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
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
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE SERIAL NUMBER
ENGINE 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
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 Apply Engine Oil
Apply Engine Oil Remove negative screw Remove negative screw
1.0~1.2
3.5~4.5
0.8~1.2
0.8~1.2
1.0~1.4
0.35~0.5
6.0~7.0
6.0~7.0
5.0~6.0
3.0~3.4
1.0~1.4
1.0~1.4
1.0~1.4
1.0~1.4
1.0~1.2
1.0~1.2
1.0~1.2
0.4~0.8
1.0~2.0
1.0~1.2
1.0~1.2
1.0~1.4
1.0~2.0
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
1
2
4
2
1
1
1
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
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
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
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.. ἱ
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
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
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2-4
2-4
2-4
2-5
2-6
2-6
3-3
3-4
2-8
2-10
2-10
2-11
2-12
2-12
2-12
2-12
2-14
2-14
2-15
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
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
FUEL TUBE
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
2~6mm
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
ADJUSTER
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
LOCK NUT
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
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
SCREWS
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
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
SPARK PLUG
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
FEELER GAUGE
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
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
“T” MARK
Measure the valve clearance with a feeler gauge.
VALVE CLEARANCE : INTAKE : 0.15mm
EXHAUST : 0.20mm
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
VALVE RIFTER
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