Daelim ROADWIN VJ125 SERVICE MANUAL

SM48-0401-01E

HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524

OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure for the VJ125 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 Co., Ltd.,

CONTENTS

GENERAL INFORMATION

INSPECTIONS / ADJUSTMENTS

LUBRICATION

FUEL SYSTEM

ENGINE

1

2

3

4

COOLING SYSTEM

5

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

6

7

8

9

10

11

12

13

14

15

16

17

WIRING DIAGRAM

18

TROUBLESHOOTING

19

20

21

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

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/dis-

connecting.

󳢯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 care-

fully 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.

1-10

GENERAL INFORMATION

SPECIFICATIONS

ITEM SPECIFICATIONS

OVERALL LENGTH 2,010mm OVERALL WIDTH 740mm OVERALL HEIGHT 1,040mm

DIMENSIONS

WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 150mm DRY WEIGHT 130kgf CURB WEIGHT 147kgf

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 16ℓ FUEL RESERVE CAPACITY 1.1ℓ CASTER ANGLE 25.2° TRAIL 93.5mm FRONT FORK OIL CAPACITY 265±2.5cc

TYPE Air Cooled 4-stroke SOHC CYLINDER NUMBER, ARRANGEMENT

1 Cylinder, 15°Inclined from vertical

BORE AND STROKE 56.5 X 49.5mm DISPLACEMENT 124.1cm

3

COMPRESSION RATIO 10.7:1 VALVE TRAIN SOHC Chain Drive OIL CAPACITY 1.1 ℓAfter Disassembly

1.05ℓAfter Draining and Oil Filter Change

ENGINE

1.0 ℓAfter Draining

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

2

(600rpm)

INTAKE VALVE OPEN 6°BTDC

CLOSED 22°ABDC (1.12mm Lift)

EXHAUST VALVE OPEN 24°BBDC

CLOSED -4°ATDC (1.12mm Lift)

VALVE CLEARANCE INTAKE 0.12±0.02mm (A COOLING-OFF PERIOD)

EXHAUST 0.12±0.02mm

ENGINE DRY WEIGHT 32.3kgf

1-11

GENERAL INFORMATION

ITEM SPECIFICATIONS

TYPE PD 24 VENTURI BORE 24mm SETTING SERIES MARK VJ 125 C MAIN JET #100

CARBURETOR

SLOW JET #38 PILOT SCREW INITIAL SETTING 2 1/8 FLOAT LEVEL 12.5mm IDLE SPEED 1,600±100(rpm)

CLUTCH TYPE Multiplate Wet Clutch TRANSMISSION TYPE Constant Mesh Transmission GEAR RATIO 1st 3.083(37/12 T)

DRIVE TRAIN

GEAR RATIO 2nd 1.882(32/17 T) GEAR RATIO 3rd 1.380(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

1-N-2-3-4-5

IGNITION TYPE DC-CDI Ignition IGNITION TIMING “F” MARK 8°BTDC / 1,600(rpm)

FULL ADVANCE

28°BTDC / 4,000(rpm)

AC GENERATOR 12V-11A/5,000(rpm) BATTERY CAPACITY 12V 10AH SPARK PLUG CR8EH - 9 SPARK PLUG GAP 0.8 - 0.9mm FUSE CAPACITY 15A STARTING SYSTEM Starter Motor

ELECTRICAL

HEADLIGHT (HIGH/LOW BEAM) 35W/35W POSITION LAMP 3W WINKER LAMP 10W×4 STOP/TAIL LIGHTS 21W/5W SPEEDOMETER LAMP 3W FUEL RESERVE INDICATOR LAMP 2W NEUTRAL INDICATOR LAMP 3W HIGH BEAM INDICATOR LAMP 3W WINKER INDICATOR LAMP 3W×2 LICENCE PLATE LAMP 5W TACHOMETER LAMP 2W

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

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

11

3 7 1 1

10

1 2 1 2 2 4

M8×1.25

M6×1.0

M8×1.25

M6×1.0 M6×1.0

M36×1.5

M5×0.5 M16×1.0 M16×1.0

M10×1.25

M8×1.25

M6×1.0

M10×1.25

M6×1.0

M6×1.0 M14×1.5 M30×1.5

M6×1.0

M10×1.25

M6×1.0

M12×1.25 M12×1.25

M5×12

Apply Engine Oil

Apply Engine Oil Apply Engine Oil Apply Engine Oil

2.0 (20)

1.0 (10)

1.2 (12)

0.4 (4)

1.5 (15)

1.1 (11)

6.5 (65)

5.5 (55)

3.2 (32)

1.2 (12)

1.1 (11)

0.6 (6)

0.8 (8)

1.1 (11)

1.2 (12)

3.2(32)

0.4(4)

CAM SHAFT HOLDER NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW TAPPET VALVE ADJUST HOLE CAP TAPPET ADJUST NUT PRIMARY DRIVE GEAR NUT CLUTCH 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 OIL PUMP MOUNT BOLT START MOTOR NUT OIL THROUGH BOLT(CYLINDER) OIL THROUGH BOLT(RADIATOR) AIR CLEANER CASE COVER SCREW

2 1 2 1 1 1 1 4 2

M10×1.25 M10×1.25

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

4.9 (49)

2.6 (26)

1.5 (15)

4.5 (45)

0.42 (4.2)

8.8(88)

5.9(59)

3.4(34)

ENGINE HANGER BOLT (REAR) ENGINE HANGER BOLT (FRONT) STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROCKET 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.

TYPE

TORQUE

TYPE

TORQUE

kgf··mN

··

m kgf··mN

··

m

15mm BOLT, NUT 0.5 5 5mm SCREW 0.4 4

16mm BOLT, NUT 1.0 10

6mm SCREW, FLANGE BOLT

0.9 9

18mm BOLT, NUT 2.1 21

6mm FLANGE BOLT, NUT

0.9 9

10mm BOLT, NUT 3.5 35

8mm FLANGE BOLT, NUT

2.7 27

12mm BOLT, NUT 5.5 55

10mm FLANGE BOLT, NUT

4.0 40

kgf.m,(N,m)

FRAME

2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 3

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

SOCKET BOLT

3.0(30)

1.2(12)

5.9(59)

4.2(42)

3.4(34)

3.0(30)

1.2(12)

7.4(74)

0.3(3)

2.6(26)

3.4(34)

2.6(26)

8.8(88)

3.4(34)

0.6(6)

4.2(42)

2.0(20)

4.2(42)

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 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

2 16, 17 16, 17

17

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

9

24.5mm IN, EX 23mm IN

20mm EX

22mm IN, EX

Use with Valve Seat

DESCRIPTION REFERENCE SECTION REMARK

CLUTCH CENTER HOLDER 7 ACG ROTOR PULLER 8 VALVE GUIDE DRIVER 9 VALVE GUIDE REAMER 9 UNIVERSAL BEARING PULLER 11 BEARING REMOVER SET 11 THREAD ADAPTER 11 ASSEMBLY SHAFT 11 CRANK CASE ASSEMBLY COLOR 11 BALL RACE DRIVER 13 STEERING STEM DRIVER 13 FORK SEAL DRIVER 13 STEERING STEM SOCKET 13 SNAP RING PLIERS 15

WRENCH, 8

9mm 2 ADJUSTING WRENCH, B 2 FLOAT LEVEL GAUGE 4 LOCK NUT WRENCH, 20

24mm 7 EXTENSION BAR 7, 13 FLY WHEEL HOLDER 7, 8 VALVE SPRING COMPRESSOR 9 DRIVER 11, 13, 14 ATTACHMENT 11, 13, 14 PILOT 11, 13, 14 FORK SEAL DRIVER BODY 13 BEARING REMOVER HEAD 14 BEARING REMOVER SHAFT 14

1-16

GENERAL INFORMATION

WIRING DIAGRAM

FR. BRAKE HOSE

SPDMT. CABLE

THROTTLE CABLE

ST.-HAZ. SW. CORD FR. BRAKE HOSE

CABLE GUIDE

CLUTCH CABLE

CHOKE CABLE

NOISE SUPPRESSOR CAP

HORN COMP.

LH. RADIATOR HOSE

RH. RADIATOR HOSE

HIGH TENSION CORD

CLUTCH CABLE

RR. BRAKE HOSE

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE CLAMP

RR. BRAKE HOSE

RR. CALIPER ASS'Y.

BATTERY EARTH CABLE

ST.-MOTOR CABLE

SIDE STAND SW. CORD

RR. STOP SW. CORD

ST.-MAG SW. CORD

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

HARNESS COVER

WIRE CLIP

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

ST.-MAG. SW. WIRE

C

CLUTCH CABLE

WINKER SW. CORD

CHOKE CABLE

CABLE GUIDE

LH. FR. WINKER

HEAD LIGHT

CABLE GUIDE

SPEEDOMETER CABLE

FR.BRAKE HOSE

THROTTLE CABLE

WIRE HARNESS

WIRE CLIP

BREATHER TUBE

DRAIN TUBE

WIRE CLAMP (WIRE PIVOT)

WIRE CLIP

FUEL UNIT CORD

REG. RECTIFIER WIRE

EARTH WIRE

FUEL UNIT WIRE

ACG. WIRE

FUSE WIRE

ST.-MAG. SW. WIRE

WIRE CLIP CABLE CLAMP

SEAT LOCK CABLE

WIRE HARNESS

HELMET HOLDER & SEAT LOCK ASS'Y.

HORN COMP.

HORN CORD

WIRE GROMMET

BRAKE HOSE CLAMPER

SPDMT. CABLE CLAMP

ST.-MOTOR CABLE

ACG. CORD

HARNESS COVER(ACG. CORD SETT.)

E

A

G

1-17

GENERAL INFORMATION

WIRE HARNESS

IGN. COIL

WIRE CLIP

THROTTLE CABLE JUNCTION CLAMP

FUEL COCK

WIRE CLAMP(WIRE PIVOT)

FUEL COCK(RES)

FUEL COCK(ON)

FUEL STRAINER COMP.

WIRE HARNESS

AIR VENT TUBE

CHOKE CABLE

CLUTCH CABLE

LH. RADIATOR HOSE

RH. RADIATOR HOSE

THROTTLE JUNCTION

CABLE GUIDE

IGN. COIL CORD

CHOKE CABLE

THROTTLE CABLE (TO. ACCELERATION PUMP)

THROTTLE CABLE(TO. CARB.)

ST.-MAG. SW. WIRE

FUSE CODE

ST.-MAG. BATTERY CABLE(+)

FUSE BOX

BATTERY EARTH CABLE

BATTERY BAND

AIR VENT TUBE

CDI COMP.

HEAD LIGHT RELAY

SEAT LOCK CABLE

LH. RR. WINKER CORD

RH. RR. WINKER CORD

TAIL LIGHT SOCKET COMP.

HEAD LIGHT RELAY WIRE

CDI COMP. WIRE

WINKER RELAY WIRE

WINKER RELAY

TAIL LIGHT WIRE

WIRE CLIP

TAIL LIGHT CORD

TAIL LIGHT ASS'Y.

1-18

GENERAL INFORMATION

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

RESERVE TANK

RR. BRAKE HOSE

RR. BRAKE HOSE GUIDE

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE

RR. CALIPER

RR. BRAKE HOSE

RESERVE TANK

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE CLAMP

RR. BRAKE HOSE GUIDE

TUBE CLIP

RR. BRAKE HOSE GUIDE

DETAIL OF VIEW C

DETAIL OF VIEW B

1-19

GENERAL INFORMATION

BRAKE HOSE CLAMP

BRAKE HOSE

RH. RADIATOR HOSE

BRAKE HOSE CLAMPER

SPDMT. CABLE

HORN COMP.

SPDMT. CABLE GUIDE

DETAIL OF VIEW A

FUEL DRAIN TUBE

DRAIN TUBE

TUBE GUIDE

DRAIN TUBE

ENG. DREATHER TUBE

CLUTCH CABLE

DETAIL OF VIEW D

RH. CABLE GUIDE

COMBI. METER CORD

WINKER SW. CORD

RH. WINKER CORD

LH. WINKER CORD

WIRE CLIP

COMB. SW. CORD

COMB. SW. WIRE

HAZARD SW. CORD

DETAIL OF HEAD LIGHT CASE PART

WINKER SW. WIRE

WINKER WIRE

WIRE CLIP

WIRE HARNESS

HEAD LIGHT WIRE

RH. WINKER CORD

FR. BRAKE HOSE

THROTTLE CABLE

ST. HAZARD SW. CORD

CHOKE CABLE

CLUTCH CABLE

WIRE HARNESS

HEAD LIGHT CASE

THROTTLE CABLE

WINKER SW. CORD

CHOKE CABLE

CLUTCH CABLE

LH. WINKER CORD

LH. CABLE GUIDE

DETAIL OF VIEW G

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

2

SERVICE INFORMATION

······

2-1

MAINTENANCE SCHEDULE

····

2-3

FUEL LINE (FUEL TUBE)

······

2-4

THROTTLE GRIP OPERATION

····

2-4

CARBURETOR CHOKE

········

2-5

AIR CLEANER

··············

2-5

SPARK PLUG

··············

2-6

VALVE CLEARANCE

········

2-6

CYLINDER COMPRESSION PRESSURE

··

2-7

CARBURETOR IDLE SPEED

····

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

WHEELS/TIRES

··············

2-15

STEERING HEAD BEARINGS··2-15

THROTTLE GRIP PLAY 2~6mm SPARK PLUG CR8EH-9 SPARK PLUG GAP 0.8~0.9mm

IN. 0.12±0.02mm

EX. 0.12±0.02mm CARBURETOR IDLE SPEED 1,600±100rpm 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

200kPa (2.00kgf/㎠ ) 200kPa (2.00kgf/㎠ ) 200kPa (2.00kgf/㎠ ) 225kPa (2.25kgf/㎠ )

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) VALVE ADJUSTING NUT 1.1 kgf-m( 11N.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 ADJUSTING WRENCH, B 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

CARBURETOR CHOKE

AIR CLEANER ELEMENT

SPARK PLUG

VALVE CLEARANCE

CARBURETOR IDLE

ENGINE OIL

ENGINE OIL FILTER

DRIVE CHAIN

DRIVE CHAIN SLIDER

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

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

2-7

3-3

3-4

2-8

2-10

2-11

2-12

2-13

2-14

2-15

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

CARBURETOR CHOKE

● Check the deterioration, damage and kink of the choke

cable. Check if the choke lever operates smoothly in any position.

● Pull the choke lever to the left, and close it perfectly.

AIR CLEANER

● Remove the seat. (⇨12-2)

● 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 the removed parts in the reverse order of

removal.

● Check if the choke valve is closed perfectly by moving

the carburetor choke arm.

● When adjustment is necessary, loosen the choke cable

clamp in order that choke valve can be opened, and then adjust by moving the choke cable cover.

󳢯The element is a viscous type which contains oil.

Therefore do not use compressed air to clean the air cleaner element.

CHOKE LEVER

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

CHOKE ARM

FEELER GAUGE

2-6

INSPECTIONS / ADJUSTMENTS

CHECK GAP, DEPOSITS

CHECK FOR CRACKS

CHECK WASHER FOR DAMAGE

0.8mm~0.9mm

SPARK PLUG

● Remove the spark plug cap and disassemble the plug.

● 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 : CR8EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf··m (11N··m)

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.

󳢯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.

󳢯Inspect and adjust valve clearance while the engine

is cold. (below 35° C/95°F)

“T” MARK

0.8~0.9mm

CHECK GAP,

DEPOSITS

CHECK FOR

CRACKS

CHECK WASHER FOR DAMAGE

INDEX MARK

SPARK PLUG

● Measure the valve clearance with a feeler gauge.

VALVE CLEARANCE : INTAKE : 0.12±±0.02mm

EXHAUST : 0.12±±0.02mm

● Loosen the lock nut with a vlave wrench, and set valve

clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench.

● After setting clearance to the prescribed level, hold the

adjuster screw with a valve adjusting wrench, and tighten the lock nut.

TORQUE : 1.1kgf··m (11N··m) TOOLS : WRENCH 8x9mm

ADJUSTING WRENCH B FEELER GAUGE

2-7

INSPECTIONS / ADJUSTMENTS

● Measure the vlave clearance again.

● Install the cylinder head cover and tighten the bolts.

TORQUE : 1.0kgf··m (10N··m)

● Install the A.C generator cap and crankcase hole cap.

TORQUE : A.C GENERATOR CAP : 0.6kgf··m(6N··m) CRANK CASE HOLE CAP : 0.8kgf··m(8N··m)

CYLINDER COMPRESSION PRESSURE

● Warm up the engine.

● Stop the engine, and remove the spark plug cap 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

COMPRESSION PRESSURE : 13.0㎏㎏f/㎠㎠(600rpm)

● If compression is low, check the following:

- Incorrect valve clearance adjustment

- Valve leakage

- Leakage from the cylinder head gasket.

- Worn piston/cylinder

● If compression is high, check the following:

- Carbon deposits on the piston head, and cylinder head.

󳢯The maximum reading is usually reached within

4~7 seconds

ADJUSTING WRENCH B

SPARK PLUG WRENCH

COMPRESSION GAUGE

CARBURETOR IDLE SPEED

● Warm up the engine for about ten minutes.

● Turn the throttle stop screw as required to obtain the

specified idle speed.

IDLE SPEED : 1,600±±100rpm

THROTTLE STOP SCREW

󳢯Inspect all other engine adjustments are within

specifications and adjust idle speed.

󳢯The engine must be warm for accurate adjustment.

Support the motorcycle on a level surface and shift the transmission into neutral.

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.

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, torque them.

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.

󳢯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

BOLTS

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 15-6 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

WEAR

INDICATOR

WEAR INDICATOR

10~20mm

2-11

INSPECTIONS / ADJUSTMENTS

BRAKE SYSTEM

INSPECTION

● Firmly apply the brake lever or pedal, and check

that no air has entered the system.

● If the lever or pedal feels soft or spongy when

operated, bleed the air from the system.

● Inspect the brake hose and fittings for deterioration,

cracks and sighs of leakage.

● Tighten any loose fittings.

● Replace hoses and fittings as required.

● Refer to page 15-4 for brake bleeding procedures.

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 15-6 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

BOLT

10~20mm

󳢯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.

● If the adjuster is threaded out near its limit and the

correct free play cannot be obtained, turn the adjuster all the way in and back out one turn.

● Tighten the lock nut and make a major adjustments

as described as follow.

● 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. (see section 7)

SIDE STAND

● Support the motorcycle on a level surface.

● 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. (section 17)

LOCK NUT

ADJUSTER

SIDE STAND SWITCH

2-14

INSPECTIONS / ADJUSTMENTS

REAR SUSPENSION INSPECTION

● 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. (⇨1-12)

● Check that all safety clips, hose clamps and cable

stays are in place and properly secured.

● Support 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 INSPECTION

● 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

● Support the motorcycle securely and raise the front

wheel off the ground.

● Check that the handlebar moves freely from side to

side to side.

● If the handlebar moves unevenly, binds or has

vertical movement, inspect the steering head bearings. (section 13)

STEERING HEAD BEARINGS

󳢯Check that the cables do not interfere with

handlebar rotation.

STANDARD PRESSURE

WHEELS/TIRES

󳢯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)

MEMO

3-1

3. LUBRICATION

SERVICE INFORMATION

GENERAL SAFETY

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

long period of time.

2. 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.

3. 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 SOCKET BOLT

1.2㎏f·m (12N·m)

OIL FILTER COVER BOLT

1.1㎏f·m (11N·m)

OIL PUMP MOUNTING BOLT

1.1㎏f·m (11N·m)

3

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

1.1ℓ (After disassembly)

1.05ℓ (After Oil filter change)

1.0ℓ (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 PUMP SIDE CLEARANCE 0.05~0.09 0.12

ITEM STANDARD VALUE SERVICE LIMIT

OIL PUMP

Unit : mm

3-2

LUBRICATION

TROUBLESHOOTING

Engine oil level too low

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

Oil contamination

󳢯Oil or filter not changed often enough. 󳢯Faulty head gasket. 󳢯Worn piston rings.

Low or no oil pressure

󳢯Clogged oil orifice. 󳢯Incorrect oil being used.

ENGINE OIL LEVEL INSPECTION

● Support 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.

● Extract the spring and screen.

● Start the kick starter arm 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: 1.1ℓℓ(After disassembly)

1.05ℓℓ(After oil filter change)

1.0ℓℓ(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 insufficient, supply the recommended oil.

● Make sure that there are no oil leaks.

3-3

LUBRICATION

󳢯Make the engine warm and support the motorcycle

with its side stand in order to assure complete and rapid draining.

OIL LEVEL GAUGE

TAPPET ADJUST HOLE CAP

OIL FILTER SCREEN

OIL FILTER SCREEN SPRING

3-4

LUBRICATION

OIL PUMP

FLANGE BOLTS

󳢯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.

OUTER ROTOR

INNER ROTOR

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SPACER

PUMP BODY

PUMP SHAFT

OIL SEAL

OIL FILTER ELEMENT CHANGE

● Drain the engine oil. (⇨3-3)

● Loosen the 3 flange bolts securing the oil filter cover,

remove the oil filter cover.

● Remove the oil filter element and oil filter spring.

● Change the oil filter element with a new one.

● Check the operation of the relief valve.

If the relief valve is fully opened when released, it is in good condition.

● Check if the oil filter seal is in good condition.

● 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 right crankcase cover. (⇨7-3)

● Loosen the 2 flange bolts securing the oil pump,

remove the oil pump.

DISASSEMBLY

● Remove the oil pump body, the oil pump plate, and

lock pin.

● Clean the oil pump body, inner and outer rotors with

fresh cleaning oil.

OIL FILTER COVER

RELIF VALVE

BOLTS

OIL FILTER ELEMENT

3-5

LUBRICATION

OUTER ROTOR

INNER ROTOR

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SETTING

RING

SPACER

PUMP BODY

PUMP SHAFT

OIL SEAL

INNER ROTOR

OUTER ROTOR

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.

● Measure the rotor end clearance.

SERVICE LIMIT : 0.20mm

● Measure the pump side clearance.

SERVICE LIMIT : 0.12mm

3-6

LUBRICATION

● Install the pump shaft, oil seal and spacer, then

assemble into the setting ring.

● Install the inner and outer rotors to the pump body.

● Install the dowel pins and oil pump plate into the pump

body.

INSTALLATION

● Install the oil pump into the right crankcase cover and

tighten the bolts with the specified torque.

TORQUE : 1.1 kgf··m (11 N··m)

● Install the right crankcase cover. (⇨7-12)

● Fill the crankcase with the recommended oil and check

that there is no oil leaks.

󳢯After installing, check the oil pump to operate

smoothly.

SETTING RING

OIL PUMP

FLANGE BOLTS

OIL PUMP PLATE

DOWEL PINS

3-7

LUBRICATION

STEERING HEAD BEARINGS

DUST SEAL

WHEEL BEARING

(AT CHANGED)

SPEEDOMETER GEAR

BRAKE CALIPER

PIVOT

BRAKE PEDAL

PIVOT

REAR FORK

PIVOT

WHEEL BEARING

(AT CHANGED

DUST SEAL)

DRIVE CHAIN

(SAE#80or#90GEAR OIL)

THROTTLE GRIP

CLUTCH LEVER

PIVOTS

THROTTLE CABLE,

CHOKE CABLE,

SPEEDOMETER CABLE,

CLUTCH CABLE

BRAKE LEVER

PIVOTS

SIDE SAND

PIVOT

FRONT FORK DUST SEAL

LUBRICATION POINTS

Use general grease unless specified here. Apply oil or grease to the other sliding surfaces not shown here.

CONTROL CABLE LUBRICATION

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

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.

● Do not excessively bend or twist cable. Distorted or damaged cable may lead to mechanical malfunctions.

● Pay particular attention to the position of O-ring. Replace with new ones when disassembled.

● Loosen the drain bolt of the float chamber before disassembly, drain residual gasoline, and then, put in a vessel.

● If it is desired to store a vehicle for a period longer than 1 month, drain gasoline out of the carburetor float chamber.

Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits, and idling may become unstable.

SPECIFICATIONS

FUEL TANK CAPACITY : 16ℓ RESERVE FUEL CAPACITY: 1.1ℓ

CARBURETOR

TORQUE VALUE

AIR CLEANER CASE COVER SCREW 0.43kgf·m (4.3N·m)

TOOL

FLOAT LEVEL GAUGE

4. FUEL SYSTEM

4

SERVICE INFORMATION

····

4-1

TROUBLESHOOTING

········

4-2

FUEL TANK

················

4-3

AIR CLEANER CASE

········

4-4

THROTTLE VALVE

··········

4-5

CARBURETOR

············

4-6

PILOT SCREW ADJUSTMENT··4-12

ITEM SPECIFICATIONS

VENTURI BORE 24mm SETTING SERIES MARK VJ125 C MAIN JET #100 SLOW JET #38 JET NEEDLE CLIP POSITION 2th Level FLOAT LEVEL 12.5mm PILOT SCREW INITIAL OPENING 2 1/8 IDLE SPEED 1,600

±

100(rpm)

THROTTLE GRIP FREE PLAY 2~6mm

4-2

FUEL SYSTEM

TROUBLESHOOTING

Engine cranks but won't start

● No fuel in tank

● No fuel to carburetor

● Cylinder flooded with fuel

● Clogged air cleaner

● No spark at plug

Rough idle, incorrect idle speed

● Faulty idle adjustment

● Excessively lean or rich mixture

● Clogged fuel system

● Intake air leak

● Clogged fuel system

Lean mixture

● Clogged carburetor jets

● Clogged fuel tank breather

● Clogged fuel strainer screen

● Twisted, pressed and clogged fuel tube

● Faulty float valve

● Float level too low

Rich mixture

● Closed choke valve

● Faulty float vlave

● Float level too high

● Clogged air jets

Load during acceleration

● Faulty accelerating pump

4-2

FUEL FILLER CAP

FUEL TANK COVER

FUEL TANK SEALING RUBBER FUEL UNIT

FUEL STRAINER

FUEL COCKFUEL TANK

FUEL CAP NECK

4-3

FUEL SYSTEM

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. (⇨12-2)

● 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. (⇨12-2)

● Disconnect the fuel unit wire coupler.

● Place the fuel tank upside down.

● Disconnect the fuel tubes from the fuel tank.

● 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 UNIT WIRE COUPLER

FUEL TUBES

󳢯Be careful not to damage the fuel tank.

AIR CLEANER CASE

AIR CLEANER INNER PIPE

AIR CLEANER ELEMENT

AIR CLEANER CASE COVER

4-4

FUEL SYSTEM

AIR CLEANER CASE

REMOVAL

● Remove the fuel tank. (⇨4-3)

● Remove the RH. LH. side covers.

● Remove the battery. (⇨16-3)

● 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

SIDE COVER

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

4-5

FUEL SYSTEM

THROTTLE VALVE

REMOVAL

● Remove the fuel tank. (⇨4-3)

● Loosen the carburetor top slowly, and remove the

throttle valve.

● Disconnect the throttle cable from the throttle

valve, and remove the throttle valve.

● Remove the throttle valve spring and carburetor top

from the throttle cable.

●

Pull out the retainer clip, and remove the jet needle.

●

Inspect the jet needle, throttle valve for damage and wear.

CARBURETOR TOP

SPRING

THROTTLE VALVE

THROTTLE CABLE

SPRING

CARBURETOR TOP

THROTTLE VALVE

RETAINER CLIP

JET NEEDLE

SPRING

THROTTLE VALVE

4-6

FUEL SYSTEM

CARBURETOR

REMOVAL

● Remove the fuel tank. (󳫻 4-3)

● Remove the carburetor top. (󳫻 4-5)

● Remove the carburetor drain screw and drain

gasoline from the carburetor.

● Remove the choke cable.

● Loosen the air cleaner connecting tube band.

INSTALLATION

● Install the clip on the jet needle.

STANDARD CLIP POSITION : 2nd LEVEL

● Install the jet needle into the throttle valve and

secure with the retainer.

● Install the carburetor top into the throttle cable.

● Route the throttle cable through the spring and

compress the spring fully.

● Attach the throttle cable end to the bottom of the

throttle valve and thread the throttle cable through the slot in the valve.

● Align the cutout in the throttle valve with the

throttle stop screw on the carburetor and install the valve on the carburetor.

● Inspect the following items.

- Throttle grip free play : 2~6mm

- Idling speed :1,600±100 rpm

󳢯 Gasoline is extremely flammable and is explosive

under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refuelled.

(Rich mixture)

1st LEVEL

2nd LEVEL

3th LEVEL

(Lean mixture)

CLIP

JET

NEEDLE

JET

NEEDLE

RETAINER

THROTTLE VALVE

CARBURETOR TOP

CHOKE CABLE

4-7

FUEL SYSTEM

● Remove the throttle cable.

● Loosen the carburetor mounting nut, and remove

the carburetor.

DISASSEMBLY

● Remove the air vent tube and drain tube.

Accelerator Pump

● Take of the 3 screws, and remove the pump cover.

● Remove the spring.

● Inspect the damage of accelerator pump rod and

diaphragm. Blow the fuel pathway of diaphragm with air lightly and clean the clogged place.

DRAIN TUBE

DIAPHRAGM

SPRING

SCREWS

AIR VENT TUBE

THROTTLE CABLE

4-8

FUEL SYSTEM

● Align the diaphragm projecting part with float

chamber groove. Install the spring to diaphragm cover, and install the cover to the float chamber preventing the diaphragm form damaging.

● Adjust the accelerator pump.

Float, Float Valve

● Take off the 3 screws and remove the float

chamber.

● Take off the float arm pin, and remove the float and

float valve.

● Check the float valve and valve seat for scores,

scratches, clogging and damage. Replace if necessary.

● Check the tip of the float valve, where it contacts

the valve seat, for stepped wear or contamination. Replace the float valve if its tip is worn or contaminated.

● A worn or contaminated valve does not seat

properly and will eventually flood the carburetor.

GROOVE

PROJECTING PART

SCREWS

FLOAT VALVE

FLOAT

FLOAT ARM PIN

FLOAT VALVE

TIP OF THE FLOAT VALVE

VALVE SEAT

4-9

FUEL SYSTEM

Jet

● Remove the main jet, needle jet holder, and needle

jet.

● Remove the slow jet.

● Remove the pilot screw after recording the number

of turns until the pilot screw is tightened to clockwise completely.

● Remove the throttle stop screw.

● Clean the jet with cleaning solvent.

● Inspect the pilot screw and jets and change the

wear and tear parts with new ones.

MAIN JET

NEEDLE JET HOLDER

SLOW JET

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

NEEDLE JET

HOLDER

MAIN JET

SLOW JET

PILOT SCREW

󳢯Do not tighten up the pilot screw by force.

It can cause the damaging of the seat part.

ASSEMBLY

4-10

FUEL SYSTEM

● Blow open air and fuel passages in the carburetor body

with compressed air.

● Install the needle jet, needle jet holder, main jet and

slow jet.

● Install the throttle stop screw and pilot screw.

● Install the float valve, float and float arm pin.

● If installing the new pilot screw, adjust the pilot

screw.

Float Level Adjustment

● Measure the float level in the state of contacting

with float valve and float arm by inclining the carburetor.

STANDARD LEVEL : 12.5mm TOOL : FLOAT LEVEL GAUGE

● Check the smooth operation of float.

MAIN JET

SLOW JET

FLOAT LEVEL GAUGE

󳢯After tighten the pilot screw completely, back it

out according to the recorded turns when removing.

FLOAT VALVE

FLOAT

FLOAT ARM PIN

4-11

FUEL SYSTEM

Accelerator Adjustment

● Adjust the idling. (󳫻 2-7)

● Adjust the operation of throttle grip. (󳫻 2-4)

● Loosen the lock nut, turn the adjuster screws to

contact with accelerator pump cap, and then adjust the accelerator pump rod clearance.

CLEARANCE : 0mm

● Tighten the lock nut.

● Install the new o-ring to the float chamber groove.

● Install the float chamber and screws.

INSTALLATION

● Install the air vent tube and drain tube.

● Install the new o-ring into carburetor intake flange.

● Install the carburetor between carburetor insulator

and connecting tube. Install the carburetor assembly nut and tighten the connecting tube bend screw.

● Connect the choke cable and throttle cable.

● Adjust the chock cable. (󳫻 2-5)

● Install the throttle valve. (󳫻 4-5)

● Adjust the throttle grip free play. (󳫻 2-4)

FUEL TUBE

DRAIN TUBE

THROTTLE STOP SCREW

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

CARBURETOR

INSULATOR

FLOAT LEVEL CHAMBER

O-RING

󳢯Do not adjust unless replacing the adjuster

screws.

FLOAT CHAMBER

O-RING

DRAIN TUBE

AIR VENT TUBE

4-12

FUEL SYSTEM

PILOT SCREW ADJUSTMENT

1. Turn the pilot screw clockwise until it seats lightly, then back it out to the specification given.

INITIAL OPENING : 2

⅛⅛

2. Warm up the engine to operating temperature. Ten minutes of stop and go driving is sufficient.

3. Stop the engine and connect a tachometer.

4. Start the engine and adjust the idle speed with the throttle stop screw.

IDLE SPEED : 1,600±±100rpm

5. Turn the pilot screw in or out slowly to obtain the highest engine speed.

6. Readjust the idle speed to the specified value with the throttle stop screw.

7. Make sure that the engine does not miss or run erratically. Repeat steps 5 and 6 until engine speed increases smoothly.

8. Readjust the idle speed with the throttle stop screw.

PILOT SCREW

THROTTLE STOP SCREW

󳢯Tightening the pilot screw against its seat will

damage the seat.

󳢯Adjust the pilot screw after all other engine

adjustments are within specifications.

󳢯The pilot screw is factory pre-set. Adjustment is

not necessary unless the carburetor is overhauled or a new pilot screw is installed.

MEMO

5-0

COOLING SYSTEM

5-1

5. COOLING SYSTEM

SERVICE INFORMATION

GENERAL SAFETY

TORQUE VALUE

OIL THROUGH BOLT 3.2kgf·m (32N·m)

5

SERVICE INFORMATION

········

5-1 RADIATOR

··················

5-2

󳢯Wait until the engine is cool before servicing the cooling system.

5-2

COOLING SYSTEM

RADIATOR

REMOVAL

● Loosen the horn mounting bolt and remove the

horn.

● Loosen the 4 radiator cover mounting screws and

remove the radiator cover.

RADIATOR HOSE INSPECTION

● Check the radiator core for clog or damage.

● Check the pin for deformation; adjust it if

necessary.

INSTALLATION

● Install the removed parts in the reverse order of

removal.

● Check the hose or clamp for damage or

deterioration.

● Loosen the 2 flange bolts and remove the radiator

from the frame.

● Remove the oil through bolts from the cylinder and

RH. LH. radiator hose.

󳢯 Replace the radiator when the choked area of

radiator core is over 20% of radiant heat area.

SCREWS

BOLT

BOLTS

SCREW

BOLT

MEMO

6-0

ENGINE REMOVAL/INSTALLATION

6-1

6. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION

GENERAL SAFETY

󳢯Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to

damage the frame, engine, cable or harness.

󳢯Attach tape to the frame to protect it during the engine removal or installation.

● The following works can be serviced with the engine installed in the frame.

- Oil pump (section 3)

- Carburetor (section 4)

- Radiator (section 5)

- Clutch (section 7)

- Geashift (section 7)

- A.C. Generator (section 8)

- Starter clutch (section 8)

● The following works require engine removal for service.

- Cylinder head/valve (section 9)

- Cylinder/piston (section 10)

- Transmission (section 11)

- Crank shaft (section 11)

SPECIFICATION

TORQUE VALUES :

ENGINE HANGER BOLT (FRONT ) : 4.9㎏f·m (49N·m)

(REAR ) : 4.9㎏f·m (49N·m) GEAR CHANGE ARM BOLT : 1.2㎏f·m (12N·m) DRIVE SPROCKET BOLT : 1.2㎏f·m (12N·m) LH. DOWNTUBE MOUNTING BOLT (SPECIAL BOLT) : 4.2㎏f·m (42N·m) LH. DOWNTUBE BRACKET MOUNTING BOLT : 2.2㎏f·m (22N·m)

6

SERVICE INFORMATION

············

6-1

ENGINE REMOVAL

····················

6-2

ENGINE INSTALLATION

············

6-3

ITEM SPECIFICATIONS

ENGINE DRY WEIGHT 32.3kg ENGINE OIL CAPACITY(AT DISASSEMBLY) 1.1ℓ

6-2

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL

● Drain the engine oil. (⇨3-3)

● Remove the muffler. (⇨12-4)

● Remove the noise suppressor cap.

● Remove the battery ground cable and clutch cable.

● Remove the SAI pipe complete and SAI reed valve

assembly from the cylinder head.

● Remove the carburetor insulator from the

carburetor.

● Remove the LH. side cover. (⇨12-2)

● Disconnect the AC generator wire coupler and gear

position switch wire coupler.

● Disconnect the starter motor cable.

● Remove the gear change arm.

● Remove the LH. rear cover.

● Loosen the rear axle nut and drive chain adjuster,

then remove the drive sprocket after pushing the rear wheel forward.

● Remove the 2 oil through bolts from the cylinder,

then remove the radiator hose from the engine.

● Remove the LH. downtube comp. B mounting

bolts and socket bolts.

● Remove the 2 rear engine hanger bolts, then

remove the LH. downtube comp. B and engine.

SOCKET BOLTS

FLANGE BOLTS

REAR ENGINE HANGER BOLTS

CLUTCH CABLE

SAI PIPE COMP.

MUFFLER

NOISE SUPPRESSOR CAP

AC GENERATOR/GEAR POSITION COUPLER

DRIVE SPROCKET

6-3

ENGINE REMOVAL/INSTALLATION

ENGINE INSTALLATION

Engine installation is essentially the reverse order of removal.

TORQUE : ENGINE HANGER BOLTS :

(FRONT ) 4.9kgf··m(49N··m)

(REAR ) 4.9kgf··m(49N··m) GEAR CHANGE ARM BOLT 1.2kgf··m(12N··m) DRIVE SPROCKET BOLT 1.2kgf··m(12N··m)

● Inspect the following after installing the engine.

- Engine oil level

- Throttle glip operation

- Clutch lever operation

- Drive chain slack

󳢯 Carefully align mounting points with the jack to

prevent damage from mounting bolt threads and wire harness and cables.

󳢯 Be careful not to damage any part of the frame

and bolt nuts.

󳢯 Be sure to install the cables, tubes, and wires to

their correct positions(󳫻 1-10~12).

CLUTCH CABLE

FLANGE BOLTS

SOCKET BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

ENGINE

HANGER BOLTS

7-0

CLUTCH/GEARSHIFT

7-1

7. CLUTCH / GEARSHIFT

SERVICE INFORMATION

GENERAL SAFETY

● The clutch, gearshift spindle can be serviced with the engine in the frame.

● If the shift fork, drum and transmission require service, remove the engine and separate the crankcase.

● The quality and level of fluid affect clutch operation. If the clutch slips, check the fluid level before servicing

the clutch system.

SPECIFICATIONS

ITEM STANDARD VALUE SERVICE LIMIT

CLUTCH LEVER FREE PLAY 10~20

CLUTCH SPRING FREE LENGTH 35.5 34.2

CLUTCH DISK THICKNESS 2.9~3.0 2.6

CLUTCH PLATE WARPAGE 0.2

CLUTCH OUTER I.D 28.000~28.013 28.030

CLUTCH OUTER GUIDE O.D. 27.967~27.980 27.950

TORQUE VALUES

CLUTCH LOCK NUT 6.5kgf·m(65N·m) - Apply engine oil DRUM STOPPER ARM BOLT 1.2kgf·m(12N·m) PRIMARY DRIVE GEAR NUT 6.5kgf·m(65N·m) - Apply engine oil RH. CRANKCASE COVER BOLT 1.1kgf·m(11N·m) GEAR SHIFT PEDAL BOLT 1.2kgf·m(12N·m)

TOOLS

CLUTCH CENTER HOLDER LOCK NUT WRENCH EXTENSION BAR FLYWHEEL HOLDER

7

SERVICE INFORMATION

······

7-1

TROUBLESHOOTING

··········

7-2

R. CRANKCASE COVER

······

7-3

CLUTCH

···· ·· ·· ··········

7-4

GEARSHIFT SPINDLE

········

7-7

CLUTCH INSTALLATION

······

7-9

PRIMARY DRIVE GEAR

······

7-10

R. CRANKCASE COVER INSTALLATION··7-11

Unit : mm

7-2

CLUTCH/GEARSHIFT

TROUBLESHOOTING

Clutch operation problem can be corrected by adjusting a cable free play.

Clutch lever pull too hard

● Damaged, clogged or sticking clutch cable

● Damaged lifter mechanism

● Damaged clutch lifter plate bearing

● Incorrect wiring of clutch cable

Clutch slips

● Too big clutch lever free play

● Clutch plate warpage

● Clutch lock nut loose

● High fluid level or high fluid weight

Clutch disengages

● Sticking lifter hydraulic system

● Worn disks

● Weak spring

● Too small clutch lever free play

Difficult to thrust the gear level

● Incorrect clutch adjustment(too big free play)

● Bent shift fork

● Bent shift fork shaft

● Damaged gear shift spindle

● Damaged shift drum guide groove

● Damaged shift drum guide pin

Gear jumps out

● Worn gear dog

● Bent shift fork shaft

● Damaged shift drum stopper

● Worn shift drum guide groove

● Worn gear shift fork groove

7-3

CLUTCH/GEARSHIFT

R. CRANKCASE COVER

REMOVAL

● Drain the engine oil. (󳫻 2-3)

● Remove the bolts and clutch wire holder, then

disconnect the clutch cable end from the clutch lever.

● Remove the right crankcase cover bolts and

remove the right crankcase cover.

● Remove the two dowel pins and gasket.

CLUTCH LEVER/LIFTER ROD

● Remove the clutch lifter rod.

● Remove the clutch lever and spring from the R.

crankcase cover.

DOWEL PINS

CLUTCH LEVER

CLUTCH LIFTER ROD

CLUTCH WIRE HOLDER

BOLTS

● Remove the clutch lever spring and O-ring from

the clutch lever.

● Check the wear and damage of the lifter rod and

clutch lever.

● Check the fatigue or damage of the clutch lever

spring.

CLUTCH LEVER SPRING

O-RING

7-4

CLUTCH/GEARSHIFT

● Coat the new o-ring with grease, and install it to

the clutch lever.

● Install the clutch lever spring to the clutch lever.

● Install the spring ends into the hole of the clutch

lever.

● After installing the clutch lever into the R.

crankcase cover, turn the clutch lever to the clockwise and install the lifter rod aligning the clutch lever with the R. crankcase cover hole.

CLUTCH

REMOVAL

● Remove the following.

- Clutch spring bolts

- Clutch lifter plate

- Clutch spring

CLUTCH SPRING BOLTS/SPRINGS

CLUTCH LIFTER PLATE

CLUTCH LEVER SPRING

CLUTCH LEVER

HOLE

SPRING ENDS

LIFTER ROD

󳢯Loosen the clutch spring bolt in a crisscross

pattern in two or three steps and remove the bolts.

● Press the clutch center using the clutch center

holder and remove the clutch lock nut.

TOOLS:

CLUTCH CENTER HOLDER LOCK NUT WRENCH, 20××24mm

EXTENSION BAR

LOCK NUT WRENCH

CLUTCH CENTER HOLDER

EXTENSION BAR

7-5

CLUTCH/GEARSHIFT

● Remove the lock washer.

● Remove the clutch center, disk, plate and pressure

plate.

● Remove the spline washer and clutch outer.

● Remove the clutch outer guide and thrust washer.

CLUTCH CENTER

SPLINE WASHER

LOCK WASHER

CLUTCH OUTER

CLUTCH OUTER GUIDE

THRUST WASHER

INSPECTION

● Inspect the lifter plate bearing for scoring and other

damage.

● Inspect the lifter plate for damage.

● If necessary, replace them.

LIFTER PLATE

BEARING

7-6

CLUTCH/GEARSHIFT

● Measure the clutch spring free length; replace the

springs if the measurement is not within the service limit.

SERVICE LIMIT : 34.2mm

● Check the clutch disk for scoring or discoloration;

replace as necessary.

● Measure the disk thickness and replace the disks if

the service limit is exceeded.

SERVICE LIMIT : 2.6mm

● Check the clutch plates for warpage or dis-

coloration; replace as necessary.

● Check for plate warpage on a surface plate using a

feeler gauge; replace if the service limit is exceeded.

SERVICE LIMIT : 0.2mm

CLUTCH SPRING

DISK

CLUTCH PLATE

FEELER CAUGE

󳢯

Warped clutch plates prevent the clutch from disengaging properly.

● Check the slots 󳤆 in the clutch outer for nicks or

indentations made by the clutch discs. If necessary replace them.

● Measure the clutch outer inside diameter.

SERVICE LIMIT : 28.030mm

● Measure the clutch outer guide outsider diameter.

SERVICE LIMIT : 27.950mm

󳢯If the motorcycle has been used for a long time,

the clutch springs free lingth will be shorten, because the clutch springs are compressed while the clutch is disengaged.

󳢯Replace the clutch springs as a set so that the

disks contact evenly with the clutch plates.

󳢯Replace the clutch disks and plates as a set.

7-7

CLUTCH/GEARSHIFT

GEAR SHIFT SPINDLE

REMOVAL

● Loosen the hex bolt and remove the gear change

arm.

● Remove the RH. crankcase cover. (⇨7-3)

● Remove chutch assembly. (⇨7-4)

● Remove the gear shift spindle and thrust washer.

● Remove the gear shift cam bolt, cam and roller.

● Remove the drum stopper bolt, drum stopper, collar

and spring.

GEAR CHANGE ARM

HEX BOLT

GEAR SHIFT SPINDLE

GEAR SHIFT CAM

BOLT

DRUM STOPPER

INSPECTION

● Check the gear shift spindle for wear or damage.

● Inspect the gear shift plate for deformation, wear,

or other damage.

● Check the return spring and gear shift plate spring

for wear or damage.

RETURN SPRING

GEAR SHIFT PLATE

7-8

CLUTCH/GEARSHIFT

INSTALLATION

● Install the collar, spring, drum stopper and bolt.

● Tighten the bolt.

TORQUE : 1.2kgf··m(12N··m)

● Press the drum stopper, and install the gear shift

cam, aligning the roller with the gear shift cam hole.

● Install the thrust washer into the gear shift spindle.

● Install the gear shift spindle into the crank case,

aligning the teeth of the return spring with the tappet of the right crank case as shown.

󳤇󳤇

PART

COLLAR

DRUM STOPPER

THRUST WASHER

GEAR SHIFT SPINDLE

RETURN SPRING TEETH

SPRING

● Install the following:

- Clutch assembly.

- R. crank case cover

● Install the gear shift arm aligning its slit with the

punch mark on the gear shift spindle.

● Install and tighten the pinch bolt to the specified

torque.

GEAR CHANGE ARM

GEAR SHIFT CAM

BOLT

DRUM STOPPER

HEX BOLT

PUNCH MARK

7-9

CLUTCH/GEARSHIFT

CLUTCH INSTALLATION

● Coat the clutch outer guide with clean engine oil.

● Install the trust washer and outer guide into the

main shaft.

● Install the clutch outer and spline washer.

● Coat the clutch and plate disk. With clean engine

oil.

● Install the 6 disks. and 5 plates to the clutch center

by turns.

CLUTCH CENTER

DISKS

PLATES

PRESSURE PLATE

CLUTCH OUTER GUIDE

THRUST WASHER

SPLINE WASHER

CLUTCH OUTER

● Install the pressure plate, disk, plate and clutch

center into the clutch outer.

● Coat the nut parts with clean engine oil, and tighten

the lock nut.

CLUTCH CENTER

LOCK WASHER

7-10

CLUTCH/GEARSHIFT

● Install the lock nut by pressing clutch center into

the clutch center holder.

TORQUE : 6.5kgf··m (65N··m) TOOLS :

CLUTCH CENTER HOLDER LOCK NUT WRENCH, 20××24mm EXTENSION BAR

● Install the clutch spring, lifter plate and clutch

spring bolt diagonally several times.

PRIMARY DRIVE GEAR

REMOVAL

● Remove the R. crankcase cover.

● Hold the flywheel using a flywheel holder, and

remove the primary drive gear lock nut.

TOOLS:

FLYWHEEL HOLDER LOCK NUT WRENCH, 20××24mm EXTENSION BAR

EXTENSION BAR

LOCK NUT

󳢯Check if the pressure plate press the disk, and

plate exactly.

LOCK WASHER

PRIMARY DRIVE GEAR

LOCK NUT WRENCH 20X24mm

● Remove the lock washer, primary drive gear and

woodruff key.

CLUTCH SPRING BOLTS/SPRINGS

CLUTCH LIFTER PLATE

LOCK NUT WRENCH

CLUTCH CENTER HOLDER

EXTENSION BAR

7-11

CLUTCH/GEARSHIFT

WOODRUFF KEY

LOCK NUT

LOCK WASHER

EXTENSION BAR

LOCK NUT

LOCK NUT WRENCH 20X24mm

INSTALLATION

● Install the woodruff key into the key groove of the

crankshaft.

● Align the primary drive gear key groove with the

crankshaft key and install the gear.

● Install the lock washer.

● Coat the nut with clean engine oil, and temporarily

tighten the lock nut.

● Hold the flywheel with a flywheel holder, and

tighten the primary drive gear lock nut with the specified torque.

TORQUE : 6.5kgf··m(65N··m) TOOLS : FLYWHEEL HOLDER

LOCK NUT WRENCH, 20××24mm EXTENSION BAR

R. CRANKCASE COVER INSTALLATION

● Remove the gasket from the crankcase surface.

● Install the two dowel pins and a new gasket.

DOWEL PINS

CLUTCH WIRE HOLDER

BOLTS

CLUTCH CABLE

7-12

CLUTCH/GEARSHIFT

● Install the right crankcase cover, aligning the spline

of the crank shaft and with the spline of the oil pump shaft.

● Install the right crankcase cover bolts.

● Tighten the bolts crisscross pattern in 2-3 steps

securely.

TORQUE : 1.1kgf··m(11N··m)

● Connect the clutch cable end to the clutch lever,

then install the clutch wire holder with the two bolts.

● Tighten the bolts securely.

TORQUE : 1.1kgf··m(11N··m)

SPLINE

● Check the clutch lever free play. (󳫻 2-12)

● Remove the oil level gauge, then fill the crankcase with the recommended oil.(󳫻 3-3)

OIL LEVEL GAUGE

󳢯If any difficulty is encountered in joining the

crank shaft spline to the oil pump shaft spline, remove the crankshaft hole cap, then install the right crank case cover while turning the crankshaft to the right slowly.

MEMO

8-0

A.C GENERATOR / STARTER CLUTCH

8-1

8. A.C GENERATOR / STARTER CLUTCH

8

SERVICE INFORMATION

····

8-1

TROUBLESHOOTING

········

8-1

A.C GENERATOR REMOVAL··8-2

STARTER CLUTCH

········

8-5

A.C GENERATOR INSTALLATION··8-7

SERVICE INFORMATION

GENERAL SAFETY

● This section covers removal and installation of the A.C. generator.

● Refer to section 16 for inspection of the A.C. generator.

● The A.C. generator/starter clutch service can be done with the engine installed in the frame.

SPECIFICATIONS

ITEM STANDARD VALUE SERVICE LIMIT

O.D. 39.622~39.635 39.607

STARTER DRIVEN GEAR

I.D 22.010~22.022 22.100

STARTER IDLE GEAR I.D 10.013~10.045 10.100

STARTER IDLE GEAR SHAFT O.D 9.991~10.000 9.970

REDUCTION GEAR I.D 10.013~10.045 10.100

REDUCTION GEAR SHAFT O.D 9.991~10.000 9.970

TORQUE VALUES

FLYWHEEL BOLT 5.5kgf·m(55N·m) STARTER CLUTCH SOCKET BOLT 3.2kgf·m(32N·m) LEFT CRANK CASE COVER BOLT 1.1kgf·m(11N·m)

TOOLS

ACG ROTOR PULLER FLYWHEEL HOLDER

TROUBLESHOOTING

Engine does not turn

● Faulty starter clutch

● Damaged idle gear/shaft

Unit:mm

8-2

A.C GENERATOR / STARTER CLUTCH

● Remove the A.C. generator wire clamp bolt and A.C. generator wire clamp.

A.C GENERATOR REMOVAL

● Remove the gear change arm.

● Remove the L. rear cover.

● Disconnect the A.C. generator wire coupler and

gear change switch wire coupler.

● Remove the reduction gear cover bolts and starter reduction gear cover.

L. REAR COVER

BOLTS

BOLT

BOLTS

GEAR CHANGE ARM

A.C. GENERATOR WIRE CLAMP

GEAR CHANGE SWITCH COUPLER

A.C. GENERATOR COUPLER

REDUCTION GEAR COVER

8-3

A.C GENERATOR / STARTER CLUTCH

BOLTS

● Remove the starter reduction gear shaft and starter

reduction gear.

● Remove the left crankcase cover bolts and left

crankcase cover.

● Remove the gasket and the dowel pins.

● Remove the starter idle gear shaft and starter idle

gear.

● Hold the flywheel rotor with a flywheel holder, and

remove the rotor bolt.

TOOL : FLYWHEEL HOLDER

STARTER REDUCTION GEAR

GEAR SHAFT

L. CLANK CASE COVER

STARTER IDLE GEAR

STARTER IDLE GEAR SHAFT

FLYWHEEL HOLDER

BOLT

8-4

A.C GENERATOR / STARTER CLUTCH

● Remove the woodruff key from the crank shaft.

● Remove the starter driven gear collar.

● After installing the ACG rotor puller on the rotor,

remove the rotor.

TOOL : ACG ROTOR PULLER

STATOR REMOVAL/INSTALLATION

● Remove the pulse generator mounting screws and

pulse generator.

● Loosen the screw and remove the wire guide.

● Remove the stator mounting screw and remove the

stator.

● Install in the reverse order of removal.

ACG ROTOR PULLER

SCREWS

WOODRUFF KEY

STARTER DRIVEN GEAR COLLAR

PULSE GENERATOR

WIRE GUIDE

GROMMET

STATOR

󳢯Make sure that the grommet is correctly placed

on the slot.

8-5

A.C GENERATOR / STARTER CLUTCH

STARTER IDLE GEAR INSPECTION

● Inspect the wear and damage of starter ldle gear.

● Measure the gear inside diameter.

SERVICE LIMIT : 10.100mm

● Measure the gear shaft outside diameter.

SERVICE LIMIT : 9.970mm

REDUCTION GEAR INSPECTION

● Inspect the wear and damage of reduction gear.

● Measure the gear inside diameter.

SERVICE LIMIT : 10.100mm

● Measure the gear shaft outside diameter.

SERVICE LIMIT : 9.970mm

STARTER IDLE GEAR

GEAR SHAFT

REDUCTION GEAR

GEAR SHAFT

STARTER CLUTCH

INSPECTION

● Check the operation of the one-way clutch by

turning the driven gear.

● You should be able to turn the driven gear

counterclockwise smoothly, but the gear should not turn clockwise.

DISASSEMBLY

● Remove the three socket bolts, and remove the one

way clutch from the flywheel.

SOCKET BOLTS

8-6

A.C GENERATOR / STARTER CLUTCH

● Check the starter driven gear for damage or wear.

● Measure the starter driven gear I.D. and O.D.

SERVICE LIMIT : O.D. : 39.607mm

I.D. : 22.100mm

INSTALLATION

● Check the one-way clutch for wear or damage.

● Install the one-way clutch flange onto the clutch

outer.

● Apply a locking agent to the starter clutch outer mounting bolt threads.

● Hold the flywheel with a flywheel holder, and tighten the starter clutch mounting socket bolts.

TORQUE : 3.2kgf··m(32N··m)

● Install the starter driven gear into the one-way clutch.

● Recheck the one-way clutch operation. (⇨8-5)

CLUTCH OUTER

FLANGE PART

SOCKET BOLTS

8-7

A.C GENERATOR / STARTER CLUTCH

A.C GENERATOR INSTALLATION

● Install the starter driven gear collar.

● Clean the taper part of crank shaft and remove the

dust. If installing the rotor with dust in taper part, the key will be damaged. Because the contacted area of taper will be small and it will occur the stress in the woodruff key.

● Install the woodruff key into the crank shaft key

groove.

● Install the rotor into the crank shaft aligning the

key.

● Install the rotor bolt temporarily. After fixing the

flywheel with a holder, tighten the rotor bolt.

TORQUE : 5.5kgf··m(55N··m) TOOL: FLYWHEEL HOLDER

FLYWHEEL ROTOR

WOODRUFF KEY

STARTER DRIVEN GEAR COLLAR

󳢯After checking whether inside magnet of rotor is

attached by the bolts and nuts, install them. If installing the rotor with the foreign material, the starter coil is damaged.

● Install the starter idle gear and starter idle gear

shaft.

● Install the new gasket and dowel pins.

STARTER IDLE GEAR

STARTER IDLE GEAR SHAFT

DOWEL PINS

8-8

A.C GENERATOR / STARTER CLUTCH

● Install the starter gear and shaft.

● Install the new O-ring.

● Install the reduction gear cover.

STARTER REDUCTION GEAR

GEAR SHAFT

O-RING

GEAR CHANGE SWITCH COUPLER

A.C.GENERATOR COUPLER

● Connect the A.C generator wire coupler and gear change switch wire coupler.

● Install the wire clamp.

● Install the L. crankcase cover.

● Install and tighten the bolts to the specified torque.

TORQUE : 1.1kgf··m(11N··m)

BOLTS

L. CLANK CASE COVER

● Install the L. rear cover.

● Install the gear change arm a ligning its slit with

the punch mark on the gearshift spindle.

● Install and tighten the pinch bolt to the specified

torque.

TORQUE : 1.2 kgf··m (12 N··m)

A.C GENERATOR / STARTER CLUTCH

8-9

L. REAR COVER

PUNCH MARK

BOLTS

GEAR CHANGE ARM

9-0

CYLINDER HEAD / VALVES

9-1

9. CYLINDER HEAD / VALVES

SERVICE INFORMATION

GENERAL SAFETY

● The rocker arm and the camshaft can be serviced without removing the engine. However, the engine must be removed

from the frame to maintain the cylinder head.

● The oil of camshaft is supplied through the cylinder head oil hole. Clean the oil hole prior to assembling the cylinder

head.

SPECIFICATIONS

9

SERVICE INFORMATION

····

9-1

TROUBLESHOOTING

········

9-2

CAMSHAFT

················

9-3

CYLINDER HEAD

··········

9-5

VALVE SPRINGS

············

9-6

VALVES

··················

9-7

VALVE GUIDES

············

9-7

VALVE SEATS

············

9-8 CYLINDER HEAD ASSEMBLY··9-11 CAMSHAFT ASSEMBLY

······

9-13

TORQUE VALUES

CAM CHAIN TENSIONER PIVOT BOLT 1.0 kgf·m (10N·m) SPARK PLUG 1.1 kgf·m (11N·m) CAMSHAFT HOLDER 8mm NUT 2.0 kgf·m (20N·m) CAM CHAIN TENSIONER MOUNTING BOLT 1.2 kgf·m (12N·m) CAM CHAIN TENSIONER SEALING SCREW 0.4 kgf·m ( 4N·m) CYLINDER HEAD COVER BOLT 1.0 kgf·m (10N·m) CRANK SHAFT HOLE CAP 0.8 kgf·m ( 8N·m) A.C.GENERATOR CAP 0.6 kgf·m ( 6N·m)

ITEM STANDARD VALUE SERVICE LIMIT

Unit : mm

ROCKER ARM

CAM HEIGHT

CAMSHAFT

VALVE,

VALVE GUIDE

ROCKER ARM INNER DIAMETER 12.016~12.034 12.060

ROCKER ARM SHAFT OUTER DIAMETER 11.982~12.000 11.950

IN 37.330~37.490 37.110

EX 37.089~37.249 36.870

VALVE SPRING FREE LENGTH IN,EX 41.65 40.00

IN 4.975~4.990 4.925

EX 4.995~4.970 4.905

VALVE GUIDE INNER DIAMETER IN,EX 5.000~5.012 5.030

CLEARANCE BETWEEN IN 0.010~0.037 0.080

STEM AND GUIDE EX 0.030~0.057 0.100

VALVE SEAT WIDTH 0.7~0.9 1.3

VALVE STEM OUTER DIAMETER

9-2

CYLINDER HEAD / VALVES

TOOLS

VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 35°(23mm)

EX 35°(20mm) IN 45°(24.5mm) EX 45°(24.5mm) IN 60°(22mm) EX 60°(22mm) CUTTER HOLDER 5mm

TROUBLESHOOTING

Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test, or by tracing noises to the top-end with a sounding rod or stethoscope.

Low comperssion

● Valves

- Incorrect valve adjustment (see section 3)

- Burned or bent valves

- Incorrect valve timing

- Broken valve spring

- Uneven valve seating

● Cylinder head

- Leaking or damage head gasket

- Warped or cracked cylinder head

● Cylinder, piston (see section 9)

Excessive white smoke

● Worn valve guide or valve stem

● Damaged valve stem seal

● Worn or damaged piston ring

Rough idle

● Low cylinder compression

Compression too high

● Excessive carbon build-up on piston or combustion

chamber

Excessive noise

● Incorrect valve adjustment

● Sticking valve or broken valve spring

● Damaged or worn camshaft

● Worn rocker arm and / or shaft

● Loose or worn cam chain

● Worn or damaged cam chain tensioner

● Damaged cylinder head gasket

● Incorrect spark plug installation

9-3

CYLINDER HEAD / VALVES

CAMSHAFT

REMOVAL

● Remove the noise suppressor cap assembly from

the spark plug.

● Remove the cylinder head cover bolts and cover.

● Remove the AC generator cap and crank shaft hole

cap out of the left crankcase cover.

● Turn the crankshaft to the left, and align the “T”mark

of the flywheel with the index mark of the LH. crankcase cover.

● Verify that the piston is located at the top dead center.

(Make all camshaft lobes face downward.)

● If all camshaft lobes face upward, rotate the crankshaft

to the left for 1 turn (360°), and align the “T” mark with the index mark once again.

● Disconnect the starter motor cable from the starter

motor.

● Remove the clutch wire holder.

● Remove the starter motor mounting bolts and

starter motor.

● Remove the O-ring and pan screw from the cam

chain tensioner lifter. Remove the tensioner mounting bolt and tensioner lifter.

● Remove the camshaft holder 8mm nuts and remove

the camshaft holder from the cylinder.

SEALING SCREW

TENSIONER MOUNTING BOLTS

CAMSHAFT HOLDER NUTS

󳢯The camshaft can be maintained without

removing the engine.

AC GENERATOR CAP

BOLTS

CAP

CRANK SHAFT HOLE CAP

9-4

CYLINDER HEAD / VALVES

● Remove the cam chain from the camshaft.

● Remove the camshaft.

CAMSHAFT HOLDER DISASSEMBLY

● Remove the rocker arm springs from the gear shift

drum pin.

● Remove the gear shift drum pin from the cam shaft

holder. (IN/EX)

● Put the 6mm bolt into the rocker arm shaft, remove

the rocker arm shaft pulling the bolt.

● Remove the rocker arm and rocker arm spring.

● Remove the other rocker arm shaft, rocker arm, and

rocker arm spring following the same order.

CAM CHAIN

CAM SHAFT

ROCKER ARM SPRINGS

DOWEL PINS

BOLT

󳢯Take precautions not to allow the cam chain to drop

into the crankcase.

INSPECTION

● Check the rocker arm and rocker arm shaft for wear or

damage.

● Measure the inner diameter of the rocker arm.

SERVICE LIMIT : 12.060 mm

● Measure the outer diameter of the rocker arm shaft.

SERVICE LIMIT : 11.950 mm

9-5

CYLINDER HEAD / VALVES

● Manually turn the camshaft bearing outer race, and

check if it turns smoothly.

● Check the bearing for wear or damage.

CYLINDER HEAD

REMOVAL

● Remove the engine from the frame. (section 6)

● Remove the camshaft. (⇨9-3)

● Remove the cylinder head from the cylinder.

● Check the cam lobes of the camshaft for wear or

damage.

● Measure the height of the cam lobe.

SERVICE LIMIT : IN : 37.110 mm

EX: 36.870 mm

󳢯Be sure to check the valve clearance.

CAMSHAFT BEARINGS

● Remove the gasket, dowel pins and cam chain

guide from the cylinder.

CAM CHAIN GUIDE

9-6

CYLINDER HEAD / VALVES

● Remove the valve spring, valve cotter, retainer, spring

and valve. Using the valve spring compressor.

TOOL : VALVE SPRING COMPRESSOR

● Remove the valve spring seat and valve stem seal.

Remove carbon deposits from the inside of the combustion chamber.

INSPECTION

● Remove gasket marks from the cylinder head gasket.

● Check the spark plug assembling hole and the valve

seat for cracks.

● Using a square and a feeler gauge, check the cylinder

head distortion.

SERVICE LIMIT : 0.1 mm

VALVE SPRINGS

● Measure the free length of the inner and outer valve

springs.

SERVICE LIMIT : 40.00 mm

DISASSEMBLY

● Loosen the pivot bolt and remove the cam chain

tensioner.

● Remove the carburetor insulator.

● Remove the spark plug from the cylinder head.

● Remove the spark plug cover from the cylinder

head.

PIVOT BOLT

CAM CHAIN TENSIONER

·To prevent the loss of tension, do not compress the

valve spring more than necessary.

·Mark the disassembled parts so that they can be

reassembled into the original position later.

·Take precautions not to damage the cylinder head

gasket attachment.

·Replace the valve spring with new one if the length of

any one is less than the service limit.

9-7

CYLINDER HEAD / VALVES

VALVES

● Inspect each valve for bending, burning, scratches or

abnormal wear.

● Insert the valves in their original positions in the

cylinder head. Check that each valve moves up and down smothly, without binding.

● Measure and record the valve stem outer diameter in

three places along the valve guide sliding area.

SERVICE LIMIT : IN : 4.925 mm

EX: 4.905 mm

● Replace the valve with a new one if the service limit is

exceeded.

VALVE GUIDES

INSPECTION

● Insert the valve guide reamer from the combustion

chamber side and ream the guide to remove any

carbon build-up before measuring the guide.

TOOL : VALVE GUIDE REAMER

● Measure and record each valve guide inner diameter.

SERVICE LIMIT : 5.030 mm

● Measure the guide-to-stem clearance with a dial

indicator while rocking the stem in the direction of

normal thrust.

SERVICE LIMIT : IN : 0.080 mm

EX: 0.100 mm

● Measure the inner diameter of the new valve guide. If

the clearance is not within the service limit, replace the

valve.

VALVE GUIDE DRIVER

·Take care not to tilt or lean the reamer in the guide

while reaming.

Otherwise, the valve is installed slanted, that causes

oil leaks from the stem seal and improper valve seat

contact and results in the valve seat refacing not able

to be performed.

·Rotate the reamer clockwise, never counterclockwise

when inserting and removing.

VALVE GUIDES REPLACEMENT

●

Heat the cylinder head to 130°C - 140°C (275°F - 290°F).

● Do not heat the cylinder head beyond 150°C (300°F).

● Use temperature indicator sticks, available from

welding supply stores, to be sure the cylinder head is

heated to the proper temperature.

󳢯Refinish the valve seats whenever the valve guides

are replaced to prevent uneven seating.

Daelim ROADWIN VJ125 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual