installing the oil pump driven gear,


align the pin (1) with the groove.

(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

 Improper throttle operation  Float level too low


 Intake air leak

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

Misfiring during acceleration


 Faulty ignition system

 Faulty carburetor
Backfiring at deceleration
 Float level too low

 Incorrectly adjusted carburetor

 Faulty exhaust muffler

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

FUEL TANK Fuel Valve


REMOVAL
Warning

 Keep sparks and flames away from the


work area.
 Wipe off any spilled gasoline.

Remove the seat (See page 2-3), and front


fender.

The fuel valve “OFF” when engine off. Fuel Tube


And fuel valve“ON”when engine running.
Disconnect the fuel tube from carburetor.

Disconnect the fuel unit connectors.


Remove the four bolts , then remove
the fuel tank.

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.

Disconnect all fuel tubes and remove the two


bolts, then remove fuel valve.

Replace the O-rings with new ones if they


are damaged or deteriorated.
Bolts O-ring

CARBURETOR

5-6
5. FUEL SYSTEM

CONSTRUCTION

REMOVAL
Disconnect the fuel hose (1).

5-7
5. FUEL SYSTEM

(1)

Loosen the carburetor clamp screw.

Remove the carburetor side cap (2).

(2)

Disconnect the throttle cable (1). Nuts


Remove the O-ring.
(1)

5-8

O-ring
5. FUEL SYSTEM

DISASSEMBLY

Remove the fuel hose (2) and air vent hoses (3).
(3)

(2)

Remove the throttle stop screw (4).


Remove the choke lever (5). (4)

(5)

Remove the carburetor top cap (1).

5-9
5. FUEL SYSTEM

(1)

* Do not use compressed air on the carburetor


body removing the diaphragm : this may
damage the diaphragm.

Remove the spring (2), along with the


diaphragm assembly (3).

(3)

(2)

Remove the jet needle holder (4), spring (5),


E-ring (6), ring (7) and jet needle (8).
(4) (6)

(5)
(7) (8)

Remove the diaphragm cover (1).

5-10
5. FUEL SYSTEM

(1)

Remove the diaphragm (2).

(2)

Remove the float chamber body (3). (3)

Remove the O-ring (1).

(1)

*Replace the removed O-ring with a new


5-11
one to prevent leakage of fuel.
5. FUEL SYSTEM

Remove the float pin (2), float (3) and needle


valve (4).

(3)

(2)
(4)

Remove the valve seat (5).

(5)

Remove the main jet (1), jet holder (2) and (1),(2)
pilot jet (3).

(3)

5-12
5. FUEL SYSTEM

remove the pilot air jet (4) counting and


tightening the number of turn. (4)


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

Pilot jet Piston valve


Main jet Starter jet
Main air jet Gaskets and O-rings
Pilot air jet Pilot outlet and bypass Foreign substance
Needle jet holder Float
Needle valve Jet needle
Valve seat Diaphragm
Needle valve
If any abnormal condition is found, wash the
part clean.
If damage or clogging is found, replace the
part with a new one.

CLEANING
Clean all jets by using compressed air.
After cleaning, reassemble the carburetor
with new seals and gaskets.

* Do not use wire to clean the passageways,


5-13
valve seat and jets. Used compressed air
only.
5. FUEL SYSTEM

FLOAT HEIGHT ADJUSTMENT


To check the float height, turn the carburetor
upside down. Measure the float height (A) (A) 13mm
while the float arm is just contacting the
needle valve using a vernier calipers.

Bend the float arm (1) as necessary to bring


the height to the specified level.

After adjustment, check the float height and


the fuel level again.

(1)

REASSEMBLY
Carburetor reassembly can be performed in
the reverse order of disassembly. (1)
When reassembling, carefully observe the
following instructions.

After cleaning, reinstall the pilot air jet (1) to


the original setting by turning the screw in until

5-14
5. FUEL SYSTEM

it lightly seat, and then backing it out the same


number of turns counted during disassembly.

Install the pilot jet (2), jet holder (3) and


main jet (4).

(3),(4)
(2)

Align the hole (5) of the diaphragm with


passageway on the carburetor body.

* When installing the diaphragm, make sure


the diaphragm is seated at the concave
section of the carburetor. (5)

Apply SUPER GREASE to thread part of the


throttle stop screw, then install the throttle
stop screw to the carburetor.

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.

After the carburetor assembly has been


remounted onto the engine, perform the
following adjustment.

Throttle cable adjustment. -----------Refer to page 3-3


Idle speed adjustment. -----------Refer to page 3-10

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

ENGINE REMOVAL (1)


Drain engine coolant and remove the radiator.
(Refer to chapter 12).
Remove the engine under cover (1).
Drain engine oil. (Refer to page 3-11).
Remove the seat. (Refer to page 2-3)
Remove the headlight connector. (Refer to page 2-5)
Remove the 2 side fenders. (Refer to page 2-6)
Remove the fuel tank. (Refer to page 5-5)

Disconnect the breather hose (2) and remove the oil return tank (3) with hose (4).

(3) (4)

(2) (4)

Remove the carburetor with throttle cable.

6-3
6. ENGINE REMOVEL

Disconnect the battery (-) lead wire.

(3)
Disconnect the spark plug cap (1), oil tank
overflow hose (2) and breather hose (3).

(1) (2)

Remove the engine sprocket cover.

6-4
6. ENGINE REMOVEL

Remove the reverse gear cable bracket (1). (1) (3)


Disconnect the reverse gear cable (2).
Remove the engine sprocket (3) with drive chain (4).
Remove the gear position switch (5).

(2) (5) (4)

Remove the gearshift lever (6).


Remove the engine oil outlet hose (7) and
inlet hose (8).

(6)

(7) (8)

6-5
6. ENGINE REMOVEL

Remove the engine coolant inlet hose. (1)

(1)

Remove the engine coolant outlet hose (2).

(2)

Remove the pressure release hose. (3)

(3)

6-6
6. ENGINE REMOVEL

Disconnect the starter motor lead wire (1)


and ground wire (2).

(1)

(2)

Remove the clutch cable bracket (3). (4)


(3)
Disconnect the clutch cable (4) end out
of the clutch lever.
Disconnect the clutch cable (4) end out
of the clutch release arm.
Remove the clutch release arm (5).

(5)

6-7
6. ENGINE REMOVEL

(2)
Disconnect the magneto lead wire couplers (1)
and gear position switch lesd wire coupler (2).

(1)

Remove the exhaust pipe (3).


(Refer to page 2-8)

(3)

6-8
6. ENGINE REMOVEL

Remove the engine mounting bolts and nuts.


Remove the engine mounting brackets (1).
Remove the engine from the left side.

(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.

Refer to the chapter 1 (page 1-24)

7-4
7.CYLINDER HEAD/VALVES

CYLINDER HEAD COVER


REMOVAL (3) (1) (2)
Remove the fuel tank. (Refer to page 5-4)
Disconnect the spark plug cap (1), oil tank
overflow hose (2) and breather hose (3).

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

Apply engine oil to both sides of the washer (4)


Lightly tighten the cylinder head cover bolts
in diagonal stages, and then tighten them to the
specified torque.
Torque:1.4 kgf-m(14Nm)
*Use a new washer (4). (5) (4)

(1)
CAMCHAIN TENSION ADJUSTER
REMOVAL

Remove the cam chain tension adjuster bolt (1).


Remove the cam chain tension adjuster (2).

(2)

INSTALLATION

7-6
7.CYLINDER HEAD/VALVES

Apply engine oil to the push rod.


Unlock the ratchet mechanism and push the push rod
(3) all the way.

(3)

Install the new gasket and cam chain tension


adjuster to the cylinder.
Tighten the cam chain tension adjuster mounting
bolts (4) to the specified torque. (4)

Torque:1 kgf-m(10Nm)

Tighten the cam chain tension adjuster


bolts (5) to the specified torque.

(5)
Torque:2 kgf-m(20Nm)

Remove the 2 nd pipe.

7-7
7.CYLINDER HEAD/VALVES

Remove the thermostat cover.

Torque:1kgf-m (10 Nm)

Remove the thermostat.

CYLINDER HEAD
REMOVAL
Remove the CYLINDER HEAD COVER. (Refer to page 7-4)

7-8
7.CYLINDER HEAD/VALVES

Remove the CAM CHAIN TENSION ADJUSTER. (Refer to page 7-5)


Remove the thermostat cover、2 nd pipe and thermostat. (Refer to page 7-7)
Remove the carburetor. (Refer to the “carburetor remove” section in the chapter 5)
Remove the exhaust muffler. (Refer to the “exhaust muffler remove” section in the chapter 2)

Remove the valve timing inspection plug (1). (1)


Remove the magneto cover cap (2).

(2)

Turn the magneto rotor until the “T” line on the


magneto rotor is aligned with the triangle mark
on the crankcase.

Remove the cam chain guide (3) and camshaft


housing (4).

(3)
(4)

Remove the dowel pin, intake camshaft (1)


and exhaust camshaft (2).
(1)

7-9 (2)
7.CYLINDER HEAD/VALVES

Remove the four cylinder head bolts in


diagonal stages.

Remove the cylinder head base bolts, and


then remove the cylinder head.

* If the cylinder head dose not com off easily,


lightly tap it using a plastic hammer.
INSPECTION
CAMSHAFT JOURNAL WEAR
Determine whether or not each journal is worn down
to the limit by measuring the oil clearance with the
camshaft installed in place.

7-10
7.CYLINDER HEAD/VALVES

Use the plastigauge to read the clearance at the


Widest portion, which is specified as follows:
Camshaft journal oil Service limit
clearance (IN & EX) 0.15mm (0.006 in)

If the camshaft journal oil clearance exceeds the


service limit, measure the inside diameter of the
camshaft housing and outside diameter of the
camshaft journal. Replace the camshaft or the
cylinder head and camshaft housing depending
upon which one exceeds the specification.

camshaft housing I.D Standard


IN. 22.012~22.025 mm
EX. (0.8666~0.8671 in)

camshaft O.D Standard


IN. 21.959~21.980 mm
EX. (0.8645~0.8654 in)

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.

Camshaft runout Service limit


0.10mm (0.004 in)

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

Cam height H Service limit


Intake cam 39.88 mm (1.570 in)
Exhaust cam 39.88 mm (1.570 in)

7-12
7.CYLINDER HEAD/VALVES

CYLINDER HEAD
DISASSEMBLY

Remove the tappets (1) and shims (2)


by hand or by using a magnet.
(1) (1)

(2)
(2)

Compress the valve springs, and then remove the


valve cotters from the valve stem using the
valve springs compressor.

Special
Special

Valve springs compressor:71605-E12-000


Valve springs compressor attachment

7-13
7.CYLINDER HEAD/VALVES

Remove the valve spring retainer (1), inner


valve spring (2) and outer valve spring (3).
(1)
Remove the valve (4) from the other side.
Remove the oil seal (5) with long-nose pliers. (2)
Remove the valve spring seat (6). (3)
(5)
(6)

(4)

CYLINDER HEAD INPECTION

Check the spark plug hole and valve areas


for cracks.

Check the cylinder head for warp age with a


straight edge and feeler gauge.

Service Limit: 0.05 mm repair or replace if


over.

VALVE GUIDE INSPECTION


VALVE FACE WEAR
Visually inspect each valve face for wear or damage.
If any abnormal wear is found, replace the
respective valve with a new one.
The thickness of the valve face decreases as the
face wears.
Measure the valve head thickness “A”.
If the valve head thickness is not within the
specified value, replace the valve with a new one. A=0.5 mm

7-14
7.CYLINDER HEAD/VALVES

VALVE STEM RUNOUT


Check the valve stem for abnormal wear or bend.
Support the valve using a V-block and measure the
valve stem runout using the dial gauge, as shown.
If the service limit is exceeded or abnormal
condition exists, replace the valve with a new one.

Valve stem runout Service limit


0.05mm (0.002 in)

VALVE HEAD RADIAL RUNOUT


Support the valve using a V-block and measure the
valve head radial runout using the dial gauge,
as shown.
If the runout exceeds the service limit,
replace the valve with a new one.

Valve head radial Service limit


runout 0.35mm (0.014 in)

VALVE STEM DEFLECTION


Life the valve about 10 mm (0.39 in) from the
valve seat.
Measure the valve stem deflection in two directions,
“X” and “Y”, perpendicular to each other.
Position the dial gauge as show.
If the deflection exceeds the service limit,
determine whether the valve or the guide should
be replaced with a new one.
Valve stem deflection Service limit
IN. 0.35mm (0.014 in)
EX. 0.35mm (0.014 in)

7-15
7.CYLINDER HEAD/VALVES

VALVE STEM DIAMETER


Measure the valve stem outside diameter using the
micrometer.
If the diameter measured exceeds the standard,
replace the valve.
Valve stem diameter Standard
IN. 4.975~4.990 mm
(0.1959~0.1965 in)
EX. 4.955~4.970 mm
(0.1951~0.1957 in)

TAPPET & SHIM WEAR


When measuring the valve clearance, the clearance
should be within the standard range.

Valve clearance Standard(when cold)


Intake valve 0.1~0.2 mm
(0.004~0.008 in)
Exhaust valve 0.2~0.3 mm
(0.008~0.012 in)

Inspect the tappet for wear and scratch.


If modification or scratch is present, replace the tappet.
When you checked the valve clearance, if the valve
clearance is wide please replace the present shim
into thick one, if the valve clearance is narrow
please replace the present shim into thin shim.
(refer to page 9-38&9-39)

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.

VALVE SPRING INSPECTION

7-16
7.CYLINDER HEAD/VALVES

The force of the coil spring keeps the valve seat


tight.
A weakened spring results in reduced engine power
output and often accounts for the chattering
noise coming from the valve mechanism.
Check the valve spring for proper strength by
measuring their free length and also by the force
required to compress them. If the spring length
is less than the service limit or if the force
required to compress the valve spring is not
within specification. Replace both the inner and
outer spring as a set.

Valve spring free length Service limit


Inner 36.9 mm(1.45 in)
Outer 39.9 mm(1.57 in)

Valve spring tension Standard


Inner 6.5~7.1 kgf
(14.3~15.7 lbs)
at length 32.0 mm(1.26in)
Outer 12.0~14.0 kgf
(26.5~30.9 lbs)
at length 35.5 mm(1.40in)

REASSEMBLY
Install each valve spring seat (1).

7-17
7.CYLINDER HEAD/VALVES

Apply MOLY PASTE to each oil seal (2) and press


fit them into position.

(2)
* (1)
Be sure to install new oil seal.

Apply MOLY PASTE to the valve as shown, and


Then insert them into the valve guides.


When inserting each valve into the valve
guides, make sure not to damage the lip
of the oil seal.

install the valve spring with the smaller pitch “A”


facing the cylinder head.

Head direction

Install the valve spring retainer by pressing down


the spring using the valve spring compressor. (3) (2)
Fit the cotter halves to the stem end and release

7-18
7.CYLINDER HEAD/VALVES

the lifter to allow the cotter (1) to wedge between


the retainer and the valve stem.
Make sure that the rounded lip (2) of the cotter fits (1)
snugly into the groove (3) in the stem end.

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)

Reverse the“CYLINDER HEAD REMOVAL”


procedures.

Tighten the cylinder head bolts diagonally to the


specified torque.

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

Turn the magneto rotor until the “T” line on the


magneto rotor is aligned with the triangle mark
on the crankcase.

Place each camshaft into the correct position.

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

SHAFT ROTAT ONAL DIRECT ON


3
1 st pin 15 th pin
2

Install the dowel pins (1).


Place each camshaft housing and cam chain guide
into the correct position.
(1)
(1)

7-21
7.CYLINDER HEAD/VALVES

Tighten the camshaft housing bolts to the specified


torque.

Torque:1 kgf-m (10 Nm)

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

SERVICE INFORMATION 8-2


TROUBLESHOOTING 8-2
CYLINDER/PISTON 8-3

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.

Refer to the chapter 1 (page 1-24)

SPECIFICATIONS

8-3
8.CYLINDER/PISTON

Item Standard(mm) Service Limit


(mm)
Cylinder I.D. 96.000~96.015 96.075

War page ― 0.05


Cylindricity ― 0.05
True roundness ― 0.05
Piston, Piston ring free end 1 st Approx 11
Piston ring gap
2 nd Approx 10

Piston ring end gap 1 st 0.25~0.40 0.5


(assembly condition) 2 nd 0.40~0.55 0.7
Piston ring groove 1 st 0.150
clearance 2 nd 0.150
Piston ring groove 1 st 1.21~1.23
width 2 nd 1.01~1.03
Oil 2.01~2.03
Piston ring 1 st 1.170~1.190
thickness 2 nd 0.970~0.990
Piston O.D. 95.945~95.960 95.88

Piston O.D. measuring position 18 mm from bottom of ―


skirt
Piston-to-cylinder clearance 0.050~0.060 0.120

Piston pin hole I.D. 19.002~19.008 19.030

Piston pin O.D 18.992~18.995 18.980

Conrod deflection ----- 3.0


Conrod big end side clearance 0.10~0.65 1.0
Conrod small end I.D. bore 19.006~19.014 19.040

Cylinder base nut orque:1.0kgf-m (10Nm)


Item Standard Service Limit
Cylinder Compression pressure(at 500rpm) 16kg/cm2 14kg/cm2

8-4
8.CYLINDER/PISTON

CYLINDER/PISTON
REMOVAL
Remove the cylinder head.(Refer to the Dowel Pins Gasket
chapter 7)

Remove the two dowel pins and cylinder head


gasket.

Remove the cam chain guide. Cam chain guide


Remove the cylinder base nuts.
Remove the cylinder.

Nut
Cylinder base nut
Torque:1.0gf-m (10Nm)

Remove the cylinder gasket and dowel pins.


Clean any gasket material from the cylinder
surface. Gasket


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.

* Place a clean rag over the cylinder base


to prevent the piston pin clip from dropping
into the crankcase.
Press the piston pin out of the piston and
remove the piston.

Clip Piston Pin


INSPECTION
Inspect the piston, piston pin and piston
rings.
Remove the piston rings.
* Take care not to damage or break the
piston rings during removal.

Clean carbon deposits from the piston ring


grooves.

Inspect the piston will for


wear/scratches/damage.
If any defects are found, replace the piston
with a new one.

8-6
8.CYLINDER/PISTON

PISTON DIAMETER INSPECTION


Measure the outside diameter of piston in the
direction perpendicular to the piston pin axis
at the height from the skirt as shown in the
illustration using a micrometer.
If the measurement is found less than the
service limit, replace the piston.

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

PISTON PIN HOLE BORE


Using a dial calipers, measure the piston pin hole
bore both the vertical and horizontal directions.
If the measurement exceeds the service limit,
replace the piston with a new one.

Service Limit:19.030mm

8-7
8.CYLINDER/PISTON

PISTON PIN DIAMETER INSPECTION


Measure the piston pin O.D.
Service Limits(replace if below):
18.980 mm

PISTON RING FREE END GAP INSPECTION


Before installing piston rings, measure the free end
gap of each ring using vernier calipers.
If the gap is less than the service limit,
replace the ring.

PISTON RING END GAP INSPECTION


(Assembly condition)
Insert the piston ring squarely into the
cylinder using the piston head.

Measure the end gap with a thickness gauge.

If the gap exceeds the service limit,


replace the piston ring with a new one.

Service Limits: 1 st…0.5mm


2nd…0.7mm

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.

Groove clearance service limit:


1 st &2 nd…0.150mm
Groove width standard:
1 st…1.21~1.23mm
2 nd…1.01~1.03mm
Oil…2.01~2.03mm
Piston ring thickness standard:
1 st…1.170~1.190mm
2 nd…0.970~0.990mm

CAM CHAIN TENSION ADJUSTER


AND TENSIONER

CAM CHAIN TENSION ADJUSTER


Check that push rod slides smoothly with the
lock shaft handle clockwise.
If it does not slides smoothly, replace the
cam chain tension adjuster with a new one.

8-9
8.CYLINDER/PISTON

CAM CHAIN TENSIONER


Check the contacting surface of the cam chain
ten-sioner.
If it is worn or damaged, replace it with a new
one.

CAM CHAIN AND CAM CHAIN GUIDE


Check the cam chain for wear, damage and
kinked or binding links. If any defects are found,
replace it with a new one.

Check the cam chain guide for wear and


damage.
If it is found to be damage, replace it with a new
one.

PISTON RING INSTALLATION

8-10
8.CYLINDER/PISTON

Install the piston rings onto the piston.


Apply engine oil to each piston ring.
* Be careful not to damage or break
the
piston and piston rings.
All rings should be installed with the
markings facing up.
After installing the rings, they
should
rotate freely without sticking.

CONROD SMALL END INSIDE DIAMETER INSPECTION


Measure the connecting rod small end I.D.
Service Limit (replace if over):
19.040 mm

CONROD DEFLECTION INSPECTION


Wear on the big end of the conrod can be

8-11
8.CYLINDER/PISTON

estimated by checking the movement of the


small end of the rod.
Turn the conrod and see if it moves smoothly
without play and noise. This method can also
be used to check the extent of wear on the
conrod’s big end.

Service Limit (replace if over):


3.0 mm

CONROD BIG END SIDE CLEARANCE


INSPECTION
Push the big end of the conrod to one side and
measure the side clearance using a thickness
gauge.
If the clearance exceeds the service limit, replace
the crankshaft assembly with a new one or
bring the deflection and the side clearance
within the service limit by replacing the worn
parts (conrod, big end bearing, crankshaft,
crank pin, etc.) with new ones.

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

Install the piston, piston pin and a new


piston pin clip.

* Install the piston with the punch


A
mark “A” on the piston head facing
toward the exhaust side.
Place a clean shop towel in the
crankcase to keep the piston pin clip (2)
from falling into the crankcase.

CYLINDER INSTALLATION (1)


Install the dowel pins (1) and a new cylinder
gasket (2) on the crankcase.
Coat the cylinder bore, piston and piston
rings with clean engine oil.
Carefully lower the cylinder over the piston
by compressing the piston rings.

* Apply proper clean engine oil around


cylinder wall.
Be careful not to damage or break the
piston rings.
Stagger the ring end gaps at 120° to the
piston pin.

8-13
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

CRANK SHAFT/BLANCER DRIVE GEAR


CLUTCH/TRANSMISSION
CRANK CASE/CLUTCH COVER

SERVICE INFORMATION 9-1


TORQUE VALUES/ SPECIAL TOOLS 9-2
REMOVAL 9-3
INSPECTION & SERVICE 9-13
REASSEMBLY 9-26
TAPPET SHIM SELECTION CHART 9-38

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

Crankcase bolt 1.1kgf-m(11Nm)


Gear position switch bolt 0.65kgf-m (6.5 Nm)
Cam chain tensioner mounting bolt 1.0kgf-m (10Nm)
Magneto rotor nut 12kgf-m (120Nm)
Primary drive gear nut 14kgf-m (140Nm)
Gearshift cam stopper 3.2kgf-m (32Nm)
Clutch sleeve hub nut 9kgf-m (90Nm)

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

Remove the magneto cover.

9-3
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Remove the dowel pins and gasket.

Remove the clutch cover (1).


A

(1)

* When remove or inspect the clutch drive


and driven plate, remove only the clutch
pressure cover A.

9-4
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Remove the dowel pins (1) and gasket (2).


(2)
(1)

(1)

Loosen the clutch spring mounting bolts


working in diagonal stages.
Remove the bolts and spring.
Remove the clutch pressure disk (3).

(3)

Remove the clutch drive plates No. 1


and driven plates.
Remove the spring washer and spring washer
seat.
Remove the clutch drive plate No. 2.

9-5
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Remove the clutch push piece (1) and


push rod (2).
Flatten the clutch sleeve hub washer (3). (1) , (2)
(3)
(1)

(3)

(2)

Hold the clutch sleeve hub using the special tool,


(4)
and then remove the clutch sleeve hub nut (4).

Special
Special

Clutch sleeve hub holder:71600-E12-000

Remove the clutch sleeve hub (5).

(5)

(6)

9-6
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Remove the primary driven gear assembly (6)


and washer.

Remove the collar (7). (7)

Remove the oil pipe (1).


(1)

9-7
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Remove the oil pump driven gear (3)


by removing the circlip (2). (3)

(2)

Remove the oil pin (4) and oil pump assembly.

(4)

Remove the gearshift shaft (2) by removing


the circlip (1).

(2) (1)
(2)

Remove the gearshift cam stopper (3).

9-8

(3)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Loosen the gearshift cam plate bolt (4). (4)


Remove the gearshift cam plate.

With the crankshaft held immovable using the


special tool, remove the primary drive gear nut
(1), washer and water pump drive gear (2).

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

With the magneto rotor held immovable using


the special tool, loosen the rotor nut.

Special
Special

Conrod holder:71612-E12-000

remove the magneto rotor using the special tool.

Special
Special
Rotor remover:71604-E12-000


Do not hit the magneto rotor with a
hammer, otherwise the rotor may be
damaged.

Remove the magneto rotor key (1).


(1)
Remove the starter driven gear (2).
(2)

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

Remove the gear position switch (7).


Remove the O-ring (8), switch contact (9)
and spring (10).

(10) (9) (10)


(7) (8)
(7)

(9)
(8)

Remove the left crankcase securing bolts.

Remove the right crankcase securing bolts.

9-11
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Separate the crankcase using the special tool.

Special
Special

Crankcase separator:71607-E03-000

* Fit the crankcase separator, so that



the tool arms parallel the side of the
crankcase.

Remove the dowel pins (1).


Remove the gearshift fork shafts (2), (1)
(2)
gearshift forks (3) and gearshift cam (4).

(4) (3)

(2)
(1)
(3)

Remove the countershaft assembly (5) and


(7)
driveshaft assembly (6).
Remove the reverse idle gear with its shaft (7).

9-12
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

(6)
(5)

Remove the crank balancer (8).

(8)

Remove the crankshaft from the crankcase


using the special tool.

Special
Special

Crankcase separator:71607-E03-000

INSPECTION & SERVICE

CRANKSHAFT

9-13
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

CRANKSHAFT RUNOUT INSPECTION


With the right and left crank journals supported
using a V-block, turn the crankshaft slowly.
At this time, measure the crankshaft end
runout using a dial gauge. If the runout exceeds
the service limit, replace the crankshaft with
a new one.

Service limit:0.05mm

CRANK BALANCER AND BALANCER DRIVE GEAR


DISASSEMBLY
Disassemble the crank balancer and balancer drive gear as show in the illustration.

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.

Torque:2.3~2.8 kgf-m (23~28 Nm)

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.12.92~3.08 mm(0.115~0.121 in)
NO.23.42~3.58 mm(0.135~0.141 in)
Thickness service limit:
NO.12.62 mm(0.103 in)
NO.23.12 mm(0.123 in)
Claw width standard:
NO.115.9~16.0 mm(0.626~0.630 in)
NO.215.9~16.0 mm(0.626~0.630 in)
Claw width service limit:
NO.115.1 mm(0.595 in)
NO.215.1 mm(0.595 in)

9-16
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

CLUTCH DRIVEN PLATES


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

Distortion service limit:


0.1 mm (0.004 in)

CLUTCH SPRING FREE LENGTH


Measure the free length of each clutch a vernier
calipers. If any spring is not within the service
limit, replace all of the spring with new ones.

Service limit:51.6 mm(2.032 in)

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.

Shift fork to groove clearance


standard:0.10~0.30 mm(0.004~0.012 in)
service limit:0.50 mm(0.020 in)

Shift fork groove width (NO.1 NO.2 NO.3)


standard:4.85~5.00 mm(0.191~0.197 in)

Shift fork thickness (NO.1 NO.2 NO.3)


standard:5.3~5.4 mm(0.209~0.213 in)

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.

When installing a new circlip, pay attention to


the direction of the circlip. Fit it to the side
where the thrust is as shown in figure.

When installing the third drive gear bushing,


align the its oil hole with the driveshaft

9-20
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

oil hole.

When installing the reverse driven gear bushing,


align the its oil hole with the driveshaft
oil hole.

TRANSMISSION GEARS AND RELATED PARTS

9-21
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

CRANKCASE
OIL STRAINER CAP
Remove the oil strainer cap.

Remove the oil strainer screw.

Clean the oil strainer using compressed air.

9-22
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

OIL PUMP DRIVE GEAR


Remove the oil pump drive gear (1).

(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

OIL SEAL INSPECTION


Damage to the lip of the oil seal result in leakage
of the engine oil. Inspect the oil seal for wear or
damage. If any damage are found, replace the
oil seal with a new one.

OIL SEAL REMOVAL


Remove the oil seal retainer (1).
(1)

Remove the oil seal (2).


(2)

9-24
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

* Replace the removed oil seals with


new ones.

OIL SEAL INSTALLATION


Install the oil seals into the crankcase.
Pay attention to the following points:
Apply SUPER GREASE to the lip of the oil seals.

Install the new oil seals.

GREASE

CLUTCH RELEASE CAMSHAFT


remove the clutch release camshaft (1).
(1)

Install the clutch release camshaft correctly.

(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

Determine the width between the webs referring


to the figure when rebuilding the crankshaft.
When mounting the crankshaft in the crankcase,
it is necessary to pull its left end into the
crankcase by using the special tools.

Width between web standard:


71.0±0.1 mm(2.795±0.004 in) 71.0±0.1
Special
Special

Crankshaft installer:71613-E12-000

* Never fit the crankshaft into the crankcase


by striking it with a plastic hammer.
Always use the special tool, otherwise the
accuracy of the crankshaft alignment will
be affectd.
9-26
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

GEARSHIFT CAM, FORK AND REVERSE LOCK SHAFT

(1)
(5)

(2)

(4)

(3)
(5)

Install the gearshift forks into the gearshifting


grooves in the correct position and direction.
(1) Gearshift fork No.1
(2) Gearshift fork No.2 (1)
(3) Gearshift fork No.3
(2)
(3)

Install the gearshift cam (4).


Install the gearshift fork shaft (5).

* After the gearshift fork shaft and gearshift


forks have been fitted, make sure that the
gears engine normally.
Set the transmission gears to the neutral
position. (5) (5)
(4)

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)

Tighten the crankcase bolts to the specified


torque.

Torque:1.1 kgf-m (11 Nm)

After the crankcase bolts have been tightened,


check if the crankshaft, countershaft, and

9-28
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

driveshaft rotate smoothly. If a large resistance


is felt to rotation, try to free the shafts by tapping
them with a plastic hammer.

(3)

GEAR POSITION SWITCH


Install the spring (1), contacts (2) and new
O-ring (3).
Install the gear position switch and tighten the
bolts to the specified torque.

Torque:0.65 kgf-m (6.5 Nm)

(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).

Torque:1.0 kgf-m (10 Nm)


(4)

STARTER CLUTCH AND MAGNETO ROTOR


Remove the grease from the tapered portion
of the crankshaft and the magneto to rotor.

9-29
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
(2)
TRANSMISSION/CRANKCASE/CLUTCH COVER

Install the starter driven gear (1) and key (2).

(1)

Tighten the magneto rotor nut to the specified


torque using the special tool.

Torque:12 kgf-m (120 Nm)

Special
Special

Conrod holder:71612-E12-000

PRIMARY DRIVE GEAR AND WATER PUMP DRIVE GEAR

Install the primary drive gear to the crankshaft


(1). (1)
Install the water pump drive gear (2).
Apply engine oil to the thread and inside

9-30
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

surface of the nut.


With the crankshaft held immovable using
the special tool, and then tighten the primary
drive gear nut (3) to the specified torque.

* This nut has left-hand thread.


Apply engine oil to the primary drive gear
nut.

Nut Torque:14 kgf-m (140 Nm)

Special (2)
Special

Conrod holder:71612-E12-000

(3)

GEARSHIFT CAM STOPPER


Apply a small quantity THREAD LOCK (4)
“1324” to the gearshift cam plate bolt (4).

Install the gearshift cam plate and gearshift


cam plate bolt (4).

Install the gearshift cam stopper (1) to the


specified torque.

Torque:3.2 kgf-m (32 Nm)

9-31
(1)
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Install the gearshift shaft (2).


Install the circlip (3).

(2) (3) (3)

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.

Apply a small quantity of THREAD LOCK


to the oil pump mounting screws,
and then tighten them securely.

When installing the oil pump driven gear,


align the pin (1) with the groove.

(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)

Hold the clutch sleeve hub using the special


tool, and then tighten the clutch sleeve hub
nut to the specified torque.

Torque:9.0 kgf-m (90 Nm)


Special
Special

Clutch sleeve hub holder:71600-E12-000

Bend the tongue of the washer (1) securely.


Install the push rod (2), clutch push piece (3).
(1) (2) , (3)

(3)

(1)

(2)

9-34
9. CRANK SHAFT/BLANCER DRIVE GEAR/CLUTCH/
TRANSMISSION/CRANKCASE/CLUTCH COVER

Install the clutch drive plate NO.2 (A).


Install the spring washer seat (B) and spring washer (C) onto the clutch sleeve hub correctly.
Install the clutch drive plates (D) and drive plates NO.1 (E) one by one into the clutch sleeve hub in
the prescribed order.

E A

D
(A) NO.2 (E) NO.1

C B

Tighten the clutch spring set bolts securely in


Diagonal stages.

(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

* Use a new gasket to prevent oil leakage.

Tighten the clutch cover bolts securely.

MAGENTO ROTOR COVER


(1)
Install the dowel pins and new gasket (1).

* Use a new gasket to prevent oil leakage.

Tighten the magneto rotor cover bolts securely.

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

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

CLEARANCE (mm) (mm)

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

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

CLEARANCE (mm) (mm)

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

Radiator (cooling system)


Complaint Symptom and possible causes Remedy
Engine overheats 1. Not enough engine coolant. Add coolant
2. Radiator core clogged with dirt or scale. Clean
3. Faulty cooling fan. Repair or replace
4. Defective cooling fan thermo-switch. Replace
5. Clogged water passage. Clean
6. Air trapped in the cooling circuit. Bleed out air
7. Defective water pump. Replace
8. Use of incorrect engine coolant. Replace
9. Defective thermostat. Replace
Engine overcools 1. Defective cooling fan thermo-switch. Replace
2. Extractive thermostat. Put on the radiator cover
3. Defective thermostat. Replace

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

OFFON Approx.95
Water temperature switch operating
temperature Approx.105
ONOFF
OFFON Approx.85°C
Cooling fan thermo-switch operating
temperature ONOFF Approx.75°C

Coolant capacity Total system 1400±20㏄ Radiator:1000±20㏄


Reserve tank:400±20㏄

Cautions for Using Coolant:


Does not mix coolant concentrate of different brands?
Do not drink the coolant which is poisonous.
The freezing point of coolant mixture shall be 5℃ lower than the freezing point of the riding
area.

COOLING SYSTEM TESTING

10-3
10.COOLING SYSTEM

RADIATOR CAP INSPECTION


Install the radiator cap onto the radiator
tester and apply specified pressure to it . It
must hold specified pressure for at least six
seconds.

* Apply water to the cap sealing surface


before testing.
Radiator Cap Relief Pressure:
0.75~1.05 kgf/cm2
(75~105 kpa, 10.65~14.91 psi)

Install the radiator tester onto the radiator


and apply specified pressure to it. It must
hold specified pressure for at least six
seconds.
Check the water hoses and connectors for
leaks.
* The test pressure should not exceed 1.05
kg/ cm2 (105kpa, 14.91 psi).Excessive
pressure can damage the radiator and its
hose connectors.

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

Inspect the radiator soldered joints and


seams for leaks.
Blow dirt out from between core fins with
compressed air. If insects, etx., are clogging
the radiator, wash them off.
Carefully straighten any bent fins.

Radiator
Radiator Cap
RADIATOR REMOVAL
Remove the radiator cap.
Remove the drain bolt and drain the coolant
from the system.

Coolant Drain Bolt

(2)
Disconnect the radiator hose (1).
Disconnect the Aux. Liquid Bottle hose (2).

(1)

(2)

10-6
10.COOLING SYSTEM

Disconnect the cooling fan thermo-switch lead


wire coupler (1).
Disconnect the water temperature switch lead (3)
wire coupler (2).
Disconnect the cooling fan motor lead wire coupler
(3).

(2)

(1)

Aux. Liquid Bottle Aux. Liquid Bottle


REMOVAL/REMOUNTING
Remove the bolts (4).
Remove the Aux. Liquid Bottle.
Remove the bolts (5).
Remove the Aux. Liquid Bottle holder. (4)
(5)

Aux. Liquid Bottle holder

INSPECTION OF WATER HOSE


Any water hose found in a cracked condition or flattened or water leaked must be replaced.
Any leakage from the connecting section should be corrected by proper tightening.

10-7
10.COOLING SYSTEM

Remove the two bolts on the radiator.


Raise the radiator from frame.

Torque:0.8~1.2 kgf-m (8~12 Nm)

Bolts

RADIATOR DISASSEMBLY
Remove the fore bolts and then remove the
fan shroud from the radiator.
Check fan motor by battery.

Bolts

Cooling fan thermo-switch


CHECK THERMOSTATIC SWITCH

10-8
10.COOLING SYSTEM

COOLING FAN THERMO-SWITCH


When coolant temperature lower then
75℃ the thermostatic switch “OFF”.
When coolant temperature over 85℃
the thermostatic switch “ON”.

Water temperature switch


WATER TEMPERATURE SWITCH
When coolant temperature lower then
105℃ the thermostatic switch “OFF”.
When coolant temperature over 95℃
the thermostatic switch “ON”.

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.

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.

Remove the radiator cap.


Remove the drain bolt and drain the coolant
from the system.
Coolant Drain Bolt

10-10
10.COOLING SYSTEM

Remove the reserve tank cap and drain the


coolant from the reserve tank. Coolant Reservoir Cap Minimum Mark
Remove the drain bolt with the new sealing
washer securely.

Place the vehicle on a flat, level surface.


Fill the reserve tank to the upper level line.

Maximum Mark

Filler Neck
Fill the system with the recommended
coolant through the filler opening up to the
filler neck.

Bleed air from the system as follow:


1. Start the engine and let it idle for 2-3
minutes.
2. Snap the throttle three to four times to
bleed air from the system.
3. Stop the engine and add coolant to the
proper level if necessary. Reinstall the
radiator cap.
4. Check the level of coolant in the reserve
tank and fill to the upper level if it is
low.

10-11
10.COOLING SYSTEM

WATER PUMP
REMOVAL AND DISASSEMBLY
Drain engine coolant.
Drain engine oil.
Disconnect the water hoses.

Remove the right nerfbar and footrest.


(Refer to page 2-4).

Remove the cotter pin (1).


Remove the pin (3) and washer (2).
Remove the bolt and nut (4).
Remove the swing arm, footbrake (5).

(1)
(2)
(4) (3)

(5)
(4)

(4)

(1),(2),(3)

10-12
10.COOLING SYSTEM

Remove the clutch cover.

Remove the circlip and water pump driven gear


(1).

(1)

(2)
Remove the pin (2) and washer (3).

(3)

Remove the water pump case (1) from the

10-13
10.COOLING SYSTEM

clutch cover.

(1)

Remove the O-ring (2).

(2)

remove the E-ring (3) from the impeller shaft.

(3)

Remove the impeller (1) from the other side.

10-14
10.COOLING SYSTEM

(1)

Remove the bearing.

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.

REASSEMBLY AND INSTALLATION

Install the water pump in the reverse order of removal.

OIL TANK AND HOSES


CONSTRUCTION

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).

Remove the engine under cover (1).

10-17
10.COOLING SYSTEM

(Refer to page 2-4)

(1)
Remove the oil hoses.

Remove the oil tank.

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.

Remove the thermostat.

Thermostat case bolt torque:


1.0 kgf-m (10 Nm)

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)

Thermostat valve lift Standard


Over 8.0mm at 90°C
(Over 0.32in at 194°F)

* Do not let the thermostat touch the pan


as it will give a false reading.
Replace the thermostat if the valve
stays open at room temperature.
Test the thermostat after if is operned for
about 5 minutes and holds the
temperature at 70℃.
THERMOSTAT INSTALLATION
The installation sequence is the reverse of
removal.

Fill the cooling system with the specified


coolant. (10-10)

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

Poor brake performance Brake noise


Air in brake system Contaminated brake pad surface
Deteriorated brake fluid Excessive brake disk run out
Contaminated brake pads and brake disk Incorrectly installed caliper
Worn brake pads Brake disk or wheel not aligned
Worn brake mater cylinder piston oil seal
Clogged brake fluid line Hard braking
Deformed brake disk Seized hydraulic brake system
Unevenly worn brake caliper Seized piston

11-3
11.BRAKE SYSTEM

FRONT HYDRAULIC BRAKE

BRAKE PADS REMOVAL


Remove the front wheel. (chapter 12)
Remove the two bolts and then remove
brake caliper.

Bolts

Compress the brake caliper holder and


remove brake pads.

A wear indicator is provided on each brake.


The indicators allows checking of brake
pads wear. Check the position of the
indicator.

11-4
11.BRAKE SYSTEM

FRONT BRAKE DISK


Measure the brake disk thickness.
Service Limit:. 2.7(0.0106)
Measure the brake disk run out.
Service Limit: 0.3 mm(0.012 in)
INSTALLATION
Reverse the “BRAKE PADS REMOVAL”
procedures.

FRONT BRAKE FLUID


CHANGE/AIR BLEED
BRAKE FOUID DRAINING
Place the vehicle on a level surface and keep
the handlebar straight.
Remove the master cylinder reservoir cap
and diaphragm.
Suck up the old brake fluid as much as possible.
Fill the reservoir with new brake fluid.

* Use shop towels to cover plastic parts


and coated surfaces to avoid damage
caused by splash of brake fluid.

Connect a transparent hose to the brake


caliper bleed valve and then loosen the
bleed valve nut.
Use a syringe to draw the brake fluid out
through the hose.

Bleed Valve

11-5
11.BRAKE SYSTEM

BRAKE FLUID REFILLING Reservoir


Connect a transparent hose and syringe to
the brake caliper bleed valve and then
loosen the bleed valve nut.
Fill the brake reservoir with brake fluid and
use the syringe to draw brake fluid into it
until there is no air bubbles in the hose.
Then, tighten the bleed valve nut.
Torque:6.0 kgf-m(6Nm, 4.32 lbf-ft)

*When drawing brake fluid with the


syringe, the brake fluid level should be
kept over 1/2 of the brake reservoir
height.
Use only the recommended brake fluid.
Recommended Brake Fluid: DOT-4

BRAKE SYSTEM BLEEDING


Connect a transparent hose to the bleed
valve and fully apply the brake lever after
continuously pull it several times. Then,
loosen the bleed valve nut to bleed air from
the brake system. Repeat these steps until
the brake system is free of air.

* When bleeding air from the brake


system, the brake fluid level should be
kept over 1/2 of the brake reservoir.

11-6
11.BRAKE SYSTEM

BRAKE MASTER CYLINDER Fluid Tube Bolt


DISASSEMBLY
Remove the brake reservoir cover
Drain the brake fluid from the hydraulic
brake system.

* Do not splash brake fluid onto any


rubber, plastic and coated parts. When
working with brake fluid, use shop
towels to cover these parts.

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.

Remove the two master cylinder holder


bolts and remove the master cylinder.

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

Remove the washer, main piston and spring


Master Cylinder Spring Main Piston
from the brake master cylinder.
Clean the inside of the master cylinder and
brake reservoir with brake fluid.

Snap Ring Rubber Cover

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.

*During assembly, the main piston and


spring must be installed as a unit
without exchange.
When assembling the piston, soak the
cups in brake fluid for a while.
Install the cups with the cup lips facing
the correct direction.
Install the main piston, spring and snap ring.
Install the rubber cover.
Install the brake lever.

“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)

Instll the brake fluid tube with the


attaching bolt and two sealing washers, then
tighten the bolt. Washers
Torque: 3.4 kgf-m (34Nm, 25 lbf-ft)

Connect the front stop switch wire


connector.

Fill the brake reservoir with the specified


brake fluid and bleed air from the brake
system. (11-4)

Install the brake reservoir cover.

11-9
11.BRAKE SYSTEM

FRONT BRAKE CALIPER


REMOVAL
Remove the front wheel. (chapter 12)
First drain the brake fluid from the
hydraulic brake system. (11-4)

Remove the brake fluid tube bolt.


Remove the two caliper holder bolts.
Remove the brake caliper.

Fluid Tube Bolt Bolts

DISASSEMBLY
Remove the brake pads. (11-3)
Remover the brake pad spring plate.

Spring Plate

Remove the piston from the brake caliper.


If necessary, use compressed air to squeeze
out the piston through the brake fluid inlet
opening and place a shop towel under the
caliper to avoid contamination caused by
the removed piston.
Check the piston cylinder for scratches or
wear and replace if necessary.

11-10
11.BRAKE SYSTEM

Push the piston dust seal inward to remove.

Pushing the piston oil seal outward to


remove it.

Dust Seal

Clean the seals groove with brake fluid. Inner Seal

* Be careful not to damage the piston


surface.

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.

* Install the piston with its outer end


protruding 3~5 mm beyond the brake
caliper.
Wipe off excessive brake fluid with a clean
shop towel.

Install the caliper spring plate into the


caliper.

* Make sure that the boss on the caliper


correctly engages with the location slot
on the caliper spring plate.

INSTALLATION
Reverse the “FRONT BRAKE CALIPER
REMOVAL” procedures.

* When installing the brake caliper, be


sure to position the brake disk between
the two brake pads.
Connect the brake fluid tube to the brake
caliper and tighten the fluid tube bolt.
Torque:3.4 kfg-m (34Nm, 25 lbf-ft)

Fill the brake reservoir with the specified


brake fluid and bleed air from the brake
system. (11-4)

* When installing the brake fluid tube, be


sure to install the two sealing washer.

11-12
11.BRAKE SYSTEM

REAR HYDRAULIC BRAKE


REAR BRAKE PADS REMOVAL
Remove the two caliper holder bolts.
Remove the brake caliper.

Bolts

Compress the brake caliper holder and


remove brake pads.

INSTALLATION
Reverse the “REAR BRAKE PADS
REMOVAL” procedures.

11-13
11.BRAKE SYSTEM

BRAKE FLUID DRAINING


Place the machine on the level ground.
Remove the reservoir cap.

* Use shop towels to cover plastic parts


Front Left Lever and coated surfaces
to avoid damage caused by splash of
brake fluid.

Connect a transparent hose to the brake


caliper bleed valve and then loosen the
bleed valve nut. Bleed Valve
Use a syringe to draw the brake fluid out
through the hose.

BRAKE FLUID REFILLING


Connect a transparent hose and syringe to
the brake caliper bleed valve and then
loosen the bleed valve nut.
Fill the brake reservoir with brake fluid and
use the syringe to draw brake fluid into it
until there is no air bubbles in the hose.
Then, tighten the bleed valve nut.
Torque: 0.6 kfg-m (6Nm, 4.32 lbf-ft)

*When drawing brake fluid with the


syringe, the brake fluid level(pedal)
should be kept over 1/2 of the brake
reservoir height.
Use only the recommended brake fluid.

11-14
11.BRAKE SYSTEM

Recommended Brake Fluid:DOT-4

BRAKE SYSTEM BLEEDING


Connect a transparent hose to the bleed
valve and fully apply the brake lever(pedal)
after continuously pull it several times.
Then, loosen the bleed valve nut to bleed air
from the brake system. Repeat these steps
until the brake system is free of air.

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

FOOT BRAKE MASTER


CYLINDER (FOOT BRAKE
PEDAL)
FOOT MASTER CYLINDER
DISASSEMBLY
Refer to the “FRONT BRAKE MASTER
CYLINDER DISASSEMBLY” section in
the chapter 11.

ASSEMBLY
Refer to the “FRONT BRAKE MASTER
CYLINDER ASSEMBLY” section in the
chapter 11.

REAR MASTER CYLINDER ON THE


REEAR BRAKE PEDAL DISASSEMBLY
Remove the brake reservoir cap.
Drain the brake fluid from the hydraulic
brake system. (11-13)

Loosen the lower nut.

Lower nut

Fluid Inlet Tube Bolt Fluid Inlet Tube

Disconnect the fluid inlet tube and remove


the fluid bolt to disconnect the fluid outlet
tube.
Remove the two bolts and remove the
master cylinder.
Washers

Bolts

11-16
11.BRAKE SYSTEM

Remove the inlet tube.


Remove the Dust Seal and remove the circlip Fluid Inlet Tube Dust Seal O-ring
Remove the the fluid inlet duct.
Remove the O-ring.
Check the O-ring for wear or damage and
replace if necessary.

Circlip

Seal Boot

Remove the seal boot.


Remove the circlip and then pull out the
push rod, washer, piston and spring.

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.

* During assembly, the master cylinder,


piston and spring must be installed as a
unit without exchange.

Reverse the “MASTER CYLINDER ON


THE REAR BRAKE PEDAL
DISASSEMBLY” procedures.

Connect the brake fluid tube to the master


cylinder with the fluid bolt and new sealing
washers.
Tighten the fluid tube bolt.
Torque: 3.4 kgf-m(34Nm, 25 lbf-ft)

Fill the brake reservoir with recommended


brake fluid to the upper level.

Bleed air from the hydraulic brake system.


(11-13)

11-18
11.BRAKE SYSTEM

REAR BRAKE CALIPER


REMOVAL
Drain brake fluid of both the rear brake side
and the combination brake side. (11-13)

* To prevent brake fluid from splashing on


the parts nearby, cover the parts with
cloth.

Bolts

Remove the caliper mounting bolts and


remover the caliper.
Remove the brake pads. (11-12)

Using an air blow gun, pressurize the


caliper fluid chamber to push out the piston.

* Place a rag over the piston to prevent it


from popping out and flying and keep
hand off the piston.
Be careful of brake fluid which can
possibly splash.
Do not use high pressure air but
increase the pressure gradually.

11-19
11.BRAKE SYSTEM

Remove the dust seals and piston seals.


* Use care not to cause scratch on the
cylinder bore.
Do not reuse the piston seal and dust
seal that have been removed.

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.

* Wash the caliper components with fresh


brake fluid before assembly. Do not
wipe off brake fluid after washing the
components.
Replace the piston seal and dust seal
with new ones with brake fluid applied.

Brake fluid specification and


classification: DOT4

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)

Fill the system with brake fluid and bleed


air. (11-13) Washers

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

Measure the wheel run out.


Replace wheel or check bearing play if out
of specification
Rim run out limits:
Vertical: 2 mm (0.08 in)
Lateral: 2 mm (0.08 in)

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)

* Be sure the tapered side of the wheel


nuts face the wheel rim.

FRONT WHEEL HUB Cotter Pin


REMOVAL AND INSPECTION
Place the machine on a level place.
Remove the front wheel (12-3) and
caliper (11-9)
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.
Nut Cap
Nut
Remove the nut cap.
Remove the cotter pin.
Remove nut from the front wheel hub and
then remove front wheel hub.

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

Outside Collar Dust Seal

Outside Collar Dust Seal

Bearing

Inspect the bearings for allow play in the


front wheel hub or the wheel turns roughly.

Bearing
If any defects are found, replace the
bearings

12-6
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Remove the bearings using a general


bearing puller.

Distance Collar

Remove the distance collar from the front


wheel hub.

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

Oil seal and bearing install 71620-E10-000


*Apply the grease onto the oil seal lips,
bearing.

Install the distance collar.


*Be sure the tapered side of the distance
collar face the wheel.

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

Oil seal and bearing install 71620-E10-000


* Do not allow the bearings to tilt while
driving them in.
Do not strike the center race or balls
of the bearing. Contact should be made
only with the outer race.
Pack all bearing cavities with grease.
Drive in the bearing squarely with the
sealed end facing out.

INSTALLATION
Reverse the “FRONT WHEEL HUB
REMOVAL AND INSPECTION’’

*Apply the grease onto the bearing and dust


seal lips of the wheel panel.

Tighten the front wheel hub nut.


Torque: 7.0 kgf-m (70 Nm, 50 lbf-ft)

Install the cotter pin and band ends of cotter


pin.

*Do not loosen the wheel hub nut after


torque tightening. If the wheel hub nut
groove is not aligned with the cotter pin
12-9
hole, align groove with the hole by
tightening up on the wheel hub nut.
Always use a new cotter pin.
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

*Always use a new cotter pin.

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.

Remove the front wheel (12-3), caliper


(11-9) and front wheel hub. ( 12-4)

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.

Nut Nuts Cotter Pins

Release the ball joints of the upper and

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

Special tool: Ball join remover 71608-A03-000

Apply grease to the ball joint remover at the


point shown.
This will ease installation of the tool and
prevent damage to the pressure bolt threads.
Insert the jaws carefully, making sure that
Ball Join Remover
you do not damage the ball joint boot.
Adjust the jaw spacing by turning the
pressure bolt.
Tighten the pressure bolt with a wrench
until the ball joint stud pops loose.
Remove the knuckle from the upper and
lower arms

Inspect the steering knuckle for cracks,


pitting or damage.
If any defects are found, replace the steering
knuckle with a new one.

Bolts

12-12
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Remove the front shock absorber upper mount


and lower mount bolts/nuts, then remove the
front shock absorber.

Inspect the shock absorber rod.


Bends/damage→ Replace the shock
absorber assembly.
Inspect the shock absorber.
Oil leaks→ Replace the shock absorber
assembly.
Inspect the spring of the shock absorber by
move the spring up and down.
Fatigue→ Replace the shock absorber
assembly.

Shock Absorber

Check the upper front arm brackets of the


frame.
If bent, cracked of damaged, repair or
replace the frame.
Check the tightening torque of the front
arms securing nuts.

12-13
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
Torque: 4.5 kgf-m (45 Nm, 32 lbf-ft)

Check the upper front arm side play by


moving it from side to side.
If side play noticeable, replace the inner
collars and bearings as a set.

Check the front arm vertical movement by


moving it up and down.
roughs, replace the inner collars and bearings
as a set.

Remove the band and then disconnect the


front brake fluid tube from the upper front
arm.
Remove the two nuts and two bolts
attaching the upper front arm, then remove
the upper front arm.

Bolts

Inspect the front arm.


Cracks/bends/damage→ Replace.
* Do not attempt to straighten a bent arm,
this may dangerously weaken the arm.
12-14
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Inspect bearings.
Wear/damage→ Replace.

Check the lower front arm brackets of the


frame.
If bent, cracked or damaged, repair or
Check the tightening torque of the front
arms securing nuts.
Torque: 4.5 kgf-m (45 Nm, 32lbf-ft)

Check the lower front arm side play by


moving it from side to side.

If side play noticeable, replace the inner


collar and bearing as a set.

Check the lower front arm vertical


movement by moving it up and down.
If vertical movement is tight, binding or
roughs, replace the inner collar and
bearings as a set.

12-15
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Remove the two nuts and two bolts


attaching the lower front arm, then remove
the lower front arm.

Bolts

Inspect the lower front arm.


Cracks/bends/damage → Replace.
* Do not attempt to straighten a bent arm,
this may dangerously weaken the arm.

Inspect bearings.
Wear/damage → Replace.

12-16
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
INSTALLATION
Reverse the “FRONT SUSPENSION
REMOVAL AND INSPECTION’’
procedures.

*Apply the grease onto the bearings and


inner collars.

Install the lower and upper front arms nuts


onto the frame and tighten the nuts.
Torque: 4.5 kgf-m (45 Nm, 25lbf-ft)

Install the steering knuckle onto the upper


and lower front arms and tighten the nuts.
Torque: 3.5 kgf-m (35 Nm, 25 lbf-ft)

Install the tie-rod onto the steering knuckle


and tighten the nut.
Torque: 2.1 kgf-m (21 Nm, 15 lbf-ft)

Install the all cotter pins and band ends of


cotter pins.

*Always use a new cotter pin.

Apply the grease onto the bush, then install


the shock absorber and tighten the upper
mount and lower mount bolts.
Torque: 4 kgf-m (40 Nm, 29 lbf-ft)

Install the front wheel hub (12-7), caliper


(11-11)and front wheel, (12-3)

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

Inspect the tie-rod.


Bend/damage → Replace.

Cheek the tie-rod end movement.


Tie-rod end exists free play or turns

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

Set the rod-end (steering column side)in an


angle where the indentation surface of the
toe-rod is parallel to the rod-end shaft, and
then tighten the lock nut.
Torque: 3.0 kgf-m(30 Nm, 22lbf-ft)

* After making adjustment on both tie rods


be sure to mark them R and L for
identification.

* the threads on both rod-end must be of


the same length

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.

Install the all cotter pins and band ends of


cotter pins.

*Always use a new cotter pin.

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

Remove the right master cylinder Master cylinder


and remove bands then disconnect the
front fluid tube from the handlebar.

Remove the two screws and remove the


handlebar switch.

Screws

12-24
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Remove the two screws and remove throttle


unit.

Screws

Clutch lever Ass’y

Remove the two screws and remove


clutch lever Ass’y.

Screws

Bolts

Remove the handlebar cover, then remove


four handlebar holder bolts and handlebar

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)

Install the throttle unit in the handlebar


and then install the lower holder and tighten
the two screws.

12-29
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Clutch lever Ass’y


Install the Clutch lever Ass’y in the handlebar
and then install the two screws.

Screws

12-30
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

STEERING COLUMN
REMOVAL AND INSPECTION
Remove handlebar. (12-19)

Remove the two bolts and remove the cable


holder, steering brackets and dust seal.

Bolts Steering Bracket

Steering Bracket Dust Seal

Remove the cotter pins and nuts attaching

12-31
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM
the tie-rods, then disconnect the tie-rods
from the steering column.

Cotter Pin Nut

Remove the cotter pin and nut attaching the


steering column under the frame body, then
remove steering column.

Inspect the steering column.


Bends/damage → Replace.

* Do not attempt to straighten a bent shaft,


this may dangerously weaken the shaft.
thiar holder surface.
Inspect the steering brackets and oil seal.
Wear damage → Replace.

12-32
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

INSTALLATION
Reverse the “REMOVAL” procedures.

Install the steering column, then


tighten the nut under the frame body.
Torque: 7.0 kgf-m (70 Nm, 50 lbf-ft)
Install the cotter pin and band ends of cotter
pin.

* Always use a new cotter pin.

Assembly the steering column and tighten


the two bolts.
Torque: 2.2 kgf-m (22 Nm, 16 lbf-ft)

12-33
12.FRONT WHEEL/FRONT SUSPENSION
STEERING SYSTEM

Install the tie rods, then tighten the nut.


Torque: 3.5 kgf-m (35 Nm, 25 lbf-ft)
Install the cotter pins and band ends of
cotter pins.
* Always use a new cotter pin.

Refer to the “TOE-IN ADJUSTMENT”


section in the CHAPTER 3 to adjust toe-in

12-34
13.REAR WHEEL/AXLE/SUSPENSION

REAR WHEEL/ AXLE /SUSPENSION


SERVICE INFORMATION----------------------------------------13-2
TROUBLESHOOTING---------------------------------------------13-3
REAR WHEEL/ AXLE/ AXLE HUB-----------------------------13-3
REAR SHOCK ABSORBER / REAR FORK--------------------13-12

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

Soft rear shock absorber


Weak shock absorber spring
Faulty damper

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)

Use the nut wrench to loosen two rear axle


nuts (inner and outer )of the rear axle.

Nut

Special
Special
Nut wrench 71601-E10-000

Remove four nuts attaching the rear wheel


hub of the both rear wheels. then remove
the both rear wheels.


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

Remove the nut cap. Cotter Pin


Remove the cotter pin and then remove nut. Nut Cap
Remove the rear wheel hub.

Nut
Rear Wheel Hub

13-4
13.REAR WHEEL/AXLE/SUSPENSION

Inspect the rear wheel hub.


Cracks/damage → Replace.

Inspect the rear wheel hub splines.


Wear/damage → Replace.

Splines

Measure the wheel run out.


Service Limit:
Vertical: 2mm (0.08 in)
Lateral: 2 mm (0.08 in)
Out of specification → Replace wheel.

Remove the two rear axle nuts (outer and


inner), washer.

Nut

13-5
13.REAR WHEEL/AXLE/SUSPENSION

Loosen the driven chain (refer to the


“DRIVE CHAIN SLACK ADJUSTMENT”
section in the chapter 3).

Find the fixed clip and remove it.

Drive Sprocket Cover

Remove the two bolts at the drive sprocket,


then disconnect the drive chain from the driven
sprocket.
Bolts

Bolts

Inspect the drive chain stiffness.


Stiff → Clean and lubricate or replace.

13-6
13.REAR WHEEL/AXLE/SUSPENSION

Rear sprocket
Remove the bolt、washer and nut.

Remove the rear sprocket.

Nut and washer

Inspect the rear sprocket.


More than 1/4 teeth wear→Replace.
Inspect the rear sprocket holder splines.
Wear/damage → Replace.

Remove the two caliper holder bolts.


Remove the brake caliper.

Bolts

13-7
13.REAR WHEEL/AXLE/SUSPENSION

Remove the rear axle from right side.


* Tap the axle and with a rubber hammer,
this will avoid damage the axle thread.

REAR AXLE DISASSEMBLY

Washer
Remove the rear axle nut and washer.

Rear Axle Nut

Splines

13-8
13.REAR WHEEL/AXLE/SUSPENSION

Remove the four bolts attaching the rear


Splines
brake disk holder at the brake disk and
then remove brake disk.

Bolts

Inspect the rear brake disk.


Cracks/damage → Replace.
Inspect the rear brake disk holder splines.
Wear/damage→Replace.

Inspect the rear axle.


Scratched (excessively)/damage → Replace.
Inspect the splines and threads of the rear
axle
Wear/damage → Replace.

13-9
13.REAR WHEEL/AXLE/SUSPENSION

Measure the rear axle run out.


Service limit: less than 1.5mm (0.06 in)
Out of specification → Replace.

Do not attempt to straighten a bent axle.

REAR AXLE ASSEMBLY


Reverse the “REAR AXLE
DISASSEMBLY” procedures.

Apply grease onto the rear axle splines.

Remove the four bolts attaching the rear


axle hub at the rear fork.

Rear axle hub

Remove the rear axle hub from left side.

13-10
13.REAR WHEEL/AXLE/SUSPENSION

Inspect rear axle hub.


Bearings allow play in the axle hub or the
bearing turns roughly → Replace.
Dust seals is wear/damage → Replace.
Axle hub is cracks/damage → Replace.

REAR AXLE HUB DISASSEMBLY


Bearing and dust seal replacement steps:
Clean the outside of the rear axle hub.
Remove the dust seal by a flat-head screw
driver.
*Place a wood block against the outer
edge to protect this edge.

Remove the bearing by a general bearing Dust Seal


puller.

Dust Seal Bearing Dust Seal


REAR AXLE HUB ASSEMBLY
Install the new bearing and dust seal by
reversing the previous steps.
* Do not strike the center race or balls of
the bearing.
Contact should be made only with the
outer race.
Make sure install the distance collar into
the rear axle hub
Rear Axle Hub Distance Collar

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.

Install the rear axle.

Connect the drive chain.

Install the rear brake disk, collar inner nut,


washer and outer nut.

*At this time, the nuts should not


be tightened completely.

13-12
13.REAR WHEEL/AXLE/SUSPENSION

Install the rear wheel hub and tighten the


nut.
Torque: 10.0 kgf-m (100 Nm, 72 lbf-ft)
Install cotter pin (new)
*Do not loosen the wheel hub nut after
torque tightening. If the wheel hub nut
groove is not aligned with the cotter pin
hole, align groove with the hole by
tightening up on the wheel hub nut.
Always use a new cotter pin.

Install the rear wheel and tighten the four


nuts.
Torque: 4.5kgf-m (45 Nm, 32 lbf-ft)
*Be sure the tapered side of the wheel nuts
face the wheel rim.

Tighten the two rear axle nuts (inner and outer).

Special
Special
Nut wrench 71601-E10-000
Torque: 12.0 kgf-m (120 Nm, 86 lbf-ft)

Adjust drive chain slack. (Refer to the


“DRIVE CHAIN SLACK ADJUSTMENT” Nut
Drive chain slack: 30~40mm

13-13
13.REAR WHEEL/AXLE/SUSPENSION

REAR SHOCK ABSORBER/


REAR FORK
REMOVAL AND INSPECTION
Place the machine on a level place.
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.
Bolts
Remove the rear wheels, rear axle and rear
hub.
Refer to the ”REAR WHEEL/AXLE/AXLE
HUB REMOVAL AND INSPECTION”
section in chapter 13.

Remove the upper and lower mount


bolts/nuts, then remove rear shock absorber

Inspect the shock absorber rod.


Bends/damage → Replace the shock
absorber assembly.
Inspect the shock absorber.
Oil leaks → Replace the shock absorber
assembly.
Inspect the bush.
Wear/damage → Replace.

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

Check the rear fork side play by moving it


from side to side.
If side play noticeable, check the inner
collar, bearing, bushing and thrust cover, or
adjust the shim.

Check the rear fork vertical movement by


moving it up and down.
If vertical movement is tight, binding or
rough, check the inner collar, bearing,
bushing and thrust cover, or adjust the shim.

Rear Fluid Tube


Remove the band and then disconnect the
rear brake fluid tubes and packing cable
from the rear fork.

Band

Packing cable

13-15
13.REAR WHEEL/AXLE/SUSPENSION

Remove the nut and pivot shaft, then


Pivot Shaft
remove rear fork and drive chain.

Remove the five bolts from the lower guard


and then remove the lower guard.

Lower guard

Bolts

Thrust Covers
Remove the thrust covers.

13-16
13.REAR WHEEL/AXLE/SUSPENSION

Inspect the rear fork. Thrust Covers


Crack/bend/damage → Replace.
Roll the axle on a flat surface to inspect the
Roll the axle on a flat surface to inspect the
pivot shaft.
Bends → Replace.

Do not attempt to straighten a bent axle.
Inspect the thrust covers, collar and bushes.
Wear/damage → Replace.

Collar

Inspect the shock link, rear.


Crack/bend/damage → Replace.
Inspect the space.
Wear/damage → Replace.
Bearings allow play in the shock link, rear.
bearing turns roughly → Replace.
Dust seals is wear/damage → Replace.

Spacer
Oil seal Shock link, rear

Spacer Grease valve


Needle bearing

Needle bearing
Oil seal

Needle bearing

Grease valve Spacer


Guard

Bolts
.threaded.

13-17
13.REAR WHEEL/AXLE/SUSPENSION

Inspect the housing, shock link, rear.


Needle bearing Oil seal
Crack/bend/damage → Replace.
Inspect the space. Spacer
Wear/damage → Replace.
Bearings allow play in the housing, shock link, rear.
bearing turns roughly → Replace.
Dust seals is wear/damage → Replace.

Grease valve

Housing, shock link, rear

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)

Install the shock absorber and tightening the


bolts.
Torque: 4.0 kgf-m (40 Nm, 29 kbf-ft)

Install the rear hub and rear wheels.


Refer to the “REAR WHEEL
INSTALLATION” section.

Adjust the drive chain slack.


Refer to the “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3.
Drive chain slack: 30~40mm

13-18
14.BATTERY/CHARGING SYSTEM/MAGNETO

BATTER/CHARGING SYSTEM/MAGNETO

SERVICE IMFORMATION 14-2


TROUBLESHOOTING 14-3
BATTERY REMOVEAL 14-4
CHARGING SYSTEM 14-6
REGULATOR/RECTIFIER 14-8
MAGNETO 14-9

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

Low power Charging system failure


 Weak battery Loose, broken or shorted wire or connector
 Loose battery connection Faulty regulator/rectifier
 Charging system failure Faulty A.C. generator

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

Nuts and Washer


3. Remove the nuts and washer.

4. Remove the fixing bracket.


Fixing bracket

14-5
14.BATTERY/CHARGING SYSTEM/MAGNETO

positive (+) negative (-)


5. Disconnect the negative (-) terminal lead
from the battery first, then disconnect
the positive (+) terminal lead.

Remove the battery.

When disconnecting the battery positive


(+) cable, do not touch the frame with
tool; otherwise it will cause short circuit
and sparks to fire the fuel.

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

BATTERY VOLTAGE (OPEN CIRCUIT


VOLTAGE) INSPECTUIN
Remove the seat.
Disconnect the battery cables.
Measure the voltage between the battery
terminals.
Fully charged : 13.1V
Undercharged : 12.3V max
* Battery charging inspection must be
performed with a voltmeter.

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.

*  Quick charging should only be done in


an emergency.
 Measure the voltage 30 minutes after
the battery is charged.

Charging current: Standard: 1.2A


Quick : 3.0A
Charging time : Standard: 5 ~ 10 hours
Quick : 30 minutes
After charging: Open circuit voltage: 12.8 V min

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.

Specified current leakage:


1 mA maximum
If current leakage exceeds the specified
value, a shorted circuit is likely.
Locate the short by disconnecting
connections one by one and measuring the
current.

CHARGING VOLTAGE INSPECTION


Start the engine and warm it up to operating
temperature; stop the engine.
Connect the multi-meter between the
positive and negative terminals of the
battery.
* Make sure the battery is in good
condition before performing this test.
 To prevent a short, make absolutely
certain which are the positive and
negative terminals or cable.
14-8
14.BATTERY/CHARGING SYSTEM/MAGNETO

With the headlight on high beam, restart the


engine. Measure the voltage on the
multimeter when the engine runs at 5000 rpm.
Limit Voltage/Current: 13.5 ~ 15.5 V/0.5A max
.

14-9
14.BATTERY/CHARGING SYSTEM/MAGNETO

REGULATOR/RECTIFIER Regulator/rectifier Connectors


INSPECTION
Remove the regulator/rectifier wire
connectors.
Check the continuity between the wire
terminals.

Using the pocket tester (×1 MΩ range), measure


the resistance between the terminals in the
following table. Lock Nut Regulator/rectifier

If the resistance checked is incorrect, replace the


regulator/rectifier.

Unit :MΩ
(+) Tester probe
    
(-) Tester probe

 3~4 3~4 1~2 1~2


 3~4 3~4 1~2 1~2
 3~4 3~4 1~2 1~2
 1~2 1~2 1~2 32KΩ
 1~2 1~2 1~2 32KΩ


 

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.

Stator coil resistance Standard


Pick-up coil G-L 90~110
Charging coil Y-Y 0.3~0.8


When mounting the stator on the magneto cover,
apply a small quantity of “THREAD LOCK” to the
threaded parts of screws.

MAGNETO NO-LOAD PERFORMANCE

14-11
14.BATTERY/CHARGING SYSTEM/MAGNETO

Disconnect the three lead wires from the magneto


terminal.
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the AC voltage
between the three lead wires.
If the voltage is under the specified value,
replace the magneto with a new one.

Standard NO-load performance of magneto Over 70V(at 5,000 rpm)

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

IGNITION UNIT REMOVE


Remove the fender cover
Disconnect the ignition unit coupler and
remove the ignition unit.

Plastic Rivet

IGNITION COIL INSPECTION


CONTNUTTY TEST
Remove the front fender. (Refer to the
chapter 2)
Remove the spark plug cap. (Refer to the
chapter 6)
Disconnect the ignition coil wires.

* This test is to inspect the continuity of


ignition coil.

Measure the resistance between the ignition


coil primary coil terminals.
Resistance: 3.8~5.2Ω/20℃

15-5
15.IGNITION SYSTEM

Remove the spark plug cap and measure the


secondary coil resistance between the spark
plug wire and the primary coil terminal.
Resistance:
(with plug cap): 12~18KΩ/20℃

*This test is for reference only. Accurate


test should be performed with a CDI
tester.

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 Button/Stop Switches Fuse/Battery/Starter Relay

Starter Motor

STARTER SYSTEM DESCRIPTION

START BATTERY( MF)


SW. HAND BRAKE. COMB. SW. FUSE START MAG. SW. START MOTOR 12V 10AH
BAT

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.

* When motor is in operation, do not touch


with hand to small gear to prevent from
STARTER
danger. MOTOR INSTALLATION

Connect the starter motor cable connector


and properly install the waterproof rubber O-Ring
jacket.
Check the O-ring for wear or damage and
replace if necessary.
Apply grease to the O-ring and install the
starter motor.
Tighten the two mounting bolts.
Torque:0.9~1.2kgf-m
* The starter motor cable connector must
be installed properly.

16-4
16.STARTING SYSTEM

STARTER RELAY Starter Relay


INSPECTION
Remove the seat. (Refer to the chapter 2)
Turn the ignition switch ON and the starter
relay is normal if you hear a click when the
starter button is depressed.
If there is no click sound:
 Inspect the starter relay voltage
 Inspect the starter relay ground circuit
 Check for continuity between the starter
relay yellow/red and green/yellow wire
terminals

Yellow /Red Wire


STARTER RELAY VOLTAGE
INSPECTION
Connect a 12V battery across the starter
relay yellow/red and green /Yellow wire
terminals.
Connect an electric tester between the
starter relay large terminals and check for
continuity between the two terminals.
The relay is normal if there is continuity.
Replace the starter relay with a new one if
Green/Yellow Wire Starter Realy
there is no continuity.

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.

Remove the rubber boot from the headlight


case.
Disconnect the headlight wire connector.

Relax the lock clips to remove the bulb and


replace with a new one.

Install the bulb, aligning the bulb socket


groove with the bulb tab and set the lock
clips.
Connect headlight were connector.
Install the rubber boot.
Install the front fender cover in the reverse order
of removal.

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.

Pull the lever rear and pull up the seat at


the rear
Remove the seat.

Lever

Remove the screws from the 2 side fenders.

Screw Screw

Remove the 2 bolts.

Bolts

17-4
17.LIGHTS/SWITCHES

Remove the plastic rivet from


the rear fender.

Plastic Rivet Plastic Rivet

Remove the 2 bolts from support under rear


Fender and right & left signal light, tail light
connector.

Bolts Bolts

Remove the 2 nuts and washer.


Remove the fixing bracket. Nuts and Washer
band

17-5
17.LIGHTS/SWITCHES

Remove the battery wire.


Remove the battery. Fuse Box Starter Relay

Battery wire

Fixing bracket

Remove the 2 screws from rear cover fender.


Remove the rear cover fender.

Tail/brake light

Screws

Remove the 2 nuts from rear cover fender.


Remove the tail/brake light assembly.

Nuts

17-6
17.LIGHTS/SWITCHES

INSTALLATION
The installation sequence is the reverse of
removal.

SIGNAL LIGHT (ON ROAD)

FRONT Signal light wire leads

This ATV’s signal light is LED type.

Disconnect the signal light wire leads.


Remove the nut.
Remove the signal light assembly.

Wire color:Left---DBr & B


RIGHT---DG &B

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

HORN (ON ROAD)


REMOVAL
Disconnect the horn wire leads.
Remove the bolt and remove horn.

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.

Check for continuity between the switch


side connector terminals in each switch
position.
Continuity should exist between the color
coded wires as right:

REPLACEMENT
Remove the ignition switch clips.
Remove the ignition switch from the cover.

Install a new ignition switch by aligning the


locating tab with the groove in the cover.

Install the removed parts in the reverse order


of removal.

17-9
17.LIGHTS/SWITCHES

HANDLEBAR SWTTCH
INSPECTION
Remove fender cover.
Disconnect the connectors.

Check for continuity between the switch


side connector terminals in each switch
position.
Continuity should exist between the color
coded wires as nest page:
Plastic Rivet

Light Switch Hazard Switch

Winker Switch

Start Switch

17-10
17.LIGHTS/SWITCHES

GEAR POSITION SWITCH


INSPECTION
Measure switch for continuity using a tester.
If any abnormality is found, replace the
gear position switch with a new one.

Gear position switch

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

CLEARANCE (mm) (mm)

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

CLEARANCE (mm) (mm)

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 .

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