Daelim ROADWIN R SERVICE MANUAL

HEAD OFFICE(FACTORY)

#58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL: (82-55) 239-7000 / FAX: (82-55) 239-7520

OVERSEAS SALES OFFICE(FACTORY)

13-5,SEONGSU 1-GA,2DONG, SEONGDONG-GU, SEOUL, KOREA TEL: (82-2) 3408-2634 / FAX: (82-2) 467-9997

SERVICE MANUAL

2007. 01 PRINTED

2007. 01 PUBLICATION

CC OO PP YY PP RR OO HH II BB II TT

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure for the VJF125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 2). Sections 1 through 2 provide information on overall vehicle; and section 3 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 21: Troubleshooting.

Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM MOTOR.

CONTENTS

GENERAL INFORMATION

INSPECTIONS / ADJUSTMENTS

LUBRICATION

FUEL SYSTEM

ENGINE

COOLING SYSTEM

EMS (

Engine Management System

)

ENGINE REMOVAL

CLUTCH / GEARSHIFT

A.C.GENERATOR / STARTER CLUTCH

CYLINDER HEAD / VALVES

CYLINDER / PISTON

CRANKCASE / TRANSMISSION / CRANKSHAFT

EXTERNAL PARTS

REAR WHEEL /REAR SUSPENSION

FRONT WHEEL/FRONT FORK/STEERING

HYDRAULIC BRAKE

FRAME

ELECTRICAL SYSTEM

BATTERY / CHARGING SYSTEM

ELECTRIC STARTER

LIGHTS/METER/SWITCHES

IGNITION SYSTEM

WIRING DIAGRAM

TROUBLESHOOTING

1-1

1. GENERAL INFORMATION

SERVICE INFORMATION 1-1 SERVICE RULES

1-1

CAUTION WHEN WIRING

1-5

MODEL IDENTIFICATION

1-9

SPECIFICATIONS

1-10

TORQUE VALUES

1-12

SYMBOLS / ABBREVIATIONS

1-14

TOOLS

1-15

WIRING DIAGRAM

1-16

SERVICE INFORMATION

1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide.

2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children)

3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops.

4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark.

5. When more than two person are working, always pay attention to other worker’s action and always have safety in mind.

6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash carefully with soap and water after handling.

7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc.

8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark.

SERVICE RULES

1. Parts and lubrication oil must be DAELIM genuine or recommended parts.

2. Before maintenance, remove deposit or dust from the chasis.

1-2

GENERAL INFORMATION

9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils.

10. Recommended grease must be applied to or filled in the specified place.

7. Align the bolts to uniform the tightening points before tightening them when you don’t know the bolt length.

8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque.

5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation.

6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing.

3. Store the parts of each system discriminatively to install each part in the right place.

4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.

1-3

GENERAL INFORMATION

11. Maintenance needed to use the specialized tools must be performed with the right tool.

12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing.

13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually.

Replace the ball bearing having excessive axial/

longitudinal hanging. Wipe the ball bearing likely to have hanging with cleaning oil.(except double-sided sealed type ball bearing)

Replace the ball bearing of which press-fitted part is

slacked at the case or shaft.

14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle.

15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing.

16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring.

17. Check each part for proper tightening and operation after installation.

18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact.

’

1-4

GENERAL INFORMATION

21. Keep the pneumatic system interior or the engine interior from the infiltration of dust.

22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally.

19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil)

Pay attention not to bend or damage the lip. Apply the grease to the lip.

20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end.

23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage.

24. Install the boots with the installing groove by inserting the boots into the groove.

’

1-5

GENERAL INFORMATION

Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. Identify the two-colored cord by main color first and then spriped color .

When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler.

Recheck the condition of contact, securing and continuity of each part after maintenance. When connecting the battery, the plus terminal must be connected first. After connecting the terminal, apply the grease to the terminal.

When disconnecting the battery, the minus terminal must be disconnected first. Make sure that the tool such as spanner do not contact with the frame.

Connect covers to the terminal after maintenance.

If the fuse is short-circuited, find out the cause and repair. Replace with the fuse having the specified capacity.

If there is rust in the terminal, remove the rust with sand paper prior to connecting.

CAUTION WHEN WIRING

VALIDATION OF CAPACITY!

REMOVE THE RUST!

1-6

GENERAL INFORMATION

Insert the lock of the coupler until the lock is fully secured.

Turn off the main switch before connecting/disconnecting. Release the lock to disconnect the lock of the coupler. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.

- Typical releasing method of the coupler is illustrated in the following.

When disconnecting the coupler, disconnect it while holding the coupler body. Pull while holding the wire harness cord and do not remove the coupler connection.

Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler.

Pay attention not to damage the vinyl cover of the coupler.

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

If the wire harness coating is damaged, repair by winding vinyl tape or replace it. Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened.

1-7

GENERAL INFORMATION

Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part.

Secure the wire harness firmly using the clamp.

Insert the connector until the vinyl cover is fully inserted into the terminal. The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction.

When removing T-start, broaden the groove of T-start using the wiring driver and release the torque. Connect the harness and the hose to T-start and then insert until the groove is locked. When removing T-start from the frame, replace it with the new one.

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

When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part.

When clamping the wire, pay attention not to contact with hot part.

The wire harness must be routed without contacting with the end of the lamp or any sharp edge. The wire harness must be routed without contacting with the end of the bolt or the piece.

1-8

GENERAL INFORMATION

If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness

is not pressed by the parts.

In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape.

The wire must not hang down or be pulled excessively.

Do not twist the wire harness. Wire the wire harness not to be pulled or expanded

when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine.

Prior to using the tester, please read the manual carefully and understand the contents. When testing the resistance of the tester, the zero adjustment must be performed before testing.

Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop.

NOT TO PULL!

Is this measurement range or configuration in accord

with the manual?

1-9

GENERAL INFORMATION

MODEL IDENTIFICATION

ENGINE SERIAL NUMBER LOCATION

The engine serial number is stamped on left crankcase.

FRAME SERIAL NUMBER LOCATION

The frame serial number is stamped on the left side of steering head.

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

1-10

GENERAL INFORMATION

SPECIFICATIONS

ITEM SPECIFICATIONS

OVERALL LENGTH 2,025mm OVERALL WIDTH 764mm OVERALL HEIGHT 1,180mm

DIMENSIONS

WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 139mm DRY WEIGHT 162kgf CURB WEIGHT 292kgf

TYPE Double Cradle FRONT SUSPENSION / STROKE Telescopic / 130mm REAR SUSPENSION / STROKE Swingarm / 28mm FRONT TIRE SIZE (TYPE) 110/70-17 54P (Tubeless) REAR TIRE SIZE (TYPE) 140/60-17 69P (Tubeless) TIRE PRESSURE 1 PERSON FRONT

2.00kgf/cm2(200kPa)

REAR 2.00kgf/cm

2

(200kPa)

FRAME 2 PERSON FRONT

2.00kgf/cm2(200kPa)

REAR 2.25kgf/cm

2

(225kPa) FRONT BRAKE Hydraulic Disk REAR BRAKE Hydraulic Disk FUEL CAPACITY 14.85 FUEL RESERVE CAPACITY 4.0 CASTER ANGLE 25.2 TRAIL 93.5mm FRONT FORK OIL CAPACITY 265

2.5cc

TYPE Liquid 4-stroke DOHC(4 Valve) CYLINDER NUMBER, ARRANGEMENT

1 Cylinder, 20 Inclined from vertical BORE AND STROKE 56.5 X 49.5mm DISPLACEMENT 124.1cm

3

COMPRESSION RATIO 11.8:1 VALVE TRAIN DOHC Chain Drive OIL CAPACITY 1.5

After Disassembly

1.35 After Draining and Oil Filter Change

ENGINE

1.3 After Draining LUBRICATION SYSTEM Wet Pressing and Spray AIR FILTRATION TYPE Paper Filter CYLINDER COMPRESSION 13.0kgf/cm

2

(600rpm)

INTAKE VALVE OPEN 23

BTDC

CLOSED 55

ABDC (1.12mm Lift)

EXHAUST VALVE OPEN 66.3

BBDC

CLOSED 23.6

ATDC (1.12mm Lift)

VALVE CLEARANCE INTAKE 0.15

0.02mm

(A COOLING-OFF PERIOD)

EXHAUST 0.20 0.02mm

ENGINE DRY WEIGHT 32.0kgf

1-11

GENERAL INFORMATION

ITEM SPECIFICATIONS

CLUTCH TYPE Multiplate Wet Clutch / 5 TRANSMISSION TYPE Constant Mesh GEAR RATIO 1st 3.200(37/12 T)

DRIVE TRAIN

GEAR RATIO 2nd 2.143(32/17 T) GEAR RATIO 3rd 1.438(29/21 T) GEAR RATIO 4th 1.095(23/21 T) GEAR RATIO 5th 0.923(24/26 T)

GEARSHIFT PATTERN Left foot operated return system

Down 1-N-2-3-4-5 Up

IGNITION TYPE Full Transisterized IGNITION TIMING “F” MARK 18 BTDC / 1,600(rpm)

FULL ADVANCE 30 BTDC / 8,500(rpm) AC GENERATOR 12V-17A/5,000(rpm) BATTERY CAPACITY 12V 10AH SPARK PLUG CR9EH -9 SPARK PLUG GAP 0.8 - 0.9mm FUSE CAPACITY 30A STARTING SYSTEM Starter Motor

ELECTRICAL

HEADLIGHT (HIGH/LOW BEAM) 55W/55W POSITION LAMP 5W TURN SIGNAL LAMP 10W 4 STOP/TAIL LIGHTS 21W/5W SPEEDOMETER LAMP 3W NEUTRAL INDICATOR LAMP LED 1 HIGH BEAM INDICATOR LAMP LED WINKER INDICATOR LAMP LED LICENCE PLATE LAMP 5W TACHOMETER LAMP LED 1 MALFUNCTION INDICATOR LAMP LED

1-12

GENERAL INFORMATION

TORQUE VALUES

ENGINE

FRAME

kgf.m,(N.m)

TORQUE

kgf.m,(N.m)

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

8 4 4 1 2 1 1 1 1 3 2 3 1 2

12

1 7 1 1

10

1 1 1 1

M6 1.0

M10

1.25

M6

1.0

M6

1.0

M6

1.0

M6

1.0

M16

1.0

M16

1.0

M12

1.25

M8

1.25

M6

1.0

M10

1.25

M6

1.0

M6

1.0

M6

1.0

M6

1.0

M6

1.0

M14

1.5

M30

1.5

M6

1.0

M10

1.25

M6

1.0

M36

1.5

M12

1.25

Apply Engine Oil Apply Engine Oil

Apply Engine Oil Remove negative screw Remove negative screw

1.0~1.2

3.5~4.5

0.8~1.2

1.0~1.4

0.35~0.5

6.0~7.0

5.0~6.0

3.0~3.4

1.0~1.4

1.0~1.2

0.4~0.8

1.0~2.0

1.0~1.2

1.0~1.4

1.0~2.0

CAM HOLDER BOLT(SHBOLT) CYLINDER HEAD SPECIAL SOCKET NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARING SET PLATE BOLT OIL FILTER COVER SOCKET BOLT SHIFT DRUM STOPPER ARM BOLT DRIVE SPROCKET BOLT R.CRANKCASE COVER BOLT OIL FILTER COVER BOLT L.CRANKCASE COVER BOLT A.C GENERATOR CAP CRANKSHAFT HOLE CAP CRANKCASE BOLT SPARK PLUG START MOTOR NUT TAPPET ADJUST HOLE CAP ENGIN TEMPERATURE SENSOR

1

2

4

2

1

4

2

M10

1.25

M10

1.25

M10

1.25

M8 1.25

M8

1.25

M10

1.25

M10 1.25

M 5

0.8

M14

1.5

M10

1.25

M10

1.25

HEX NUT

U- NUT U- NUT

4.5~5.5

5.0~6.0

4.5~5.5

2.4~3.0

1.0~2.0

4.0~5.0

0.35~0.5

8.0~10.0

5.5~6.5

3.4~4.0

REAR ENGIN HANGER BOLT(UPPER) REAR ENGIN HANGER BOLT(UNDER) FRONT ENGIN HANGER BOLT(UPPER/UNDER) FRONT ENGIN HANGER PLATE BOLT STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROKET NUT REAR BRAKE OIL BOLT

TORQUE

1-13

GENERAL INFORMATION

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

*Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.

*SH(Small Head) : It describe 6mm bolt of 8mm flange bolt.

TYPE

TORQUE

TYPE

TORQUE

kgf mNm kgf mNm

15mm BOLT, NUT 4.0~6.0 0.45~0.6 5mm SCREW 3.4~5.0 0.35~0.5

16mm BOLT, NUT 8~12 0.8~1.2

6mm SCREW, FLANGE BOLT

7~11 0.7~1.1

18mm BOLT, NUT 18~25 1.8~2.5

6mm FLANGE BOLT, NUT

9.8~14 1.0~1.4

10mm BOLT, NUT 29~39 3.0~4.0

8mm FLANGE BOLT, NUT

24~29 2.4~3.0

12mm BOLT, NUT 49~59 5.0~6.0

10mm FLANGE BOLT, NUT

34~44 3.5~4.5

(Include SH type)

kgf.m,(N,m)

FRAME

2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5

M8

1.25

M6

1.0

M14

1.5

M8

1.25

M10

1.25

M8

1.25

M6

1.0

M22

1.0

M22

1.0

M8

1.25

M8

1.25

M8

1.25

M14

1.25

M10

1.25

6mm Tapping

M8

1.25

M8

1.25

M8

1.25

U- NUT

2.8~3.4

1.0~1.4

5.5~6.5

4.0~4.5

3.0~4.0

2.8~3.4

1.0~1.4

6.0~9.0

0.25~0.35

2.4~3.0

3.0~4.0

2.4~3.0

8.0~10.0

3.5~4.5

0.5~0.7

4.0~4.5

1.8~2.5

4.0~4.5

REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER SOCKET BOLT FRONT AXLE NUT FRONT BRAKE DISK BOLT BRAKE OIL BOLT (FRONT/REAR) CALIPER BRACKET BOLT (FRONT/REAR) FRONT MASTER CYLINDER HOLDER BOLT STEERING STEM NUT STEERING TOP THREAD FORK TOP BRIDGE PINCH BOLT BOTTOM BRIDGE PINCH BOLT FORK HANDLE PIPE MOUNTING BOLT SWINGARM PIVOT NUT REAR CUSHION UPPER/UNDER BOLT CHAIN SLIDER SCREW L. DOWNTUBE COMP ‘B’ HANDLE WEIGHT SOCKET BOLT REAR BRAKE DISK SOCKET BOLT

SYMBOL

1-14

GENERAL INFORMATION

SYMBOLS / ABBREVIATIONS

The following symbols are used in this manual to represent job-related warnings or cautions.

MEANING

Indicates dangerous area. Serious

accident may result if instructions are not

followed.

MEANING

Indicates important work. Minor injury or

vehicle part damage may result if instruction

are not followed.

Indicates general safety matters. Provides

safety and appropriate handling procedures.

SYMBOL

The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance.

CAUTION

Use option tool. These tools are obtained as you order parts.

Indicates reference page. (Example : Refer to page 3-1)

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)

Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent)

Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent)

Use silicone grease

Apply a locking agent. Use the agent of the middle strength, unless otherwise specified

Apply sealant

Replace the parts with new ones before assembly

Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified

Use Fork or Suspension Fluid

Use special tool

Special grease, etc. that do not correspond to the above are indicated without using symbols.

( 3-1)

1-15

GENERAL INFORMATION

TOOLS

SPECIAL COMMON

DESCRIPTION REF. SEC. DESCRIPTION REF. SEC.

TESTER, GAUGE

COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER TESTER RECORDER

2 17, 18 17, 18

18

5

DESCRIPTION REFERENCE SECTION REMARK

VALVE SEAT CUTTER

VALVE SEAT CUTTER 45 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 60 CUTTER HOLDER 5mm

10 10 10 10 10

24.5mm IN, EX 23mm IN

20mm EX

22mm IN, EX

Use with Valve Seat

DESCRIPTION REFERENCE SECTION REMARK

CLUTCH CENTER HOLDER 8 ACG ROTOR PULLER 9 VALVE GUIDE DRIVER 10 VALVE GUIDE REAMER 10 UNIVERSAL BEARING PULLER 12 BEARING REMOVER SET 12 THREAD ADAPTER 12 ASSEMBLY SHAFT 12 CRANK CASE ASSEMBLY COLOR 12 BALL RACE DRIVER 14 STEERING STEM DRIVER 14 FORK SEAL DRIVER 14 STEERING STEM SOCKET 14 SNAP RING PLIERS 16

WRENCH, 8

9mm 2 ADJUSTING WRENCH, B 2 LOCK NUT WRENCH, 20

24mm 6 EXTENSION BAR 8, 14 FLY WHEEL HOLDER 8, 9 VALVE SPRING COMPRESSOR 10 DRIVER 12, 14, 15 ATTACHMENT 12, 14, 15 PILOT 12, 14, 15 FORK SEAL DRIVER BODY 14 BEARING REMOVER HEAD 15 BEARING REMOVER SHAFT 15 LOCK NUT(M8) 10

1-16

GENERAL INFORMATION

WIRING DIAGRAM

REG. EARTH WIRE

ST.-MAG SW.,RR. STOP SW.,

SIDE STAND SW. HARNESS COVER

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

REG. RECTIFIER

ST.-MAG. SW. WIRE

A

RR. BRAKE HOSE

RR. CALIPER ASS'Y.

BATTERY EARTH CABLE

ST.-MAG. BATTERY CABLE(+)

ST.-MOTOR CABL E

RR. BRAKE HOSE CLAMP

RADIATOR RESERVE TANK

WATER PASS TUBE ASS'Y D

FUEL DRAIN TUBE

DRAIN TUBE

CLUTCH CABLE

B

RR. BRAKE HOSE

RR. BRAKE RESERVE TUBE

ST.-HAZ. SW.

*

‡“» »Œ 1.5»Œ ‚ﬁ

D

ST.-HAZ. SW. CORD

CLUTCH CABLE

WATER PASS TUBE ASS'Y C

RADIATOR HOSE A

RADIATOR HOSE C

BY PASS TUBE

TEMPERATURE SENSOR

SPEEDOMETER CABLE

THROTTLE CABLE

FR. BRAKE HOSE

ST.-HAZ. SW. CORD

CLUTCH CABLE

POSITION LIGHT

HEAD LIGHT

FR. BRAKE HOSE

RADIATOR HOSE B WA TER PASS TUBE ASS'Y. THERMO SWITCH ASS'Y

C

RH. FR. WINKER CORD

POSITION LIGHT

HEAD LIGHT

LH. FR. WINKER CORD

CLUTCH CABLE

WINKER SW. CORD

THROTTLE CABLE

O2 SENSOR

FR.BRAKE HOSE

SPEEDOMETER CABLE

SPDMT. CABLE CLAMP

COMBI.METER CORD

O2 SENSOR WIRE

WIRE HARNESS

WA TER TEMPERATURE SENSOR

COMB. METER EARTH

BREATHER TUBE

HEAD LIGHT RELAY

ST.-MOTOR CABLE

ACG. CORD

BATT. + WIRE

BATT. - WIRE ST.-MAG. SW.√¯ WIRE

CABLE CLAMP

ECU WIRE

ACG., FUEL PUMP, GEAR POSITION, CPS CORD HARNESS COVER

WIRE CLIP

SEAT LOCK CABLE WIRE HARNESS

HELMET HOLDER & SEAT LOCK ASS'Y.

1-17

GENERAL INFORMATION

IDLE SPEED ACTUATOR

(ISA)

THROTTLE POSITION SENSOR

(TPS)

ST.-MAG. BATTERY CABLE(+)

WA TER TEMPERATURE SENSOR

CORD

CONN-TUBE

BATTERY EARTH CABLE

CLUTCH CABLE

THROTTLE CABLE

ST.-HAZ. SW.

FUEL INJECTOR

MAP & AT SENSOR

(MAPAT)

BY PASS TUBE

WIRE HARNESS

O2 SENSOR COUPLER

HIGH TENSION CORD

»”˛ »……(D)

DETAIL OF VIEW (D)

NOISE SUPPRESSOR CAP

IG. COIL EARTH

ST.-HAZ. SW.,COMB.& LOCK SW., WINKER SW.. ∞·º±

THROTTLE CABLE

FAN MOTOR ASS'Y

WIRE CLIP

CLUTCH CABLE

EMI. FILTER COUPLER

MOTOR EMI. FILTER RADIATOR HOSE A

WATER PASS TUBE ASS'Y C

WINKER SW. CORD

THROTTLE CABLE

ST.-HAZ. SW. CORD

CABLE GUIDE

WATER PASS TUBE ASS'Y.

LH. FR. WINKER CORD

HEAD LIGHT COUPLER

FR. BRAKE HOSE

POSITION LIGHT COUPLER

HORN CORD

LH. HEAD LIGHT

DETAIL OF VIEW (C)

‚Ø”˛ »……(C)

CLUTCH CABLE

CABLE GUIDE WINKER SW. CORD

THROTTLE CABLE

COMB.& LOCK SW. CORD

HORN COMP

RH. HEAD LIGHT COUPLER

RH. HEAD LIGHT

RH. FR. WINKER CORD

˙ ¶ ˘ﬁ”˛ »……

DETAIL OF HEADLIGHT CASE PART

1-18

GENERAL INFORMATION

RESERVE TANK

RR. BRAKE HOSE

RR. BRAKE HOSE GUIDE

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE

ST.-MAG. BATTERY CABLE(+)

ST.-MAG. SW. WIRE

BATTERY EARTH CABLE

WIRE CLIP

HARNESS COVER

ST.-MAG. BATTERY CABLE(+)

ST.-MAG. SW. ASS'Y.

ST.-MOTOR CABLE

BATTERY EARTH CABLE

SIDE STAND SW. CORD

RR. STOP SW. CORD

RR. BRAKE HOSE CLAMP

DETAIL OF VIEW (B)

RR. CALIPER

RR. BRAKE HOSE

RR. BRAKE HOSE GUIDE

RESERVE TANK

RR. BRAKE RESERVE TUBE

TUBE CLIP

DETAIL OF VIEW (A)

1-19

GENERAL INFORMATION

ECU COMP.

WIRE HARNESS

FUEL PUMP RELAY

SPARE FUSE(30A,15A)

FUSE BOX

WINKER RELAY

FUSE

DETAIL OF FUSE BOX PART

R/L.RR.WINKER CORD

FAN MOTOR RELAY

WIRE CLIP

BATTERY EARTH CABLE

BATT. BAND

BATTERY(12V 10AH MF.)

ST.-MAG.BATTERY CABLE(+)

ST.-MAG.BATTERY CORD(+)

ECU COMP. C OUPLER

ECU COMP. EARTH C OR D

DETAIL OF BATTER PART

REG. RECTIFIER REG. EARTH WIRE

REG. RECTIFIER COUPLER

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

DETAIL OF REGRECTIFIER PART

ST.-MAG. SW. WIRE

O2 SENSOR WIRE

DETAIL OF THROTTLE BODY PART

MEMO

2-1

2. INSPECTIONS/ADJUSTMENTS

SERVICE INFORMATION

The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a

long period of time.

SPECIFICATIONS

TIRES

SERVICE INFORMATION 2-1 MAINTENANCE SCHEDULE 2-3 FUEL LINE (FUEL TUBE) 2-4 THROTTLE GRIP OPERATION

2-4

AIR CLEANER

2-5

SPARK PLUG

2-6

VALVE CLEARANCE

2-6

CYLINDER COMPRESSION PRESSURE

2-7

DRIVE CHAIN

2-8

DRIVE CHAIN SLIDER

2-10

BRAKE FLUID

2-10

BRAKE PAD WEAR

2-10

BRAKE SYSTEM

2-11

BRAKE STOP SWITCH

2-12

HEADLIGHT AIM

2-12

CLUTCH SYSTEM

2-12

SIDE STAND

2-13

SUSPENSION

2-14

BOLTS, NUTS, FASTENERS

2-14

WHEEL/TIRE

2-15

STEERING STEM

2-15

COOLANT LEVEL INSPECTION

2-16

COOLANT REPLACEMENT

2-16

THROTTLE GRIP PLAY 2~6mm SPARK PLUG CR9EH-9 SPARK PLUG GAP 0.8~0.9mm

IN. 0.15mm EX. 0.20mm

CYLINDER COMPRESSION 13.0kgf/

( 600rpm ) DRIVE CHAIN SLACK 10~20mm REAR BRAKE PEDAL FREE PLAY 10~20mm CLUTCH LEVER FREE PLAY 10~20mm

For information on engine oil and oil filter, refer to sections 3-3 and 3-4. Stand the main stand prior to beginning work.

VALVE CLEARANCE

COLD TIRE PRESSURE

TIRE SIZE

DRIVER ONLY

DRIVER AND A

PASSENGER

FRONT

REAR

FRONT

REAR

FRONT

REAR

FRONT

REAR

2.00kgf/

(200kPa, 29psi )

2.00kgf/ (200kPa, 29psi )

2.00kgf/

(200kPa, 29psi )

2.25kgf/

(225kPa, 32psi )

110/70-17 54P

140/60-17 60P

5.5mm

7.0mm

TIRE PART MINIMUM-DEPTH

2-2

TORQUE VALUES

SPARK PLUG 1.1 kgf-m( 11N.m) CYLINDER HEAD COVER BOLT 1.0 kgf-m( 10N.m) AC GENERATOR CAP 0.6 kgf-m( 6N.m) CRANKSHAFT HOLE CAP 0.8 kgf-m( 8N.m) AIR CLEANER CASE COVER SCREW 0.43kgf-m(4.3N.m) REAR AXLE NUT 8.8kgf-m(88N.m) DRIVE SPROCKET BOLT 1.2kgf-m(12N.m) DRIVEN SPROCKET NUT 5.9kgf-m(59N.m)

TOOLS

WRENCH, 8 9 mm COMPRESSION GAUGE

INSPECTIONS / ADJUSTMENTS

2-3

INSPECTIONS / ADJUSTMENTS

MAINTENANCE SCHEDULE

Perform the Self Inspections Before Operation at each scheduled maintenance period.

I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN

These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart.

If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs. To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers.

NOTES :

(1) At higher odometer readings, repeat at the frequency interval established here. (2) Service more frequently when riding in unusually wet or dusty areas. (3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires

mechanical skill.

FUEL LINE

FUEL FILTER

THROTTLE GRIP OPERATION

AIR CLEANER ELEMENT

SPARK PLUG

VALVE CLEARANCE

ENGINE OIL

ENGINE OIL FILTER ELEMENT

DRIVE CHAIN

BRAKE FLUID

BRAKE /PAD WEAR

BRAKE SYSTEM

BRAKE STOP SWITCH

HEADLIGHT AIM

CLUTCH SYSTEM

SIDE STAND

SUSPENSION

BOLTS, NUTS, FASTENERS

WHEELS/TIRES

STEERING HANDLE BEARING

RADIATOR COOLANT

RADIATOR CORE

RADIATOR CAP

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

2-4

2-5

2-6

3-3

3-4

2-8

2-10

2-11

2-12

2-14

2-15

6-3

6-5

6-6

NOTE (2)

NOTE (3)

Every 1,000

: I and L

FREQUENCY

ODOMETER READING(NOTE 1)

61218

1 4 8 12 REMARK

ITEM

x 1000Km

MONTH

REFER TO

PAGE

2-4

INSPECTIONS / ADJUSTMENTS

FUEL LINE (FUEL TUBE)

Check the fuel tube for deterioration, damage or leakage. Replace it if necessary.

THROTTLE GRIP OPERATION

Check if the throttle grip operates smoothly in all steering positions. If not operating smoothly, check the deterioration, damage and kink of the throttle cable. Measure the free play at the throttle grip.

FREE PLAY : 2~6mm

Throttle grip free play can be adjusted at either end of the throttle cable.

Minor adjustment are made with the upper adjuster. Adjust the free play by loosening the lock nut and turning the adjuster.

FUEL TUBE

2~6mm

ADJUSTER

LOCK NUT

Major adjustments are made with the lower adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary.

2-5

INSPECTIONS / ADJUSTMENTS

AIR CLEANER

Remove the seat. ( 13-2) Loosen the 4 screws, remove the air cleaner housing cover.

Remove and discard the air cleaner element in accordance with the maintenance schedule. (

2-3)

Also replace the air cleaner element any time it is excessively dirty or damage.

Install in the reverse order of removal.

Do not reuse the air cleaner element to clean by compressed air.

SCREWS

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

SPARK PLUG

Remove the spark plug cap. Check the plug for damage, contamination or deposits. If the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug. Always use a feeler gauge to check the gap.

GENUINE PLUG : CR9EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf

m

Assemble the spark plug.

Make sure there is no dirt or debris on the seat of the spark plug hole before inserting the spark plug.

To prevent damage to the cylinder head, handtighten the spark plug before using a wrench to tighten to the specified torque.

Do not overtighten the spark plug.

0.8~0.9mm

CHECK GAP,

DEPOSITS

CHECK FOR

CRACKS

CHECK WASHER FOR DAMAGE

SPARK PLUG

FEELER GAUGE

2-6

INSPECTIONS / ADJUSTMENTS

VALVE CLEARANCE

Remove the cylinder head cover. Remove the A.C generator cap and crankcase hole cap. Rotate the flywheel counterclockwise to align the "T" mark with the index mark on the left crankcase cover. Make sure the piston is at TDC(Top Dead Center) on the compression stroke.

SHIM ADJUSTMENT

If the valve clearance is out of standard, adjust the shim as below.

Remove the camshaft. Remove the valve lifter and seam.

Remove the valve lifter and clean by compressed air. Mop the oil from the attahed area of shim, and measure and record the thinkness with a micrometer.

Inspect and adjust valve clearance while the engine is cold. (below 35° C/95°F)

If the valve lifter is to be removed, use the special tool.

Be careful not to drop the shim into the cylinder when remove the shim with valve lifter.

If it is too difficult to remove the shim, use a tweezer or magnet.

Valve lifter, and shim should be preserved on the assembly position distinguishably.

“T” MARK

Measure the valve clearance with a feeler gauge.

VALVE CLEARANCE : INTAKE : 0.15mm

EXHAUST : 0.20mm

SHIM

VALVE RIFTER

2-7

INSPECTIONS / ADJUSTMENTS

The type of shim is 33 The clearance of shim is 1,500mm to 2,300mm with

0.025mm clearance.

The maximum reading is usually reached within 4~7seconds

compression 13.0kg f/

Meaure the thickness of new shim and removed shim, using a micrometer accurately.

If the demanded thickness of shim is over 2,300mm, to check the valve seat and remove the carbon deposit and modify the valve seat.

Demanded thickness of shim :A Recorded clearance of the valve lifter : B Specified clearance of the valve lifter : C (In :0.15mm / Ex : 0.20mm) Removed thickness of the shim : D how to calculate : A = (B-C)+D Example) B : 0.06mm D : 1.875mm C :

0.15mm(IN) A = (0.06-0.15)+1.875mm New thickness of the shim : 1.775mm

Install the chosen shim into the valve spring retainer. Apply the molybdenum to wet side of valve lifter and install the lifter. Install the cam shaft and rotate the crank shaft for many

timed and recheck the valve clearance after setting the shim.

Apply the engine oil to O-ring of pulse generator cover cap and install the cap.

TORQUE : 0.6kgf-m

CYLINDER COMPRESSION PRESSURE

Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and spark plug. install the compression gauge. open the throttle completely and crank the engine with the starter motor until the gauge reading stops rising.

Tool:compression gauge.

If compression is low, check the following

Incorrect valve clearance adjustment. Valve leakage. Leak the gasket from the cylinder head. Worn piston/cylinder.

If compression is high, check the following

Carbon deposits on the piston head, cylinder head.

COMPRESSION PRESSURE GAUGE

2-8

DRIVE CHAIN

DRIVE CHAIN SLACK ADJUSTMENT

Turn off the ignition switch, support the motorcycle on its main stand, and shift the transmission into neutral. Check slack in the lower chain with a hand midway between the sprockets.

CHAIN SLACK : 10~20mm

Adjust the slack of drive chain if necessary. Adjust it by loosening the axle nut, loosening both lock nuts of adjust, and turning the adjusting nut.

Tighten the axle nut with the specified torque.

TORQUE : 8.8kgf m(88N m)

REMOVAL

In case that the drive chain becomes extremely dirty, it should be cleaned before lubrication. Remove the drive sprocket cover. Remove the retainer clip. Remove the master link, drive chain.

(chain color change : Black

Gold)

INSPECTIONS / ADJUSTMENTS

Because there is a danger which fingers get jammed in the drive chain, never inspect or adjust it while the engine is running.

Make sure that the chain adjuster scale are aligned with the correspondidng scale graduations on both sides of the swing arm.

ADJUSTING NUT

LOCK NUT

AXLE NUT

10~20mm

RETAINER CLIP

130 LINKS

RETAINER CLIP

ROTATING DIRECTION

Check the drive chain for adherence and damaging. Measure the length between the chain’s pins and replace the chain if the prescribed limits are exceeded. Drive chain length (130 links).

2-9

INSPECTIONS / ADJUSTMENTS

DRIVE CHAIN INSPECTION

Lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying fully. Because an extremely lubricated oil splash while the chain moves round, clean it with a piece of cloth. After checking a wear and damage of the drive chain, replace it if necessary.

After inspecting an excessive wear and damage of the drive sprocket, replace it if necessary.

DRIVE CHAIN INSTALLATION

Install the drive chain. Install the master link and retainer clip.

Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, tighten them to the specified torque.

TORQUE :

DRIVE SPROCKET BOLT : 1.2kgf m(12N m) DRIVE SPROCKET NUT : 5.9kgf m(59N m)

Always replace the chain and sprocket as a set.

Because using the stretched chain and new sprocket or similar case, the parts will damage quickly cause by the pictch is not engage each other.

When installing the drive chain, it should be installed in order that the choked part of the clip can direct to a progressing derection of the chain.

WIPE AND DRY

GEAR OIL(#80-90)

DAMAGE

WEAR

NORMAL

RETAINER CLIP

MASTER LINK

OUTSIDE

RETAINER CLIP

DRIVE SPROCKET

2-10

INSPECTIONS / ADJUSTMENTS

BRAKE FLUID

DRIVE CHAIN SLIDER

Inspect the drive chain slider for excessive wear or damage. If it is worn to the wear indicator, replace the drive chain slider.

When the fluid level is low, check the brake pads for wear. If the brake pads are not worn and the fluid level is low, check entire system for leaks. (

2-11)

FRONT BRAKE

Turn the handlebar so that the reservoir is level and check the front brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear.

REAR BRAKE

Place the motorcycle on a level surface, and support it upright position. Check the rear brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear.

BRAKE PAD WEAR

FRONT BRAKE PADS

Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove.

Refer to page 16-6 for brake pad replacement.

Do not mix a dust or different types of fluid when filling the brake fluid. Mind that the reservoir is level in checking and filling it. Avoid spilling the fluid on painted, plastic, or rubber parts.

LOWER LEVEL LINE

FR. BRAKE FLUID

RR. BRAKE FLUID

. BRAKE FLUID

LOWER LEVEL LINE

UPPER LEVEL LINE

WEAR

INDICATOR

WEAR INDICATOR

UPPER

LOWER

10~20mm

2-11

INSPECTIONS / ADJUSTMENTS

BRAKE SYSTEM

Check to see if there is a crack and damage in the front and rear brake hose.

If leak, repluce it with new one.

REAR BRAKE PADS

Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove.

Refer to page 16-7 for brake pad replacement.

FRONT BRAKE LEVER FREE PLAY

Check the free play after pulling the lever.

BRAKE LEVER FREE PLAY : 10~20mm

REAR BRAKE PEDAL FREE PLAY

Adjust the brake pedal free play at the end part of pedal.

BRAKE PEDAL FREE PLAY : 10~20mm

BRAKE HOSE

10~20mm

WEAR INDICATOR

2-12

INSPECTIONS / ADJUSTMENTS

BRAKE PEDAL HEIGHT ADJUSTMENT

Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. After adjustment, tighten the lock nut securely.

After adjusting the brake pedal height, inspect the operation of rear brake light switch and brake pedal, and adjust them if necessary.

BRAKE STOP SWITCH

Adjust the brake stop switch by turning the adjust nut, pressing the switch so that the brake light will come on just before the brake pedal is depressed and brake engagement begins.

HEADLIGHT AIM

Adjust the headlight beam vertically by turning the headlight case adjustment bolts.

CLUTCH SYSTEM

Measure the clutch lever free play at the end of the clutch lever.

FREE PLAY : 10~20mm

Adjust the headlight beam as specified by local laws and regulations.

An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance.

BRAKE STOP SWITCH

STOPPER BOLT

The adjustment faulty of height may caused that the brake runs in state of operation.

2-13

INSPECTIONS / ADJUSTMENTS

Minor adjustments are made using the upper adjuster at the clutch lever. Loosen the lock nut and turn the adjuster.

Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjuster nut to adjust free play. Hold the adjuster nut securely while tightening the lock nut.

If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch.

SIDE STAND

Erect the main stand. Pull the lower end of the side stand, and see if it moves freely. If the side stand does not move smoothly, apply grease to the pivot area. If the side stand moves too freely, check the side stand spring. Check the axial movement of the side stand.

Check the side stand switch:

- Sit astride the motorcycle and raise the side stand.

- Start the engine with the transmission in neutral.

- Lower the side stand. The engine should not accelerate as the throttle grip is operated.

If there is a problem with the system, check the side stand switch.

LOCK NUT

ADJUSTER

SIDE STAND SWITCH

2-14

INSPECTIONS / ADJUSTMENTS

REAR SUSPENSION

Compress the near cushion up and down several times to check the operating conditions. Check the rear cushion for oil leakage, parts damage or looseness

.

BOLTS, NUTS, FASTENERS

Check that all frame nuts and bolts are tightened to their correct torque values. (

2-3)

Check that all safety clips, hose clamps and cable stays are in place and properly secured.

Erect the motorcycle with the main stand. Check a wear of the rear fork bush by moving the rear wheel aside. If there is a free play, replace the rear fork bush.

Tighten all nuts and bolts of the rear suspension.

FRONT SUSPENSION

Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions. Check the front fork for oil leakage, parts damage or looseness.

SUSPENSION

Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle's safety and operation efficiency.

2-15

INSPECTIONS / ADJUSTMENTS

Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tires.

SERVICE LIMIT : FRONT : 5.5mm

REAR : 7.0mm

Erect the motorcycle securely and raise the front wheel off the ground. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds or has vertical movement, inspect the steering stem.

STEERING STEM

Check that the cables do not interfere with handlebar rotation.

STANDARD PRESSURE

WHEEL/TIRE

Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires.

FRONT WHEEL

2.00(200)

REAR WHEEL

2.00(200)

2.25(225)

ITEM

DRIVER ONLY

DRIVER AND A PASSENGER

f/ (kpa)

2-16

Start the engine. Bleed air from the coolant and check the level of coolant. Install the radiator cap. Fill the coolant with the reserve tank up to the upper level.

INSPECTIONS / ADJUSTMENTS

Erect the main stand prior to beginning work. Check the coolant level and the reserve tank. The level should be between the “UPPER” and “LOWER” level lines. Fill the coolant to the reserve tank up to the “F” (upper level).

Remove the drain bolt and drain the coolant. (Tilt the vehicle to the right in order to assure complete and rapid draining.) Remove the radiator cap. Install the drain bolt. Fill the radiator with new coolant.

COOLANT CAPACITY : 1,280 20cc RADIATOR CAPACITY : 1,000 20cc RESERVE TANK CAPACITY: 280 20cc

COOLANT LEVEL INSPECTION

COOLANT REPLACEMENT

Unless the coolant is refilled or replaced, the engine temperature too high or low.

Fill to the “F”(UPPER LEVEL) line.

3-1

3. LUBRICATION

SERVICE INFORMATION

GENERAL SAFETY

The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after handling the used oil.

The oil pump can be serviced without removing the engine from the frame.

ENGINE OIL

TORQUE VALUES

TAPPET ADJUST HOLE CAP

1.5 f m (15N m)

OIL FILTER COVER BOLT

1.1

f m (11N m)

SERVICE INFORMATION 3-1 TROUBLESHOOTING

3-2

ENGINE OIL LEVEL INSPECTION

3-3

ENGINE OIL CHANGE

3-3

OIL FILTER ELEMENT CHANGE

3-4

OIL PUMP

3-4

LUBRICATION POINTS

3-7

OIL CAPACITY

RECOMMENDED

OIL

1.5 (After disassembly)

1.35

(After Oil filter change)

1.3

(After Oil change)

API service classification : SE, SF, SH grade

Viscosity : SAE10W-30

(Use appropriate type of oil with viscosity satisfying

the atmospheric temperature in your riding area

based on the table shown on the right side.)

-10 0 10 20 30 40

PUMP BODY CLEARANCE 0.15~0.20 0.25 ROTOR END CLEARANCE 0.15 0.20

ITEM STANDARD VALUE SERVICE LIMIT

OIL PUMP

Unit : mm

3-2

LUBRICATION

TROUBLESHOOTING

Engine oil level too low

Oil consumption naturally. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal.

Oil contamination

Oil or filter not changed regularly. Faulty head gasket. Worn piston rings.

Low or no oil pressure

Clogged oil orifice. Incorrect oil being used.

ENGINE OIL LEVEL INSPECTION

Erect the motorcycle by main stand. Start the engine and let it be warm fully. Stop the engine, remove the oil level gauge and wipe it clean. Check the oil level with the level gauge by inserting it

in engine screwing level gauge. It is good if the oil surface is between the lower level mark and upper that of the level gauge. If the oil level is near the lower level mark on the dipstick or below that, full to the upper level mark with the recommended oil.

ENGINE OIL CHANGE

Remove the tappet adjust hole cap.

Take out the spring and screen or remove the spark

plug cap from the spark plug, Start the starter motor for several times to drain any oil which may be left in the engine.

Clean filter screen with a clean wash. Check if the oil

filter screen and O-ring of the screen cap are in good

condition.

Install the filter screen and spring.

Install and tighten the tappet adjust hole cap.

TORQUE : 1.5 kgf m(15N.m)

Fill the crankcase with recommened engine oil.

OIL CAPACITY: 1.5 (After disassembly)

1.35

(After oil filter change)

1.3

(After oil change)

RECOMMENDED ENGINE OIL :

Genuine oil

API classification : SE or SH viscosity : 10W-30

Install the oil level gauge.

Start the engine and let it idle for a few minutes.

Stop the engine and recheck the oil level,if necessary,

supply the recommended oil.

Check to see if the oil is leak.

3-3

LUBRICATION

Make the engine warm and erect the motorcycle with side stand in order to assure complete and rapid draining.

OIL LEVEL GAUGE

TAPPET ADJUST HOLE CAP

OIL FILTER SCREEN

INNER ROTOR

3-4

LUBRICATION

Always use a genuine oil filter element. Be sure to replace the oil filter seal when removing oil filter element. Be careful not to lose the oil filter spring when assembling the oil filter element.

OIL FILTER ELEMENT CHANGE

Drain the engine oil. ( 3-3)

Loosen the 3 flange bolts securing the oil filter cover

bolt, filter cover, the oil filter element and oil filter

spring.

Change the oil filter element with a new one.

Check if the oil filter seal is in good condition, if

necessary, replace it with new one.

Install the filter element, spring and oil filter cover and

tighten the bolts to the specified torque.

TORQUE : 1.1 kgf m (11 N m)

OIL PUMP

REMOVAL

Drain the engine oil. ( 3-3)

Remove the oil filter. ( 3-4)

DISASSEMBLY

Clean the oil pump body, inner and outer rotors with

fresh cleaning oil.

OIL FILTER COVER

OIL FILTER ELEMENT

OUTER ROTOR

3-5

LUBRICATION

INSPECTION

Install the inner and outer rotors into the oil pump body. Measure the pump body clearance.

SERVICE LIMIT : 0.25mm

ASSEMBLY

Clean all parts with fresh cleaning oil.

Install the lnner and outer rotor to the pump body.

INSTALLATION

Install the oil filter cover to the RH.crank case.

Fill the recommended oil into the crankcas.

Measure the rotor end clearance.

SERVICE LIMIT : 0.20mm

After installing, check the oil pump to operate smothly

LUBRICATION POINTS

3-6

LUBRICATION

Use general grease

MEMO

4-0

FUEL SYSTEM

4-1

SERVICE INFORMATION

GENERAL SAFETY

Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. Exhaust gas contains poisonous substance. Do not keep engine running for a long period of time in a closed, or poorly ventilated area.

STANDARD OF MAINTENANCE

Fuel tank capacity : 14.85 Reserve fuel capacity: 4.0 Fuel pump specification : KGF38 Flow quantity : Mimnim 20 Flow pressure : 380kpa Injector specification Injector angle : 15 Operation pressure : 380kpa

TORQUE VALUE

Air cleaner case cover screw 0.43kgf m (4.3N m)

TOOL

Float level gauge

4. FUEL SYSTEM

SERVICE INFORMATION 4-1 TROUBLESHOOTING 4-2

FUEL TANK 4-3 AIR CLEANER CASE 4-4

TROUBLESHOOTING

Engine cranks but won’t start

No fule in tank No fule to carburetor Cylinder flooded with fuel Clogged air cleaner No spark at plug

FUEL FILLER CAP

FUEL TANK COVER

FUEL TANK SEALING RUBBER

FUEL PUMP

FUEL TANK

FUEL CAP NECK

FULE TANK

REMOVAL

INSTALLATION

Install the fuel tank in the reverse order of removal.

After installation, check if there is a gasoline leak.

Remove the seat.

Remove the fuel filler cap by looseing the 4 socket

bolts.

Remove the fuel tank cover by looseing the 2

special screws and washer bolt.

Remove the LH. side cover.

Disconnect the fuel unit wire coupler.

(Yellow/White and Green terminal)

Disconnect the fuel tubes from the fuel tank.

Remove the fuel tank upside down.

If fuel is in short supply at the fuel cock, remove the

gasoline in the tank, and clean the strainer screen by

loosening the fuel cock.

Do not smoke or allow flames or sparks in the work area because gasoline is extremely flammable. Immediately wipe off a leaked gasoline.

SOCKET BOLTS

FUEL TANK COVER

FUEL

4-2

FUEL SYSTEM

Be careful not to damage the fuel tank.

4-3

FUEL SYSTEM

Insert the hook area of battery box into the front hole of rear fender accurately when assemble the air cleaner case.

AIR CLEANER CASE

AIR CLEANER INNER PIPE

AIR CLEANER ELEMENT

AIR CLEANER CASE COVER

AIR CLEANER CASE

REMOVAL

Remove the main seat. Remove the fuel tank. Remove the RH. LH. side covers.

Remove the battery. Remove the battery box by loosening the washer bolt. Remove the air cleaner connecting tube band. Remove the air cleaner case mounting bolts, then remove the air cleaner case.

INSTALLATION

Install in the reverse order of removal.

AIR CLEANER

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

AIR CLEANER CONNECTING

TUBE BAND

WASHER BOLT

MEMO

EMS(Engine Management System)

5-1

5. EMS(Engine Management System)

1. CAUTION WHEN REPAIRING THE EMS PARTS

5-2

2. THE COMPONENT PARTS OF THE EMS 5-3

3.TERMINAL ARRANGEMENT OF THE ECU 5-4

4. WIRING DIAGRAM OF THE ECU 5-4

5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) 5-5

6. INJECTOR 5-11

7. MAPAT 5-14

8. TPS 5-18

9. ETS 5-21

10. ISA 5-24

11. O2(Oxygen) SENSOR 5-27

12. CHECKING OF ESS CIRCUIT

5-30

13. CHECKING OF MIL CIRCUIT

5-32

14. ECU (Electronic control unit)

5-33

15. CRANK POSITION SENSOR

5-34

16. FUEL PUMP 5-35

17. THROTTLE BODY

5-38

18. HOW TO USE SCAN

5-42

- SELF DIAGNOSTIC FUNCTION 5-5

- FAIL SAFE FUNCTION

5-6

- HOW TO CHECK

THE FAULT CODE

5-7

- HOW TO SHOW THE FAULT CODE

5-7

- HOW TO READ THE FAULT CODE

5-8

- FAULT CODE TABLE

5-9

- HOW TO REMOVE THE FAULT CODE

5-10

- EMS TROUBLE SHOOTING

5-10

-

WHEN THE ECU IS INITIALIZED

5-42

-WHEN THE ISA PWM ADJUSTING 5-44

-

WHEN THE IGNITION TIMING IS CHECK 5-45

-WHEN THE ENGINE RPM IS CHECK 5-46

EMS(Engine Management System)

5-2

1.CAUTION WHEN REPAIRING THE EMS PARTS.

If the fuse is short-circuited, find out the cause and repair, replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts, because these parts may be damaged by the impact of the drop.

Do not touch the ECU terminal, because it may be damaged by the static.

The ignition key off before assembly and disassembly of the ECU coupler.

otherwise, it might be damage to ECU.

Do not connect adversely the polarity of battery, otherwise, it might be broken the EMS parts

While engine operating, do not disassemble the battery terminal.

otherwise, it might cause damaged the EMS parts.

Use the specified voltmeter and resistance meter.

EMS(Engine Management System)

5-3

2.THE COMPONENT PARTS OF THE EMS

EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.

1) INTAKE SYSTEM

As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc. In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means that idle speed control system is installed in order to control small of quantity of air being necessary for combustion.

2) FUEL SYSTEM

As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division pipe and injector. The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter. Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of intake system. Injector sprays fuel into the intake system by injection signals of ECU.

3) IGNITION SYSTEM

The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to control proper spark time in cylinder, high-voltage system, and so forth.

4) CONTROL SYSTEM

Various sensors to move electric signals converted by checking the current engine status Input interface which works various processes like regulating voltage levels, removal of noise, A/D conversion, amplifying of inputted signals from above sensors. Micro-computer which decides output value through various calculating, arithmetic and logic processing. Output interface to amplify the above output signals. Actuator being mechanically worked by receiving the amplified output signals.

(Intake pressure sensor+Intake temperature)

EMS(Engine Management System)

5-4

3. TERMINAL ARRANGEMENT OF THE ECU

Remarks

ECU PIN NO. 5,6,7,8,11,14,15,16,36,38 were not connected.

Terminal arrangement is based on the ECU.

4. WIRING DIAGRAM OF THE ECU

5.

SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp)

SELF-DIAGNOSTIC FUNCTION

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

Remarks 1

If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMS’s fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.

Remarks 2

It might not be able to starting and driving when following problems happen.

- Crankposition sensor

- Injector

- Fuel pump

EMS(Engine Management System)

5-5

when the ignition key ON.

The MIL on and blink(when this function detects a malfunction in the system)

MIL

OFF

ON

Starting and driving are temporary

Unable to engine start

Able to engine start

MIL

ON

Blink

MIL on continuously, when the engine operating

MIL blinks, when the main key is turn on (engine is stop)

MIL(Malfuction Indicator Lamp)

EMS(Engine Management System)

5-6

FAIL-SAFE FUNCTION

If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible.

If there is something wrong in the EMS, it has fail safe function in order for engine to work and to cover a minimum driving of vehicle.

: MIL on/off

INTAKE

MIL

INTAKE

: MIL on

on

INTAKE

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

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

!

CAUTION

If the MIL on and blink, starting and driving are temporary by fail safe function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case. In this case, safe repairing of vehicle shall be required.

EMS(Engine Management System)

5-7

HOW TO CHECK THE FAULT CODE

There are two methods of checking the Fault codes.

1) Use the MIL in the Speedometer.

2) The diagnostic Tool.

First) Use the MIL in the Speedometer(refer to how to read the fault codes and Fault codes table and diagnostic

methods for each part)

Second) The diagnostic tool (refer to scan user’s manual.)

Turn off the ignition key Disassemble the rh.side cover The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.

(The coupler to check the malfunction of vehicle is placed in the rh.side cover)

Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool.

The wireharness to check the ECU

This wireharness is connected with the ECU and main wireharness

It has two couplers to check the terminals.

First coupler) ECU no.1~20

Second coupler) ECU no.21~40

Arrangement of ECU PIN

First coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connected

Second coupler) ECU no.36,38 were not connected

Wire color to check the malfunction diagnosis

-P/W : PINK/WHITE

-P/Y : PINK/YELLOW

-B : BLACK

-G : GREEN

Coupler to check the malfunction diagnosis

The diagnostic Tool.

The wireharness to check the ECU

EMS(Engine Management System)

5-8

HOW TO SHOW THE FAULT CODE

There are two methods to show the Fault codes.

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

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

If the MIL on when engine is working, engine is able to be operated by fail safe. However, in the event that

Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started

HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS. Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly showed. E.g. ) The Fault code of ISA

If many problems will happened in the EMS parts at the same time only one fault code is displayed by the priority, however, the ECU is remembers all the fault codes. After revise the code, remove the memorized fault code by the method of warm up.(5-10) (Refer to remove the fault codes)

When the vehicle is checked using the diagnosis tool.

- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.

1 flashing cycle : 0.5 sec

1.5 sec 3 sec

ON

OFF

!

CAUTION

EMS(Engine Management System)

5-9

FAULT CODES TABLE

No failure

Injection valve failure(IV)

Idle speed actuator failure (ISA)

Electrical fuel pump failure (EFP)

Intake Manifold absolute pressure signal failure (IMP)

Throttle position signal failure (TPS)

O2 sensor heater output failure (LSH)

Lambda signal failure (VLS)

Engine temperature signal failure (TENG)

Breathing air temperature signal failure

(TBA)

Engine speed signal output failure (ESS)

Malfunction indicate lamp failure (MIL)

EMS(Engine Management System)

5-10

HOW TO REMOVE THE FAULT CODE

Remove the fault codes in two ways;

First) Full warm up

1. Starting the engine.

- The MIL blinks continuously because the ECU memorized the fault code yet.

2. Full warm up the engine (keep idling five minutes)

3. Turn off the ignition key after full warm up the engine

4. Turn on the ignition key again, and check whether the fault code is disappeared or not.

After full warm up, it is possible to check the fault code is removed with the ignition key on/off.

If many problems happened in the EMS parts at the same time, only one defect code will is displayed by the priority order. Even thought repair a fault and remove the memorized fault code, another fault code blinks. at this time, revise the fault and remove the memorized fault code by the warm up.

Second) Malfunction diagnosis tool

(refer to the scan user’s manual)

EMS TROUBLE SHOOTING

Inspection before diagnosis

Inspection the following before malfunction diagnosis.

Quantity of engine oil and leakage Quantity of fuel and leakage Blocked of air cleaner Condition of battery Free play of throttle cable Cutting of fuse Leakage of emission gas Connection of each coupler

EMS(Engine Management System)

5-11

Remove

Injector coupler Injector cap bolt Injector

6.INJECTOR

Be sure to check the engine is cooling because a little gasoline remains. it could be still hot and it could be cause fire.

!

CAUTION

The key is off before disassembly.

!

CAUTION

INJECTOR CAP

INJECTOR

INJECTOR CONNECTOR

PRESS THE INJECTOR CAP

PULL THE INJECTOR CAP

EMS(Engine Management System)

5-12

CHECKING METHODS BY FAULT CODES

Checking of the Injector circuit

The fault code is displayed by MIL

Checking Circuit

Coupler terminal is based on wire harness.

ECU

40 : INJECTOR control

39 : FUEL PUMP control

INJECTOR FUEL PUMP RELAY

EMS(Engine Management System)

5-13

CHECKING PROCEDURE

1) Turn off the ignition key.

2) Check to see if the injector coupler has come loose or the wire is peeling off. If there is no problem, measured the resistance of injector.

3)Disassemble the injector coupler and measure the resistance between injector terminals.

The resistance of injector : 14.5±0.7[ ], 20

Remarks : measuring unit for resistance : resistance ‘ R ‘ [ ]

4)If there is no problem, check the continuity between each terminal and ground.

The resistance between each terminal and ground : ∞[ ] If resistance value is not normal, replace injector with the new one.

5)If the resistance is normal, turns on the ignition key

- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.

6) Measure between the voltage of coupler.

Measuring terminal : BLACK/RED electric wire ~ ground Measuring voltage : battery voltage – 1.0[V]over

Remarks : Measuring unit of voltage : voltage [V] 7) If the measured voltage is normal,

Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited

or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)

If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks

8) If the measured voltage is not normal,

Check the Black/Red electric wire to see if they have been broken or have short-circuited. Check the fuel pump relay.

9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

EMS(Engine Management System)

5-14

7. MAPAT(Manifold Air pressure sensor, Temperature sensor)

Remove

MAPAT coupler. (Push by hand and pull to the front-side) Loosen the MAPAT sensor screw 2EA.

MAPAT sensor.

Be sure to check the coupler is toward upside.

!

CAUTION

It is Located on the left side of the throttle body.

MAPAT CONNECTOR

MAPAT

TPS

The key is off before disassembly.

!

CAUTION

EMS(Engine Management System)

5-15

Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit

Fault code number is displayed by MIL

The Fault code of intake pressure sensor The Fault code of intake temperature sensor

Checking circuit

Coupler terminal is based on the side of wire-harness

CHECKING PROCEDURE

1) Turn off the ignition key .

2) Check to see if the MAPAT coupler has come loose or the wire is peeling off. If there is normal, measured the input voltage of MAPAT’s coupler.

3) Disassemble the coupler of MAPAT and turn on the ignition key

4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)’s coupler.

Input voltage : 4.5 ~ 5.5[V] Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal

Remarks : Measuring unit of voltage : voltage [V]

If voltage value is not normal,

Check to see if the ECU coupler is loose or if there is a bad contact. Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ to see if they have been broken short-circuited

Remark : refer to (5-16) if the intake pressure sensor is broken

refer to (5-16) if the intake temperature sensor is broken

5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

3 : Intake pressure sensor ground 26 : 5V voltage 27 : IMP 28 : TBA

MAPAT

3 : Inhalation pressure sensor GROUND

ECU

26 : 5V voltage 27 : IMP 28 : TBA

EMS(Engine Management System)

5-16

CHECKING OF THE INTAKE PRESSURE SENSOR

1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler

2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 )

3) Turn on the ignition key. Start engine and operate idle.

4) Measure the voltage of intake pressure sensor for ECU check.

Measuring the voltage of intake pressure sensor. Measuring terminal : ECU No. 27(P/L:PINK/BLUE) ~ ECU No.3(P/G : PINK/GREEN) Measuring voltage : 0.1[V] ~ 4.8[V]

Remarks : Measuring unit of voltage : Voltage [V]

The voltage of air pressure; 20[kPa]: 0.719 ~ 0.859[V] 107[kPa]: 4.154 ~ 4.294[V]

5) If the measured voltage is not normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been broken

or have short- circuited.

Replace the MAPAT sensor with the new one and it rechecks.

If measuring voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have

short- circuited if there is a bad contact.

badness of terminal No. 3, No. 26, No.27 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU.

Checking of the intake temperature sensor

1) If voltage value is normal, turn off ignition key.

2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)

Remarks : Measuring value for resistance : Resistance[ ] The Voltage of air pressure; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ]

3) If measuring resistance is not normal,

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have

short- circuited if there is a bad contact of terminal No. 3, No. 26, No. 28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks.

EMS(Engine Management System)

5-17

CHECKING OF INTAKE TEMPERATURE SENSOR

1) If voltage value is normal, turn off ignition key.

2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU No. 3(P/G : PINK/GROUND)

Remarks : Measuring value for resistance : Resistance[ ] The Voltage of air pressure; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ]

3) If measuring resistance is not normal,

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have

short- circuited if there is a bad contact of terminal No. 3, No. 26, No. 28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks. 4) Turn on the ignition key. Start the engine and idling.

5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor

- Measuring terminal: ECU No.28(TBA) ~ ECU No.3(IMP ground)

- Measuring voltage: 0.1[V] ~ 4.9[V]

Remarks : Measuring unit of voltage : Voltage [V]

6) If the measured voltage is not normal, Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ electric wire to see if they have been broken

or have short- circuited.

Replace the MAPAT sensor with new one and it rechecks.

If the measured voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire to see if they have been broken or have

short- circuited if there is a bad contact of terminal No. 3, No. 26, No.28 of ECU coupler. If the electric wire is no problem, ECU is broken. Replace ECU with the new one, it rechecks.

7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

EMS(Engine Management System)

5-18

8.TPS(THROTTLE POSITION SENSOR)

Remove

LH.side cowl TPS coupler

Remove

TPS screw 2EA Replace the TPS

It is Located on the right side of throttle body

The key is off before disassembly.

!

CAUTION

ETS

EMS(Engine Management System)

5-19

CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM

Fault code number is displayed by MIL

Checking circuit

The coupler terminal is based on the side of wire-harness

Checking Procedure

1) Turn off ignition key .

2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of TPS.

3) Disassemble the TPS coupler

4) Turn on the ignition key.

Input voltage : 4.5 ~ 5.5[V]

Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED) Measure the terminal voltage of TPS’s coupler. Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit of voltage : Voltage [V]

If voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.

Check the ‘GR/B’’ electric wire, ‘W/R’ electric wire, ‘GR /L’ electric wire to see if they have been

broken or have short- circuited.

5) If the value of voltage is normal, turn off the ignition key.

EMS(Engine Management System)

5-20

Checking Procedure

6) Check continuty between the Sensor Ground Terminal of TPS and Earth.

The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ ]

7) If not problem, measure the resistance of TPS. By turning round throttle Lever, measure the resistance. The resistance of TPS If the throttle is totally closed : 1.38~1.6[k ],20±1 If the throttle is totally opened : About 2.4[k ],20±1 Measuring Terminal : ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Remarks : Measuring value of resistance : Resistance[k ]

8) If resistance and the continuty are not abnormal. Adjust correctly the position of TPS Replace the TPS with the new one and re-check.

9) If resistance and continuty are normal, connect the coupler of TPS.

10) Turn on the ignition key.

11) Measure the TPS voltage of the wire-harness to check the ECU. Rotate the throttle lever, measure the voltage Measuring terminal: ECU No. 19 (Gr/L: GRAY/BLUE) ~ ECU No.4 (W/R : WHITE/RED) Output voltage of TPS

-If the throttle is totally closed : 0.1~0.6[V]

-If the throttle is totally opened : 4.0~5.5 [V]

Remarks : Measuring unit for voltage : Voltage [V]

12) If the measured voltage is abnormal, Replace the TPS with the new one, and re-check.

If the measured voltage is normal, Check the ‘GR/B’ electric wire, ‘GR/L’ electric wire, ‘W/R’ electric wire to see if they have been broken or

have short- circuited if there is a bad contact of terminal No. 4, No. 18, No. 19 of ECU coupler. If there is no problem in wires, ECU has broken down. Replace ECU with the new one, and recheck.

13) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

EMS(Engine Management System)

5-21

9.ETS(ENGINE TEMPERATURE SENSOR)

Remove

Rh.sided cowl Install in reverse order of removal

Remove

ETS coupler

Remove

ETS Install in reverse order of removal.

It is located on the left-hand side of cylinder head.

The key is off, before disassembly.

ETS torque:3±0.3[kgf m]

!

CAUTION

!

CAUTION

ETS CONNECTOR

ETS

TPS

EMS(Engine Management System)

5-22

1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)

Fault code number is displayed by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of wire-harness

Checking Procedure

1) Turn off the ignition key .

2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ETS.

3) Disassemble the coupler of ETS

4) Turn on ignition key.

Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE) ~ ECU No.4 (W/R : WHITE/RED)

Measure the terminal voltage of ETS’s coupler. Measuring voltage : 4.5[V] ~ 5.5[V]

Remarks : Measuring unit for voltage : voltage [V]

If the voltage value is not normal,

Check to see if the ECU coupler is loose, or bad contact.

Check the ‘G/L’’ electric wire, ‘W/R’ electric wire, ‘W/R’ electric wire to see if they have been

broken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key.

6) Disassemble the coupler of ETS, and measure the resistance of ETS.

Resistance of ETS :1.6[k ]~10.6[k ],20 ~80 Measuring terminal : Each terminal of ETS

Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [k ]

ETS

ECU

4 : SENSOR GROUND 20 : ETS

EMS(Engine Management System)

5-23

6-1) If the measured value is not normal,

Replace the ETS with the new one, recheck.

If the measured value is normal,

Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if

the ECU coupler is a bad contact ( No.4, No. 20.)

If the electric wire is no problem, ECU is broken.

Replace ECU with the new one, recheck.

6-2) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).

Checking Procedure

1) Disassembly Disassemble the ETS(Engine Temperature Sensor) : (Refer to 5-21)

2) Check the ETS(Engine Temperature Sensor) Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil. Read the temperature of thermometer depending upon oil temperature’s change and tester’s value.

Characters of ETS

Measuring unit of resistance : Resistance ‘ R ‘[k

]

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

1)Be careful do not fell down the ETS, because its weakness.

2)Be careful the ETS and the Thermometer do not to touched to oil bowl.

3)Be careful oil temperature will not raised more than measurement temperature.

3) Install Install in the reverse order of removal with standard torqve.

ETS torque : 3.0[kgf m]

Temperature

20

80

110

Resistance value

10.6[k

]~14.4[k ]

1.35[k

]~1.65[k ]

0.57[k

]~0.69[k ]

!

CAUTION

EMS(Engine Management System)

5-24

10.ISA(IDLE SPEED ACTUATOR)

Remove

Fuel tank ISA coupler

Remove

ISA screw

Remove

ISA

It is located upwards on the throttle body

The key is off, before disassembly.

!

CAUTION

ISA

ISA CONNECTOR

AIR CLEANER

ISA SCREW

EMS(Engine Management System)

5-25

1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT.

Showing of defects codes by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of the wire-harness

CHECK PROCEDURE

1) Turn off ignition key .

2) Check to see if the ISA(Throttle Position Sensor) coupler is loose, or bad.If there is no defect, measure the input voltage of ISA

3) Disassemble the coupler of ISA, measure the resistance

between ISA terminals.

ISA resistance : 31.5~ 38.5[ ],20

remarks : Measuring unit of resistance : Resistance ‘R’[ ]

4) If there is no problem, check about the level of electricity flow between each terminal, and between each ground.

Resistance between each terminal , and between each ground : ∞[ ] If measure resistance value is not normal, replace with the new one Disassembly and Assembly : refer to ( 5-23 )

remarks : Measuring unit for resistance : Resistance ‘R’[ ]

ECU

33 : ISA CONTROL 39:FUEL PUMP

ISA

FUEL PUMP RELAY

EMS(Engine Management System)

5-26

CHECK PROCEDURE

5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck.

6) If resistance and continuty is normal, connect the coupler of ISA.

7) Turn on ignition key

8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : 10~14[V]

Remarks : Voltage measuring unit : Voltage [V]

If the measured voltage is normal,

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

If the measured voltage is abnormal,

Check the ‘B/R’’ electric wire, ‘L/G’ electric wire, ‘W/B’ electric wire to see if they have been

broken or have short- circuited.

9) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

EMS(Engine Management System)

5-27

Remove

Center cowl O2 sensor coupler

Remove the O2 sensor coupler.

It is located on the exhaust pipe

The key is off before disassembly.

Beware of muffler after driving as it is still hot to be burnt

11.O2(Oxygen) SENSOR

O2 SENSOR

!

Warning

!

CAUTION

O2 SENSOR CONNECTOR

EMS(Engine Management System)

5-28

1) CHECKING OF OXYGEN(O

2

) SENSOR CIRCUIT

Fault code number is displayed by MIL

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.

CHECKING CIRCUIT

Coupler terminal is based on the side of Wire-Harness.

CHECKING FOR A FAULT CODE BY OXYGEN(O

2)SENSOR HEATER

1) Turn off the ignition key.

2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen)

3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key

4) Measure input voltage of oxygen(O2)sensor coupler Input voltage : Battery voltage[V] Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler (B/BR : BLACK/BROWN) ~ EARTH

Remarks : Measuring unit of voltage : Voltage[V]

OXYGEN SENSOR

2 : LAMBDA SENSOR GROUND

ECU

12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER

EMS(Engine Management System)

5-29

CHECKING FOR A FAULT CODE BY OXYGEN(O

2)SENSOR HEATER

If the voltage value is abnormal,

Check to see if the ECU coupler is loose or if there is bad contact.

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been

broken or have short- circuited.

5) If the voltage value is normal, turn off the ignition key. Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22 Measuring terminal (side of wire-harness) : oxygen(O2)3 terminal of sensor coupler

(B/BR : BLACK/BROWN) ~ ECU No.34(G/W :GREEN/WHITE)

Remarks : Measuring unit of Resistance : Resistance ‘R’[ ]

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

If the measured resistance is normal,

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been

broken or have short- circuited. If the electric wire is no problem, the ECU is broken. Replace the ECU with new one, and recheck it.

CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR LAMBDA SIGNAL

1) Turn off the ignition key

2) Check the O2(oxygen) coupler is loose, or bad. If there is no defect, measure the input voltage of O2(oxygen)

3) The wire-harness to checck the ECU is connected to the ECU with a coupler.

refer to the ECU assembly/disassembly.

4) Turn on the ignition key

5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.

Measuring terminal: ECU No.12(V :VIOLET)~ ECU No.2(V/B:VIOLET/BLACK) Output voltage of oxygen(O2) sensor : 0.1~0.8[V]

Remark : Measuring unit of voltage : Voltage[V]

Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf

If the measured voltage is normal,

Check the ‘B/R’ electric wire, ‘V’ electric wire, ‘V/B’ electric wire to see if they have been broken or

have short- circuited if there is a bad contact of terminal No. 2, No. 12 of ECU coupler.

If there is no problem in wires, ECU is broken.

Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,

Check the ‘V’ electric wire, ‘V/B’ electric wire, ‘W/B’ electric wire to see if they have been

broken or have short- circuited.

6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

EMS(Engine Management System)

5-30

12.CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT

Fault code number is displayed by MIL

CHECKING CIRCUIT

Coupler terminal is based on the side of Wire-Harness.

CHECK PROCEDURE

1) Turn off the ignition key .

2) Check the ESS coupler is loose, or bad. If there is no problem, check the resistance of tachometer.

3) Check the resistance between each terminals and ground.

Measuring terminal: B electric wire ~ EARTH, ECU NO. 32 (B/Y:BLACK/YELLOW) ~ EARTH

The resistance between each terminals and ground : ∞[ ] If the measured resistance value is abnormal, replace the part with new one. Refer to ( ) for assembly and disassembly

Remark : Measuring unit of voltage : Resistance [ ]

4) If the measured resistance and continuity are abnormal,

. Replace the tachometer with new one, and it rechecks.

5) If the resistance and continuity are normal, contact the tachometer coupler.

6)Turn on the ignition key.

7) Measure the voltage or tachometer of wire harness for ECU check.

Measuring terminal: B electric wire ~ G electric wire => Output Voltage: battery voltage

Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G electric wire =>Output voltage: 9[V]~15[V]

Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G Measuring the output voltage of electric

wire, using the PVA(peak voltage adapter) multi-tester tool.

Remark : Measuring unit of voltage : Voltage[V]

If the measured voltage is normal,

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 32 of ECU coupler.

If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and recheck it.

If the measured voltage is abnormal,

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see if they have been

broken or have short- circuited.

8) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

TACHOMETER

ECU 32 : ESS(ENGINE SPEED SIGNAL)

EMS(Engine Management System)

5-31

13.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT

Fault code number is displayed by MIL

CHECKING CIRCUIT

CHECK PROCEDURE

1) Turn off ignition key.

2) Check the ESS coupler is loose, or bad. If there is no problem.

3) Turn on the ignition key.

4) Check the MIL on for 3 seconds when turn on the ignition key at the same time. If there is no lighting, check the Lamp. But If the Lamp is working for 3 second,

5) Measure the MIL voltage of wire harness to check ECU. Measuring terminal : B electric wire ~ EARTH => Output Voltage: battery voltage Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~ EARTH => Output voltage:

battery voltage

Remarks : Measuring unit of voltage : Voltage[V]

If the measured voltage is normal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler. If there is no problem in wires, ECU has is broken.

Replace the ECU with new one, and rechecks it.

If the measured voltage is abnormal,

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to see if they have been broken or have short- circuited.

6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)

ECU

24 : MALFUNCTION INDICATOR LAMP OUTPUT

MALFUNCTION INDICATOR LAMP(MIL)

EMS(Engine Management System)

5-32

Remove

Main seat The pillion seat Flange bolt 4EA

Remove

ECU coupler

Install

Install in the reverse order of removal

It is located inside a pillion seat

The key is off before disassembly.

Be sure to assemble the ECU ground wire. (The color is green)

14.ECU(ELECTRONIC CONTROL UNIT)

!

CAUTION

!

CAUTION

SEAT

ECU

ECU GROUND WIRE

Pull

EMS(Engine Management System)

5-33

Remove

- LH. side cowl

- LH. side cover

- LH. RR cover

- Fule pump coupler

Remove

- ACG coupler

- Gear switch coupler

- LH crank case cover bolt 8EA

Remove

- Stator screw

- CPS screw

Install

- Install in the reverse order of removal

It is located inside a LH.crank case cover

The key is off before disassembly.

15.CPS(CRANK POSITION SENSOR)

!

CAUTION

CPS COUPLER(2P)

ACG COUPLER(2P)

GEAR SWITCH COUPLER(2P)

FUEL PUMP COUPLER(4P)

LH.REAR COVER

CPS

EMS(Engine Management System)

5-34

Remove

Fuel pump screw 4EA

Remove

Fuel pump

Before disconnecting the fuel hose, release the fuel pressure by loosing the fuel hose banjo bolt at the fuel tank Always replace the sealing washers when the fuel hose banjo bolt is removed or loosened.

It is Located inside a fuel tank

The key is off before disassembly.

16.FUEL PUMP

!

CAUTION

Do not push the fuel pump base under the fuel

tank when the fuel tank is stored.

Always replace the packing when the fuel pump

is removed.

!

CAUTION

NOTICE

FUEL PUMP

FUEL UNIT

EMS(Engine Management System)

5-35

The terminal arrangement of the fuel pump

(The following color chart is the internal color of the fuel pump)

16.FUEL PUMP

EMS(Engine Management System)

5-36

Remove the fuel level gauge (19-10) Measure the resistance between terminals.

The float position is based on the tank bottom plate after assemble.

Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)

wire of fuel unit terminal

Remark : Measuring unit of resistance : Resistance[ ]

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

CHECKING OF THE FUEL LEVEL GAUGE.

The FLOAT position

F : 192[mm]

1/2 : 138[mm]

E : 74[mm]

Terminals resistance [

]

33 15[ ]

300 20[ ]

566 15[ ]

EMS(Engine Management System)

5-37

DISCONNECT:

- Fuel tank and air cleaner

- Gasoline in the fuel tube.

- Fuel tube connected to the injector cap.

- TPS, ISA, MAPAT, injector coupler.

- Throttle cable

Do not disconnect both the throttle adjust screw

and adjusting nut

Disconnect the Insulator mounting two bolts

DISCONNECT THE THROTTLE BODY

INSPECTION

DISASSEMBLE

DISCONNECT:

- The insulator and throttle body mounting two bolts.

- TPS (Throttle position sensor)

- ISA (Idle speed actuator)

- O-ring from the throttle body

Do not disconnect the throttle valve

- Throttle shaft

- Throttle valve

!

CAUTION

!

CAUTION

17.THROTTLE BODY

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

THROTTLE BODY

INSULATOR

MAPAT

TPS

THROTTLE BODY

INJECTOR

ISA

THROTTLE ADJUST SCREW

ADJUST NUT

THROTTLE VALVE

THROTTLE SHAFT

EMS(Engine Management System)

5-38

DISCONNECT:

- Injector cap bolt

- Injector and injector cap at the same time from the insulator

- Injector and injector cap.

DISASSEMBLY THE THROTTLE BODY INSULATOR

CHECKING

CHECK:

- O-ring

- Inner side of insulator

- Inner side of injector

INSTALLATION

Install in the reverse order of removal. Assemble the o-ring into the insulator.

Replace the o-ring with new one.

ASSEMBLY OF THE THROTTLE BODY

Install in the reverse order of removal Assemble the o-ring into the throttle body

Replace the o-ring with new one.

!

CAUTION

!

CAUTION

MAPAT

INSULATOR

ISA

INJECTOR

TPS

EMS(Engine Management System)

5-39

Assemble the insulator into the throttle body. Torque: 1.0 kgf m

INSTALLATION OF INSULATOR AND THROTTLE BODY

Installation of insulator and throttle body is the reverse order of removal Check the o-ring when the insulator become assembly. Assemble the insulator gasket.

ADJUSTMENT OF THROTTLE CABLE

INSPECTION OF SENSOR AND ACTUATOR

Assemble the throttle cable Adjust the free play of the throttle grip (2-4)

Connect each sensor and the actuator’s coupler. Check the ISA (Idle speed actuator) (5-24) Check the TPS (Throttle position sensor (5-18)

Replace the gasket with new one.

Assemble the insulator and throttle body to cylinder head Torque : 1.2 kgf m

Check the value of TPS (Throttle position sensor) whether the standard value or not, after assembly. Check the MAPAT sensor (5-14)

!

CAUTION

!

CAUTION

EMS(Engine Management System)

5-40

ADJUSTMENT OF THROTTLE ADJUST SCREW

A vehicle is assembled in the state which engine

operation is possible.

Loosen the fuel tank, and the adjust-screw is makes

possible to adjust.. Disconnect the RH. Side cover. The couper to check the malfunction of vehicle is

connected to the coupler of diagnostic tool Press the power-button of diagnostic tool.

The ECU is always initialized, before the engine

is starting.

The vehicle is warms up enough, to adjust the idling

speed.

By adjusting throttle adjust screw. Adjust the value of ISA PWN to standard

value among the service data of diagnosis tool.

ISA (Idle speed actuator) PWM : 12 2%, 1600 100RPM After adjust the ISA PWM, fix the throttle adjust screw with adjusting nut.

If the ETS temperature is 90 degrees,

adjust the throttle adjust screw.

!

CAUTION

THE COUPLER TO CHECK THE MALFUNCTION OF VEHICLE

THE COUPLER OF DIAGNOSTIC TOOL

EMS(Engine Management System)

5-41

The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn on the lgnition key. Press the power button of the diagnostic tool. Press the enter button in the initial screen. Press the enter in the vehicle diagnosis screen.

Press the enter button on the resetting ECU values.

Press the rest button on the following screen.

If the enter-key is press than the ECU will reset.

18.HOW TO USE SCAN

WHEN THE ECU IS INITIALIZED

EMS(Engine Management System)

5-42

Press the enter button when it is ready

When the ECU was initialized. turn off the lgnition

key and then turn on the ignition key.

EMS(Engine Management System)

5-43

The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the button at the vehicle diagnostic screen.

Press the enter button on the current data.

By looking the displayed figure on the idle speed actuator PWM, adjust the throttle adjust screw.

(Refer to 5-41)

WHEN THE ‘ISA PWM’ ADJUSTING

EMS(Engine Management System)

5-44

The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen. Press the enter button on the vehicle diagnosis screen.

Press the enter button on the current data.

To check the ignition angle

WHEN THE IGNITION TIMING IS CHECK

EMS(Engine Management System)

5-45

The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen.

Press the enter button on the vehicle diagnosis

screen.

Press the enter button on the current data.

Check the engine rpm on the engine speed

WHEN THE ENGINE RPM IS CHECK

6-0

COOLING SYSTEM

6-1

6. COOLING SYSTEM

Do not remove the radiator cap, except to refill or drain the cooling system after servicing the cooling system.

Avoid spilling coolant on painted surfaces, if contaminated, do wash in water immediately.

After disassembling or servicing the cooling system, check for leaks with a radiator cap tester.(sale at a market)

SPECIFICATIONS

TORQUE VALUE

WATER PUMP IMPELLER 0.98~1.37kgf m

WATER PUMP COVER BOLT 0.78~1.18kgf

m

SERVICE INFORMATION

SERVICE INFORMATION 6-1

STROUBLESHOOTING 6-2

COOLANT 6-3

COOLING SYSTEM INSPECTION

6-3

COOLING SYSTEM TEST 6-4

RADIATOR 6-4

RADIATOR DISASSEMBLY 6-5

CHECK THERMOSTATIC SWITCH

6-6

RADIATOR INSTALLATION 6-6

WATER PUMP 6-7

TERMOSENSOR 6-10

THERMOSTATIC 6-10

Do not remove the radiator cap if the coolant temperature is over 100°C.

It is very dangerious removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding.

When the temperature is below, carefully remove the cap with a cloth.

Cooling system service should be done while the engine is cool.

Radiator coolant is toxic. Keep it away from skin, eyes and clothes.

- If any coolant gets on your skin or clothes, rinse thoroughly with soap and water.

- If any coolant gets in your eyes, rinse them with water and consults a doctor immediately.

- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.

- Especially pay attention to reserve the coolant. Keep out of reach of children.

RADIATOR CAP RELIEF PRESSURE

THERMOSTAT TEMPERATURE

BEGIN TO OPEN

FULLY OPEN

VALVE LIFT

COOLANT CAPACITY

Total system 1400

20cc

RADIATOR: 1000

20cc

RESERVE TANK : 280

20cc

80 2 C

90

C

3.5~4.5mm

0.9

0.1kg/cm

2

6-2

COOLING SYSTEM

TROUBLESHOOTING

Engine temperature too high

Faulty temperature gauge or thermo sensor Air in cooling system Faulty thermostat stuck (Thermostat stuck closed)

Passages blocked in radiator, hoses or water jacket Faulty fan motor switch Faulty water pump

Engine temperature too low or unstable

Faulty temperature gauge or thermo sensor

Faulty thermostat stuck (Thermostat stuck open)

Faulty fan motor switch

Coolant leaks

Faulty water pump mechanical seal

Damaged or deteriorated O-rings

Faulty radiator cap

TDamaged or deteriorated gasket

Loose hose connection or clamp

Daelim ROADWIN R SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual