Orion AGB-21G Service Manual

AGB-21G

SERVICE MANUAL

Congratulations on your purchase of an

Apollo AGB-21G.

127(

As improvements are made on this model,

some data in this manual may become out-

dated. If you have any questions, please con-

sult your dealer.

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.

2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

SAFETY INFORMATION

II

INTRODUCTION

6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9. THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10. PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “ OFF ” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

TO THE NEW OWNER

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your dealer.

NOTE:

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your dealer.

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel

The minimum weights for motocross machines are:

for the class 125cc.......................minimum

64 kg

In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

HOW TO USE

THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.,

Bearings Pitting/damage → Replace.

INDEX

GENERAL INFORMATION

1

SPECIFICATIONS

2

REGULAR INSPECTION AND ADJUSTMENTS

ENGINE

CHASSIS

ELECTRICAL

3

4

5

6

7

1 - 1

DESCRIPTION

GENERAL INFORMATION

DESCRIPTION

2 Clutch lever 3 Engine stop switch 4 Front brake lever 5 Throttle grip 6 Fuel tank cap 7 Engine start switch 8 9 :

Fuel tank

21

Air filter

22

Left side cover

23

Drive chain

24

Shift pedal

25

Side stand

26

Fuel cock

27

Spark plug

28

Right side cover

29

Kick starter cank

2:

Front fork

NOTE:

The machine you have purchased may differ slightly from those shown in the following. Designs and specifications are subject to change without notice.

Rear brake pedal

Front axle

1 - 2

MACHINE IDENTIFICATION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your dealer for positive identification of the model you own.

2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number ① is

stamped on the right of the steering head pipe.

ENGINE SERIAL NUMBER

The engine serial number ② is stamped into

the elevated part of the right-side of the engine.

ķ

1 - 3

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows.

Silencer exhaust port Side cover air intake port

2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section.

3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

1 - 4

IMPORTANT INFORMATION

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates ① and cotter pins

must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) ① and oil seal(s) ②

with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip

①, make sure that the sharp-edged cor-

ner ② is positioned opposite to the thrust

③　it receives. See the sectional view.

④　Shaft

1 - 5

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect: Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector

two or three times.

4. Pull the lead to check that it will not come

off.

5. If the terminal comes off, bend up the pin

①　and reinsert the terminal into the con-

nector.

6. Connect: Connector

NOTE:

The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:

If there in no continuity, clean the terminals. Be sure to perform the steps 1 to 7 listed above when checking the wireharness. For a field remedy, use a contact revitalizer available on the market. Use the tester on the connector as shown.

1 - 6

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

Tool name/How to us Illustration Tool name/How to us Illustration

Crankcase separating tool

These tool is used to remove the crankshaft from either case. Flywheel puller

This tool is used to remove the flywheel magneto.

Rotor holding tool

This tool is used when loosening or tightening the fly-wheel magneto securing nut

Dial gauge and stand Stand

These tools are used to check each part for runout or bent. Crankshaft installing tool/pot/bolt

Spacer (crankshaft installer) Adapter (M12)

These tools are used to install the crankshaft.

Piston pin puller set

This tool is used to remove the piston pin.

Steering nut wrench

This tool is used when tighten the steering ring nut to specification. Pocket tester

Use this tool to inspect the coil resistance, output voltage and amperage. Valve spring compressor

This tool is needed to remove and install the valve assemblies.

Clutch holding tool

This tool is used to hold the clutch when removing or installing the clutch boss securing nut. Valve guide remover

This tool is needed to remove and install the valve guide.

1 - 7

CONTROL FUNCTIONS

ENGINE STOP SWITCH

The engine stop switch ① is located on the left

handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

CLUTCH LEVER

The clutch lever ② is located on the left han-

dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

SHIFT PEDAL

The gear ratios of the constant-mesh 4 speed transmission are ideally spaced. The gears

can be shifted by using the shift pedal ① on

the left side of the engine.

KICKSTARTER CRANK

Rotate the kickstarter crank ① away from the

engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

THROTTLE GRIP

The throttle grip ① is located on the right han-

dlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

1 - 8

CONTROL FUNCTIONS

FRONT BRAKE LEVER

The front brake lever ① is located on the right

handlebar. Pull it toward the handlebar to activate the front brake.

REAR BRAKE PEDAL

The rear brake pedal ① is located on the right

side of the machine. Press down on the brake pedal to activate the rear brake.

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the two positions: OFF:With the lever in this position, fuel will not

flow. Always return the lever to this position when the engine is not running.

ON: With the lever in this position, fuel flows

to the carburetor. Normal riding is done with the lever in this position

SPARK PLUG WRENCH

This spark plug wrench ① is used to remove

and install the spark plug.

NIPPLE WRENCH

This nipple wrench ① is used to tighten the

spoke.

①

NO

OFF

2 - 1

SPECIFICATIONS

21G:emanledoM

:rebmunedocledoM

AGB-21G

Dimensions:

mm550,1,htgnelllarevO

mm006htdiwllarevO

mm038thgiehllarevO

mm096thgiehtaeS

mm501

,1esableehW

Minimum ground clearance 260 mm

Basic weight:

knatleufllufdnaliohtiW

Engine:

Air cooled 4-stroke epytenignE

denilcnidrawrof,rednilycelgniStnemegnarrarednilyC

m c3.6712t

nemecalpsiD

3

Bore s 0.54ekorts s 54 mm

1: 9oitarnoisserpmoC

retratskciKmetsysgnitratS

pmusyrD:metsysnoitacirbuL

Oil type or grade:

At 5 ˚C (40 ˚F) or higher SF15W/40 type SG motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower

2

GENERAL SPECIFICATIONS

66kg

and Electrical Starting

2 - 2

GENERAL SPECIFICATIONS

Oil capacity:

Engine oil

L8.0egnahcliocidoireP

With oil filter replacement 0.85 L

L9.0tnuomalatoT

tnemeleepytteW:retlifriA

Fuel:

ahtiwylnoenilosagdedaelnumuimerPepyT

research octane number of 90 or higher.

Premium gasoline

L5.3yticapacknaT

Carburetor:

Z26-5KPepyT

rerutcafunaM

Spark plug:

A7RTC/NGK

rerutcafunam/epyT

mm7.0~6.0paG

csid-elpitlum,teW:epythctulC

Transmission:

Primary reduction system Gear

)277

.3(81/76oitarnoitcuderyramirP Secondary reduction system Chain drive Secondary reduction ratio 43/15 (2.867)

deeps-4,hsemtnatsnoCepytnoissimsnarT

noitarepotooftfeLnoitarepO

)818.2(11

/63ts1:oitarraeG

)839.1(61/13dn2 )053.1(02/72dr3 )340.1

(32/42ht4

Chassis:

eldarcelbuodimeSepytemarF

3.72elgnarets

aC˚

Tire:

ebuthtiWepyT

)tnorf(eziS

)raer(eziS

Tire pressure (front and rear) 130 kPa (1.3 kgf/cm

2

)

JINGKE

60/100-14 30M

80/100-12 41M

2 - 3

GENERAL SPECIFICATIONS

Brake:

ekarbcsidelgniSepytekarbtnorF

noitarepodnahthgiRnoitarepO

ekarbcsidelgniSepytekarbraeR

noitarepotoofthg

iRnoitarepO

Suspension:

krofcipocseleTnoisnepsustnorF

)noisnepsusssorconomepytknil(mragniwSnoisnepsusraeR

Shock absorber:

repmadli

o/gnirpslioCrebrosbakcohstnorF

re

pm

a

dlio

/gnirpslioCrebrosbakcohsraeR

Wheel travel:

mm002levartleehwtnorF mm002levartl

eehwraeR

Electrical:

otengamIDCmetsysnoitingI

2 - 4

MAINTENANCE SPECIFICATIONS

ENGINE

timiLdradnatSmetI

Cylinder head:

mm30.0----timilpraW

Cylinder:

mm150.45~00.45eziseroB ----

mm50.0----timildnuorfotuO

Camshaft:

----)tfeL(evirdn

iahCdohtemevirD

Camshaft cap inside diameter

31.963 ~ 31.979 mm

----

Camshaft outside diameter

32.009 ~ 32.034 mm

----

mm071.0~030.0ecnaraelcpac-ot-tfahS

Cam dimensions

Intake “A” 26.555 ~ 26.675 mm 26.30 mm

“B” 20.99 ~ 21.01 mm 20.95 mm

Exhaust “A” 26.316 ~ 26.436 mm 26.00 mm

“B” 20.99 ~ 21.01 mm 20.95 mm

mm30.0----timiltuonurtfahsmaC

A

B

2 - 5

MAINTENANCE SPECIFICATIONS

Timing chain:

Timing chain type / No. of links 90T/90 ----

----citamotuAdohtemtnemtsujdaniahcgnimiT

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.02 ~ 0.04 mm ----

EX 0.02 ~ 0.04 mm ----

Valve dimensions:

“A” head diameter IN 26.9 ~ 27.1 mm ----

EX 22.9 ~ 23.1 mm ----

“B” face width IN 1.1~1.5 mm ----

EX 1.1~1.5 mm ----

“C” seat width IN 0.9 ~ 1.1 mm 1.6 mm

EX 0.8 ~ 1.0 mm 1.6 mm

“D” margin thickness IN 0.65~0.95 mm ----

EX 0.65~0.95 mm ----

Stem outside diameter IN 4.97~4.985 mm 4.94 mm

EX 4.955 ~ 4.97 mm 4.925 mm

Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm

EX 5.500 ~ 5.512 mm 5.550 mm

Stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.08 mm

EX 0.030 ~ 0.057 mm 0.10 mm

timiLdradnatSmetI

Head Diameter

B

Face Width

C

Seat Width

D

Margin Thickness

A

2 - 6

MAINTENANCE SPECIFICATIONS

mm30.0----timiltuonurmetS

Valve seat width IN 0.8 ~ 1.2 mm 1.6 mm

EX 0.8 ~ 1.2 mm 1.6 mm

Valve spring:

mm5.23mm87.33NIhtgneleerF

EX 35.55 mm 34.0 mm

Set length (valve closed) IN 22.45 mm ----

EX 25.45 mm ----

Compressed force

mm54.22taN46~52NI)dellatsni( ----

EX 105 ~ 129 N at 25.45 mm ----

3.1----NItimilt

liT ˚/ 0.8 mm

35.1----XE ˚/0.8 mm

Direction of winding

----esiwkcolCNI)weivpot(

----esiwkcolCXE

Piston:

Piston to cylinder clearance 0.025 ~ 0.05 mm 0.1 mm Piston size “D” 53.965 ~ 53.975 mm ----

Measuring point “H” 10 mm ----

----

edis-NI/

mm4.0tes-ffonotsiP

timiLdradnatSm

etI



H

D

2 - 7

MAINTENANCE SPECIFICATIONS

Piston pin bore inside diameter 14.002 ~ 14.013 mm 14.04 mm

Piston pin outside diameter 13.994 ~ 14.000 mm 13.98 mm

Piston rings:

Top ring:

----lerraBepyT

Dimensions (B s .980)T s 2.00mm ----

mm52.0~01.0)dellatsni(pagdnE 0.60 mm

Side clearance (installed) 0.040 ~ 0.080 mm 0.12 mm

2nd ring:

----repaTepyT

Dimensions (B s 98.0)T s 2.20 mm ----

mm03.0~51.0)dellatsni(

pagdnE 0.60 mm

mm080.0~040.0ecnaraelcediS 0.12 mm

Oil ring:

Dimensions (B s 29.1)T s 2.45 mm ----

mm05.0~02.0)dellatsni(pagdnE ----

Crankshaft:

Crank width “A” 40.15~ 40.20 mm ----

Runout limit “C” 0.03 mm 0.05 mm

Big end side clearance “D” 0.15 ~ 0.35mm 0.60 mm

Small end free play “F” 0.4 ~ 1.0 mm 2.0 mm

timiLdradnatSmetI

7

%

B

T

B

T

2 - 8

MAINTENANCE SPECIFICATIONS

Clutch:

mm95.2~85.2ssenkcihtetalpnoitcirF 2.7 mm

----3ytitnauQ

----mm6.1~4.1ssenkcihtetalphctulC

----3ytitnauQ mm1.0----t

imilpraW

mm5.91mm5.02htgneleerfgnirpshctulC

----4ytitnauQ

----

----hsupmac,hsuprennIdohtemesaelerhctulC

Shifter:

---

-rabediugdnamurdmaCepytretfihS mm50.0----timilgnidnebrabediuG

Kickstarter:

----epyttehctardnakciKepyT

:roterubraC

/Z26-5KP

rerutcafunam/epyT

JINGKE

¾

----KJkram.D.I

#58)J.M(tejniaM ¾ ----

)J.A.M(tejrianiaM ø1.0 ¾

¾

----

----26-5 38# ø2.0 8 g

2.0 ~ 3.0 mm

)N.J(eldeenteJ

)

I.J(Idle jet Float needle valve size (F.N.A) Float weight (F.W) Float height (F.H)

¾ ---¾ ---¾ ---¾ ----

Air throttle (A.T) B6L ¾ ----

timiLdradnatSmetI

3 - 1

MAINTENANCE INTERVALS

REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your dealer.

Item

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As required

Remarks

ENGINE OIL

Replace Inspect



ƽ



ƽ



ƽ

OIL FILTER ELEMENT, OIL STRAINER

Clean



ƽ

VALVES

Check the valve clearances Inspect Replace



ƽ



ƽ



ƽ



ƽ

The engine must be cold. Check the valve seats and valve stems for wear.

VALVE SPRINGS

Inspect Replace



ƽ



ƽ

Check the free length and the tilt.

VALVE LIFTERS

Inspect Replace



ƽ



ƽ

Check for scratches and wear.

CAMSHAFTS

Inspect Replace



ƽ



ƽ

Inspect the camshaft surface. Inspect the decompres-

sion system. TIMING CHAIN SPROCKETS, TIMING CHAIN

Inspect Replace



ƽ



ƽ

Check for wear on the

teeth and for damage.

PISTON

Inspect Clean Replace



ƽ



ƽ



ƽ



ƽ

Inspect crack

Inspect carbon deposits

and eliminate them. PISTON RING

Inspect Replace



ƽ



ƽ



ƽ

Check ring end gap

PISTON PIN

Inspect Replace



ƽ



ƽ

CYLINDER HEAD

Inspect and clean



ƽ

Inspect carbon deposits

and eliminate them.

Change gasket CYLINDER

Inspect and clean Replace



ƽ



ƽ

Inspect score marks

Inspect wear CLUTCH

Inspect and adjust Replace



ƽ



ƽ



ƽ

Inspect housing, friction

plate, clutch plate and

spring TRANSMISSION

Inspect Replace bearing



ƽ



ƽ

3 - 2

MAINTENANCE INTERVALS

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect



ƽ

Inspect wear

ROTOR NUT

Retighten



ƽ



ƽ

EXHAUST PIPE, SILENCER, PROTECTOR

Inspect and retighten Clean Replace



ƽ



ƽ



ƽ



ƽ

* Whichever comes first

CRANK

Inspect and clean



ƽ



ƽ

CARBURETOR

Inspect, adjust and clean



ƽ



ƽ

When using a high-pres-

sure washer, make sure

that water does not enter

the accelerator pump. SPARK PLUG

Inspect and clean Replace



ƽ



ƽ



ƽ

DRIVE CHAIN

Lubricate, slack, alignment Replace



ƽ



ƽ



ƽ

Use chain lube

Chain slack: 30 ~ 40 mm

    

OUTSIDE NUTS AND BOLTS

Retighten



ƽ



ƽ

Refer to “STARTING

AND BREAK-IN” section

in the CHAPTER 1. AIR FILTER

Clean and lubricate Replace



ƽ



ƽ



ƽ

Use foam air-filter oil or

equivalent oil OIL FILTER

Replace



ƽƽ

OIL STRAINER (frame)

Clean



ƽ

FRAME

Clean and inspect



ƽ



ƽ

FUEL TANK, COCK

Clean and inspect



ƽ



ƽ

BRAKES

Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ



ƽ

Every one year

Item

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As required

Remarks

3 - 3

MAINTENANCE INTERVALS

FRONT FORKS

Inspect and adjust Replace oil Replace oil seal



ƽ



ƽ



ƽ



ƽ



ƽ

FRONT FORK OIL SEAL AND DUST SEAL

Clean and lube



ƽ



ƽ

esaerg esab muihtiL

REAR SHOCK ABSORBER

Inspect and adjust Lube Retighten



ƽ



ƽ



ƽ



ƽ



ƽ

(After

rain ride)



ƽ

Molybdenum disulfide

grease DRIVE CHAIN GUIDE AND ROLLERS

Inspect



ƽ

SWINGARM

Inspect, lube and retighten

ƽ ƽ

Molybdenum disulfide

grease RELAY ARM, CONNECTING ROD

Inspect, lube and retighten

ƽ ƽ

Molybdenum disulfide

grease STEERING HEAD

Inspect free play and retighten Clean and lube Replace bearing

ƽ ƽ

ƽ

Lithium base grease

TIRE, WHEELS

Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate

ƽ

Lithium base grease THROTTLE, CONTROL CABLE

Check routing and connection Lubricate Inspect and clean (throttle cable)

ƽ ƽ ƽ

ƽ ƽ ƽ

SAE 10W-30 motor oil

Inspect dirt and wear on

the throttle cable on the

carburetor side.

Item

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As required

Remarks

3 - 4

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

enituoRmetI

Fuel

Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage.

Engine oil

Check that the oil level is correct. Check the crankcase and frame oil line for leakage.

Gear shifter and clutch

Check that gears can be shifted correctly in order and that the clutch operates smoothly.

Throttle grip/Housing

Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary.

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Drive chain

Check drive chain slack and alignment. Check that the drive chain is lubricated properly.

Wheels

Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play.

Steering

Check that the handlebar can be turned smoothly and have no excessive play.

Front forks and rear shock absorber

Check that they operate smoothly and there is no oil leakage.

Cables (wires)

Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down.

Exhaust pipe

Check that the exhaust pipe is tightly mounted and has no

cracks. Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. Lubrication Check for smooth operation. Lubricate if necessary. Bolts and nuts Check the chassis and engine for loose bolts and nuts.

Lead connectors

Check that the CDI magneto, CDI unit, and ignition coil are con-

nected tightly.

3 - 5

CLUTCH ADJUSTMENT

1. Check: Clutch lever free play $ Out of specification m Adjust.

Clutch lever free play $ :

5 ~ 10 mm

2. Adjust: Clutch lever free play

NOTE:

Make minute adjustment on the lever side

using the adjuster ② .

After adjustment, check proper operation of clutch lever.

Clutch lever free play adjustment steps:

Loosen the locknuts ① .

Adjust the free play by changing their tightening position. Tighten the locknuts.

THROTTLE CABLE ADJUSTMENT

1. Check: Throttle grip free play a Out of specification m Adjust.

Throttle grip free play a :

3 ~ 5 mm

2. Adjust: Throttle grip free play

Throttle grip free play adjustment steps:

Slide the adjuster cover.

Turn the adjuster ① until the specified free

play is obtained. Tighten the locknut.

NOTE:

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

WARNING

After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.

①

3 - 6

THROTTLE CABLE ADJUSTMENT/

THROTTLE LUBRICATION

1. Remove: Screw (throttle grip cap)

2. Apply: Lithium soap base grease On the throttle cable end

3. Install:

Screw (throttle grip cap)

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4 Nm (0.4 m · kg)

AIR FILTER REPLACE

NOTE:

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage.

CAUTION:

Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

1. Remove: Screw

3 - 7

2. Install:

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5 Nm (0.5 m · kg)

ENGINE OIL LEVEL INSPECTION

1. Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes.

2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine.

3. Remove:

Oil tank cap ①

ENGINE OIL LEVEL INSPECTION

Fitting Screw

3 - 8

ENGINE OIL LEVEL INSPECTION

CAUTION:

Do not add any chemical additives or use oils with a grade of CD D or higher. Do not use oils labeled “ENERGY CONSERVING II” E or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. Do not allow foreign materials to enter the crankcase.

5. Install:

Oil tank cap

6. Start the engine and let it warm up for several minutes.

7. Turn off the engine and inspect the oil level once again.

NOTE:

Wait a few minutes until the oil settles before inspecting the oil level.

Recommended oil:

Refer to the following chart for selection of oils which are suited

to the atmospheric temperatures. Recommended engine oil classification: API STANDARD:

API “SG” or higher grade

(Designed primarily for motor-

cycles)

4. Inspect: Oil level Oil level should be between maximum  and minimum  marks. Oil level is low m Add oil to proper level.

NOTE:

When inspecting the oil level, do not screw the oil tank cap into the oil tank. Insert the gauge lightly.

-20-4-101403010502068308640 50

104

122

oCTemp.

oF

10W-30

10W-40

20W-40

20W-50

15W-40

D

E

3 - 9

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up for several minutes, and then turn off the engine and wait for five minute.

2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.

3. Place a suitable container under the engine.

4. Remove:

Oil cap

5. Fill: Engine oil

6. Check: Oil leakage

7. Check: Engine oil level

Oil quantity:

Total amount:

0.9 L

Periodic oil change:

0.8 L

With oil filter replacement:

0.85 L

OIL PRESSURE INSPECTION

1. Check: Oil pressure

Checking steps:

Slightly loosen the oil pressure check bolt

. Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize. Check oil passages and oil pump for damage or leakage. Start the engine after solving the problem(s) and recheck the oil pressure. Tighten the oil pressure check bolt.

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Oil pressure check bolt:

10 Nm (1.0 m • kg)

①

a

3 - 10

PILOT SCREW ADJUSTMENT

1. Adjust:

Pilot screw ①

Adjustment steps:

NOTE:

To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

Turn in the pilot screw until it is lightly seated. Turn out the pilot screw by the factory-set number of turns.

Pilot screw:

1-5/8 turns out (example)

PILOT SCREW ADJUSTMENT

ENGINE IDLING SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.

2. Attach:

Inductive tachometer To spark plug lead.

3. Adjust:

Engine idling speed

Adjustment steps:

Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section.

Turn the throttle stop screw ① until the

engine runs at the lowest possible speed.

To increase idle speed m Turn the throt-

tle stop screw ① in .

To decrease idle speed m Turn the throt-

tle stop screw ① out B .

Engine idling speed:

1,400 ~ 1,600 r/min

A

ENGINE IDLING SPEED ADJUSTMENT

3 - 11

CHASSIS/BRAKE SYSTEM AIR BLEEDING

CHASSIS

BRAKE SYSTEM AIR BLEEDING

Bleed the brake system if:

The system has been disassembled. A brake hose has been loosened or removed. The brake fluid is very low.

The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed.

1. Remove: Reservoir cap Diaphragm

2. Bleed: Brake fluid

Front Rear

Air bleeding steps:

a. Add proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to

spill any fluid or allow the reservoir to overflow.

c. Connect the clear plastic tube ② tightly

to the caliper bleed screw ① .

d. Place the other end of the tube into a

container.

e. Slowly apply the brake lever or pedal

several times.

f. Pull the lever in or push down on the

pedal. Hold the lever or pedal in position.

g. Loosen the bleed screw and allow the

lever or pedal to travel towards its limit.

h. Tighten the bleed screw when the lever

or pedal limit has been reached; then release the lever or pedal.

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Bleed screw:

6 Nm (0.6 m • kg)

i. Repeat steps (e) to (h) until of the air

bubbles have been removed from the system.

B

A B

A

WARNING

①

②

①

②

3 - 12

FRONT BRAKE ADJUSTMENT

3. Install: Diaphragm Reservoir cap

If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared.

j. Add brake fluid to the level line on the

reservoir.

Check the operation of the brake after bleeding the brake system.

FRONT BRAKE

1. Check: Brake lever position A

Brake lever position A :

Standard position Extent of adjustment

100 mm

Unavailable

REAR BRAKE ADJUSTMENT

1. Check: Brake pedal height A Out of specification m Adjust.

Brake pedal height A :

10 mm

2. Adjust: Brake pedal height

Pedal height adjustment steps:

Loosen the locknut ① . Turn the adjusting nut ② until the pedal

height D is within specified height. Tighten the locknut.

Adjust the pedal height between the maximum and the minimum

After the pedal height adjustment, make sure that the rear brake does not drag.

WARNING

NOTE:

WARNING

3 - 13

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

1. Inspect: Brake pad thickness A Out of specification m Replace as a set.

2. Replace: Brake pad

Brake pad thickness:

4.0 mm <Limit>: 1.0 mm

Brake pad replacement steps:

Remove Bolt 1 and 2 Loosen the Caliper

CAUTION:

Do not reuse the drained brake fluid.

Tighten the bleed screw.

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Bleed screw 3 and 4 :

18 Nm (1.8 m • kg)

Install the Caliper Bolt 1 and 2

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Bolt (brake caliper):

25 Nm (2.5 m • kg)

Remove Bolt 3 and 4

Replace the Brake pad

3. Inspect: Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section.

4. Check: Brake lever operation A softy or spongy feeling m Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section.

3 - 14

REAR BRAKE PAD INSPECTION AND REPLACEMENT

1. Inspect: Brake pad thickness A Out of specification m Replace as a set.

2. Replace: Brake pad

Brake pad thickness:

4 mm <Limit>: 1.0 mm

Brake pad replacement steps:

Remove the Screw 1 and 2.

Loosen the Caliper

Remove the Nut 3.

．

Reeplace the Brake pad.

3 - 15

REAR BRAKE PAD INSPECTION AND REPLACEMENT

CAUTION:

Do not reuse the drained brake fluid.

Tighten the bleed screw 1 and 2.

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Bleed screw 1 and 2:

18 Nm (1.8m kg)

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Nut 3 (brake caliper):

20 Nm (2.0m kg)

3. Inspect: Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section.

4. Check: Brake pedal operation A softy or spongy feeling m Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section.

BRAKE FLUID LEVEL INSPECTION

1. Place the brake master cylinder so that

its top is in a horizontal position.

2. Inspect: Brake fluid level Fluid at lower level m Fill up.

D Lower level

A Front B Rear

Use only designated quality brake fluid to avoid poor brake performance. Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance. Be sure that water or other contaminants do not enter master cylinder when refilling. Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts.

Recommended brake fluid:

DOT #3 or DOT #4

A

B

WARNING

3 - 16

SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION

SPROCKETS INSPECTION

1. Inspect: Sprocket teeth a Excessive wear m Replace.

NOTE:

Replace the drive sprocket, rear wheel sprocket and drive chain as a set.

DRIVE CHAIN INSPECTION

1. Remove: Master link clip Joint  Drive chain 

2. Clean: Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and dry the drive chain.

3. Measure: Drive chain length (10 links) a Out of specification m Replace.

Drive chain length (10 links):

<Limit>: 144.4 mm

4. Check: Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff m Replace drive chain.

3 - 17

DRIVE CHAIN SLACK ADJUSTMENT

5. Install: Drive chain Joint Master link clip

CAUTION:

Be sure to install the master link clip to the direction as shown.

Turning direction

6. Lubricate: Drive chain

Drive chain lubricant:

SAE 10W-30 motor oil or suitable chain lubricants

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the

suitable stand under the engine.

2. Check: Drive chain slack A Above the seal guard installation bolt. Out of specification m Adjust.

NOTE:

Before checking or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust the drive chain slack with the rear wheel in this “tight chain” position.

Drive chain slack:

30 ~ 50 mm

ķ

ĸ

Ĺ

Ａ

3 - 18

FRONT FORK INSPECTION

3. Adjust: Drive chain slack

Drive chain slack adjustment steps:

Loosen the axle nut ① and locknuts ② .

Adjust the drive chain slack by turning the

adjusters ③ .

To tighten m Turn the adjuster ③ coun-

terclockwise.

To loosen m Turn the adjuster ③ clock-

wise and push wheel forward.

Turn each adjuster exactly the same amount to maintain correct axle alignment.

NOTE:

Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear.

CAUTION:

Too small drive chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

Tighten the axle nut while pushing down the drive chain.

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Axle nut:

65 Nm (6.5 m • kg)

Tighten the locknuts.

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Locknut:

12 Nm (1.2 m

FRONT FORK INSPECTION

1. Inspect: Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage m Repair or replace.

• kg)

3-19

CHECKING THE BATTERY

CAUTION:

ELECTRICAL SYSTEM

CHECKING THE BATTERY

Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures:

Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye

injury. First aid in case of bodily contact: External

SKIN – Wash with water.

EYES – Flush with water for 15 minutes and

get immediate medical attention. Internal

Drink large quantities of water or milk fol-

lowed with milk of magnesia, beaten egg or

vegetable oil. Get immediate medical

attention.

1. Disconnect:

battery leads (from the battery terminals)

First, disconnect the negative lead

1

, then

the positive lead

2

.

2. Remove:

Screw (Battery bracket ) :

WARNING

3-20

CHECKING THE BATTERY

CAUTION:

Add only distilled water. Tap water contains minerals which are harmful to the battery.

3. Charge:

battery

Battery charging amperage and time

0.4 amps/10 hrs

Do not quick charge a battery.

To ensure maximum performance, always

charge a new battery before using it.

Do not use a high-rate battery charger.

They force a high-amperage current into

the battery quickly and can cause battery

overheating and battery plate damage.

If it is impossible to regulate the charging

current on the battery charger, be careful

not to overcharge the battery.

When charging a battery, be sure to re-

move it from the motorcycle. (If charging

has to be done with the battery mounted on

the motorcycle, disconnect the negative

lead from the battery terminal.)

To reduce the chance of sparks, do not

plug in the battery charger until the battery

charger leads are connected to the battery.

NOTE:

Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!

Replace the battery whenever:

battery voltage does not rise to specification or bubbles fail to rise during charging, sulphation of one or more battery cells occurs (as indicated by the battery plates turning white or material accumulating in the bottom of the battery cell), specific gravity readings after a long, slow charge indicate that one battery cell’s charge is lower than the rest, warpage or buckling of the battery plates or insulators is evident.

WARNING

3-21

CHECKING THE FUSES

CAUTION:

NOTE:

CHECKING THE FUSE

The following procedure applies to all of the fuses.

To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a fuse.

Check:

fuse

a. Connect the pocket tester to the fuse and

check it for continuity.

Set the pocket tester selector to “7

1”.

b. If the pocket tester indicates “d”, replace the

fuse.

REAR SHOCK ABSORBER INSPECTION

1. Inspect: Swingarm smooth action Abnormal noise/unsmooth action m Grease the pivoting points or repair the pivoting points. Damage/oil leakage m Replace.

REAR SHOCK ABSORBER INSPECTION

3 - 22

REAR SHOCK ABSORBER SPRING PRELOAD

ADJUSTMENT

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Remove:

Rear frame

3. Loosen:

Locknut

4. Adjust:

Spring preload By turning the adjuster .

* For EUROPE

NOTE:

Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment. The length of the spring (installed) changes

1.5 mm (0.06 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjuster beyond the maximum or minimum setting.

5. Tighten:

Locknut

6. Install:

Rear frame (upper)

Rear frame (lower)

Stiffer m Increase the spring preload.

(Turn the adjuster in.)

Softer m Decrease the spring preload.

(Turn the adjuster out.)

Spring length (installed) A :

Standard length Extent of adjustment

140 mm 135 ~ 140 mm

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40 Nm

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①

②

( 4 m • kg )

40 Nm

( 4 m • kg )

3 - 23

TIRE PRESSURE CHECK/SPOKES INSPECTION AND

TIGHTENING/WHEEL INSPECTION

TIRE PRESSURE CHECK

1. Measure:

Tire pressure Out of specification m Adjust.

NOTE:

Check the tire while it is cold. Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. A tilted tire valve stem indicates that the tire slips off its position on the rim. If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position.

Standard tire pressure:

130 kPa ( 1.3 kgf/cm )

SPOKES INSPECTION AND TIGHTENING

1. Inspect:

Spokes Bend/damagem Replace. Loose spoke m Retighten.

2. Tighten:

Spokes

NOTE:

Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness.

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.

3 Nm (0.3 m · kg)

WHEEL INSPECTION

1. Inspect:

Wheel runout Elevate the wheel and turn it. Abnormal runout m Replace.

①

2

3 - 24

STEERING HEAD INSPECTION AND ADJUSTMENT

2. Inspect:

Bearing free play Exist play m Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Check:

Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play m Adjust steering head.

3. Check:

Steering smooth action Turn the handlebar lock to lock. Unsmooth action m Adjust steering ring nut.

4. Adjust:

Steering ring nut

Steering ring nut adjustment steps:

Remove the number plate. Remove the handlebar and handlebar upper bracket. Loosen the steering ring nut using the steering nut wrench .

①

ĸ

3 - 25

STEERING HEAD INSPECTION AND ADJUSTMENT

Tighten the steering ring nut using steering nut wrench .

NOTE:

Apply the lithium soap base grease on the thread of the steering stem. Set the torque wrench to the steering nut wrench so that they form a right angle.

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Steering ring nut (initial tightening):

30 Nm ( 3 m • kg )

Loosen the steering ring nut one turn. Retighten the steering ring nut using the steering nut wrench.

Avoid over-tightening.

Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings.

Install the upper bracket ⑤ , washer, steer- ing stem nut ⑥ , handlebar ⑦ , handlebar upper holder ⑧

.

CAUTION:

First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

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Steering stem nut:

70 Nm ( 7 m • kg )

Handlebar upper holder:

25 Nm ( 2.5 m • kg )

③

ĺ

WARNING

3 - 26

ELECTRICAL/SPARK PLUG INSPECTION

ELECTRICAL

SPARK PLUG INSPECTION

1. Remove:

Spark plug

2. Inspect:

Electrode ①

Wear/damage m Replace.

Insulator color ②

Normal condition is a medium to light tan color. Distinctly different color m Check the engine condition.

NOTE:

When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

3. Measure:

Plug gap D Use a wire gauge or thickness gauge. Out of specification m Regap.

4. Clean the plug with a spark plug cleaner if necessary.

Spark plug gap:

0.6 ~ 0.7 mm

5. Tighten:

Spark plug

NOTE:

Before installing a spark plug, clean the gasket surface and plug surface. Finger-tighten D the spark plug before torquing to specification E .

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15 Nm (1.5 m • kg)

3 - 27

IGNITION TIMING CHECK

1. Remove:

Timing mark accessing screw

2. Check:

Ignition timing

Checking steps:

Start the engine and let it warm up. Let the engine run at the specified speed.

Engine speed:

1,400 ~ 1,600 r/min

Visually check the stationary pointer D is within the firing range E on the rotor. Incorrect firing range m Check rotor and pickup assembly.

3. Install:

Timing mark accessing screw

4 - 1

! ! ! !

Order Job / Part name Q’ty Remarks

1 LEFT TANK COVER 2 RIGHT TANK COVER 3 SEAT 4 LEFT FENDER PLATE 5 RIGHT FENDER PLATE 6 TAIL FENDER 7 FUEL TANK 8 FUEL CAP 9 PET-COCK

Remove the parts in the order listed.

For installation, reverse the removal procedure.

1 1 1 1 1 1 1 1 1

ENGINE

SEAT, FUEL TANK AND SIDE COVERS

2

5

3

6

1

4

7

8

9

SEAT, FUEL TANK AND SIDE COVERS

4 - 2

REMOVAL POINTS Fuel Tank , Side covers and Seat

Remove:

! ! !

SEAT, FUEL TANK AND SIDE COVERS

Bolt for Tank Cover

Right Tank Cover

Seat Bolt Bolt for Fuel Tank

Fuel Tank

Screw for Tank Cover and Seat

Left Tank Cover

Screw for Fender plate Left Fender plate Right Fender plate Screw for Fender plate

Seat

4 - 3

Order Job / Part name Q’ty Remarks

1 BOLT 2 HOOP 3 RUBBER MAT 4 NUT M6×14 5 EXHAUST MUFFLER 6 EXHAUST PIPE SEAL

Remove the parts in the order listed.

For installation, reverse the removal procedure.

1 1 1 2 1 1

5

3

2

4

6

1

NEW

EXHAUST PIPE AND SILENCER

4 - 4

EXHAUST PIPE AND SILENCER

INSPECTION Silencer and exhaust pipe

1. Inspect:



Gasket ①

Damage



Replace.

ASSEMBLY AND INSTALLATION Silencer and exhaust pipe

1. Install:



Gasket ①



Exhaust muffler

 

Nut (exhaust pipe)

NOTE:

First, temporarily tighten the Nut ķ (exhaust pipe), then tighten

the bolt ĸ

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15 Nm (1.5 m • kg)

2. Install:



Washer



Bolt (silencer)

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25 Nm (2.5 m • kg)

m

4 - 5

Order Job / Part name Q’ty Remarks

1 SCREW FOR AIR-FITER CLAMP 2 AIR-FITER 3 CRBURETOR 4 GASKET,HEAT INSULATING, CRBURETOR 5 O-RING 6 INLET PIPE 7 O-RING 8 GASKET

Remove the parts in the order listed.

For installation, reverse the removal procedure.

CRBURETOR & AIR-FITER

1 1 1 2

1 1 1 1

NEW

4 - 6

CARBURETOR DISASSEMBLY

! ! ! !

Order Job / Part name Q’ty Remarks

1 UPPER COVER 2 GASKET,UPPER COVER 3 RETURN SPRING,AIR THROTTLE 4 V-CLIP 5 E-CIRCLIP 6 NEEDLE,JET 7 AIR THROTTLE 8 O-RING 9 ADJUSTING SCREW,AIR THROTTLE

Remove the parts in the order listed.

For installation, reverse the removal procedure.

10 SPRING,ADJUSTING SCREW 11 O-RING 12 WASHER 13 ADJUSTING SCREW SPRING 14 IDLE FOAM JET 15 MAIN JET,OIL 16 MAIN JET,FOAM 17 MAIN MEASURING HOLE 18 IDLE JET

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

NEW

CARBURETOR DISASSEMBLY

4 - 7

CARBURETOR DISASSEMBLY

Order Job / Part name Q’ty Remarks

Remove the parts in the order listed.

For installation, reverse the removal procedure.

19 FLOAT COMP 20 NEEDLE VALVE,CARBURETOR FLOAT 21 HOOK,NEEDLE VALVE 22 FLOAT PIN 23 GASKET,FLOAT CHAMBER 24 DRAIN SCREW 25 O-RING 27 SCREW UNIT,FLOAT CHAMPER 28 PIPE CLIP 29 HOSE

1 1

1 1 1 1 3 1 1 1

NEW

CARBURETOR DISASSEMBLY

4 - 8

CARBURETOR

INSPECTION Carburetor

1. Inspect:

Carburetor body Contamination → Clean.

NOTE:

Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Never use a wire.

2. Inspect:

Adjust Screw,Mixture ① Idle Jet ② Main Measuring Hole and Main Nozzi ③ Main Jet ④ Drain Screw ⑤

Damage → Replace. Contamination → Clean.

NOTE:

Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Never use a wire.

Needle valve

1. Inspect:

Needle valve ① Valve seat ②

Grooved wear b → Replace. Dust c → Clean.

Jet needle

1. Inspect:

Jet needle ①

Bends/wear → Replace. Clip groove Free play exists/wear → Replace. Clip position

Standard clip position:

No.4 Groove

4 - 9

! ! ! !

Order Job / Part name Q’ty Remarks

1 COVER,L.RR.CRANKCASE 2 INITIATIVE CHAIN DRIVER RIVET PLANK 3 DRIVING GEAR 4 SHIFT PEDAL 5 GUAGE OIL LEVER 6 KICK STARTER 7 SPARK PLUG CAP 8 ENGINE SKID PLATE

Remove the parts in the order listed.

For installation, reverse the removal procedure.

1 1

1 1 1 1 1 1 1 1 1 1 2

SPROCKET REPLACEMENT

1

12

2

3

4

6

7

13

10

11

9

9 SIDE STAND 10 RIGHT FOOT PAGS 11 LEFT FOOT PEGS 12 BRACKET FOR PEDAL 13 AXLE

SPROCKET REPLACEMENT

8

5

4 - 10

CYLINDER HEAD

   

CYLINDER HEAD

6

3

2

8

9

7

1

4

5

10

11

Order Job / Part name Q’ty Remarks

1 Spark plug 2 Bolt M6 x 110 3 Cylinder cover L / Gasket 4 Timing driven sprocket 5 Valve cover / O-ring 6 Valve cover / O-ring 7 Cylinder cover 8 Gasket,cylinder cover 9 Cylinder head

Remove the parts in the order listed.

For installation, reverse the removal procedure.

10 Gasket,cylinder head 11 Rectangle ring

1 1 1 1 1 1 1 1 1 1 1

NEW

4 - 11

CYLINDER HEAD

REMOVING THE CYLINDER HEAD

2. Align: “I” mark

a

on the generator rotor (with the

stationary pointer

b

on the crankcase cov-

er)

a. Turn the primary pulley counterclockwise. b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark

c

on the cam-

shaft sprocket with the mark

d

on the cylin-

der head.

3. Loosen: Bolt

1

1. Remove: Long Bolt A

4. Remove: Bolt

2

Nut B

4 - 12

CYLINDER HEAD

Bolt

1

Washer

2

Spring Chain Tensioner Push Road ③

NOTE:

To prevent the timing chain from falling into the crankcase, fasten it with a wire

a

. While holding the generator rotor bolt with a wrench, remove the bolt.

Chain Tensioner Push Road Assembly④

5 Remove Chain Tensioner

4 - 13

CYLINDER HEAD

NOTE:

6. Remove: cylinder head

Loosen the

nuts ķĸĹĺĻ

in the proper sequence. Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

CHECKING THE CYLINDER HEAD

1. Eliminate: combustion chamber carbon deposits (with a rounded scraper)

Do not use a sharp instrument to avoid damaging or scratching:

spark plug threads valve seats

2. Check: cylinder head Damage/scratches

Replace.

3. Measure: cylinder head warpage Out of specification

Resurface the cylin-

der head.

Cylinder head warpage

Less than 0.03 mm

a. Place a straightedge

1

and a thickness

gauge

2

across the cylinder head. b. Measure the warpage. c. If the limited isexceeded, resurface the cylin-

der head as follows.

d. Place a 400

600 grit wet abrasive paper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinder head several times.

4 - 14

CYLINDER HEAD

NOTE:

CHECKING THE TIMING CHAIN TENSIONER

1. Check: timing chain tensioner Cracks/damage

Replace.

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER

The following procedure applies to both of the tappet covers and O-rings.

1. Check:

tappet cover

camshaft sprocket cover

O-ring Damage/wear

Replace the defective

part(-s).

INSTALLING THE CYLINDER HEAD

1. Install: dowel pins

1

O-ring (New)

2

gasket (New)

3

2. Install: cylinder head

Apply engine oil onto the threads of the cylinder head nuts. Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages.

Cylinder head nut and bolt M7 (

1 4

) 15Nm

M6 (

5

) 10Nm

M6 (

6

) 10Nm

M6 (

7

) 10Nm

M30(

8

) 20Nm

1

4 - 15

CYLINDER HEAD

NOTE:

CAUTION:

6 Nm (0.6 m kg)

INSTALLING THE CAMSHAFT SPROCKET

1. Align: “I” mark on the generator rotor (with the mark on the generator rotor cover)

a. Turn the crankshaft counterclockwise. b. When the piston is at TDC on the compres-

sion stroke, align the “I” mark

a

on the gen-

erator rotor with the mark

b

on the genera-

tor rotor cover.

Be sure to keep the timing chain as tight as possible.

2. Install: timing chain (onto the camshaft sprocket) camshaft sprocket (onto the camshaft)

The notch

a

on the camshaft should face towards the intake side of the engine. Align the camshaft marks

a

with the edge of

the cylinder head as shown.

Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.

3. Install:

Timing chain tensioner bolt and washer (New)

1

Camshaft sprocket bolts

2

12 Nm (1.2 m kg)

4 - 16

   

Order Job / Part name Q’ty Remarks

1 RIGHT COVER,CYLINDER HEAD 2 GASKET 3 SHAFT,VALVE RROCKER ARM 4 ADJUSTING NUT 5 ADJUSTING SCREW 6 VALVE RROCKER ARM 7 CAM SHAFT 8 VALVE COTTER 9 PETAINER,VALVE SPRING

Remove the parts in the order listed.

For installation, reverse the removal procedure.

1 1 2 2 2 2 1 4 2 2 2 2 1 1

10 VALVE INNER SPRING 11 VALVE OUTER SPRING 12 VALVE STEM SEAL 13 INTAKE VALVE 14 EXHAUST VALVE

CAMSHAFT /VALVES AND VALVE SPRINGS

４

３

６

８

９

７

１

２

５

１０

１１

１２

１３

１４

NEW

4 - 17

CAMSHAFT /VALVES AND VALVE SPRINGS

REMOVING THE ROCKER ARMS AND CAMSHAFT

1. Loosen: locknuts

1

adjusting screws

2

2. Remove:

3. Remove: camshaft

1

intake rocker arm shaft ① exhaust rocker arm shaft ②

intake rocker arm exhaust rocker arm

CHECKING THE CAMSHAFTS

1. Check: camshaft bushings Damage/wear

Replace. camshaft lobes Blue discoloration/pitting/ scratches

Replace the camshaft.

3

4

3

4 - 18

CAMSHAFT /VALVES AND VALVE SPRINGS

A

2 Measure:

camshaft lobe dimensions

A

Out of specification Replace the camshaft.

Camshaft lobe dimension limit

Intake

26.30 mm

Exhaust

26.00 mm

3. Check: camshaft oil passage Obstruction

Blow out with compressed air.

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS

The following procedure applies to all of the rocker arms and rocker arm shafts.

1. Check: rocker arm Damage/wear

Replace.

2. Check: rocker arm shaft Blue discoloration / excessive wear/pitting/scratches

Replace or check the lu-

brication system.

3. Check: camshaft lobe Excessive wear

Replace the camshaft.

4. Measure: rocker arm inside diameter Out of specification

Replace.

Rocker arm inside diameter

10.000

10.015 mm

Limit 10.1 mm

5. Measure: rocker arm shaft outside diameter Out of specification

Replace.

Rocker arm shaft outside diameter

9.98 9.995 mm Limit 9.910

mm

4 - 19

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

6. Calculate: rocker-arm-to-rocker-arm-shaft clearance

Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.

Out of specification

Replace the defective

part(-s).

Rocker-arm-to-rocker-arm-shaft clearance

0.005

0.035 mm

INSTALLING THE CAMSHAFT AND ROCKER ARMS

1. Lubricate: rocker arm shaft

Recommended lubricant

Molybdenum disulfide oil

2. Install: exhaust rocker arm exhaust rocker arm shaft

Make sure that the exhaust rocker arm shaft is completely pushed into the cylinder head.

3. Install: intake rocker arm intake rocker arm shaft

1

Insert the camshaft into the hole in the cylinder

head and the intake rockerarm shaft as shown .

4. Lubricate: Camshaft

Recommended lubricant Camshaft

Molybdenum disulfide oil

Camshaft bearing

Engine oil

3

2

4

4 - 20

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

REMOVING THE VALVES

The following procedure applies to all of the valves and related components.

Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.

1. Check: valve sealing Leakage at the valve seat

Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent

a

into the intake and

exhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat

1

.

2. Remove: valve cotters

1

Remove the valve cotters by compressing the valve springs with the valve spring compressor

2

and attachment 3.

3. Remove: upper spring seat

1

valve springs

2

oil seal

3

4

valve

Identify the position of each part very carefully so that it can be reinstalled in its original place.

4 - 21

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

CHECKING THE VALVES AND VALVE GUIDES

The following procedure applies to all of the valves and valve guides.

1. Measure: valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =

Valve guide inside diameter

a

–

Valve stem diameter

b

Out of specification Replace the valve guide.

Valve-stem-to-valve-guide clearance

Intake

0.015

0.042 mm

Limit: 0.08 mm

Exhaust

0.030

0.057 mm

Limit: 0.10 mm

2. Replace: valve guide

To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100

C in an oven.

a. Remove the valve guide with a valve guide

remover

1

.

b. Install the new valve guide with a valve guide

installer

2

and valve guide remover 1.

c. After installing the valve guide, bore the

valve guide with a valve guide reamer

3

to obtain the proper valve-stem-to-valve-guide clearance.

After replacing the valve guide, reface the valve seat.

4 - 22

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

3. Eliminate: carbon deposits (from the valve face and valve seat)

4. Check: valve face Pitting/wear

Grind the valve face. valve stem end Mushroom shape or diameter larger than the body of the valve stem

Replace the valve.

5. Measure: valve margin thickness

a

Out of specification Replace the valve.

Valve margin thickness

0.65

0.95 mm

6. Measure: valve stem runout Out of specification

Replace the valve.

When installing a new valve, always replace the valve guide. If the valve is removed or replaced, always replace the oil seal.

Valve stem runout

Limit: 0.03 mm

CHECKING THE VALVE SEATS

The following procedure applies to all of the valves and valve seats.

1. Eliminate: carbon deposits (from the valve face and valve seat)

2. Check: valve seat Pitting/wear

Replace the cylinder head.

3. Measure: valve seat width

a

Out of specification Replace the cylinder head.

Valve seat width

Intake: 0.8

1.2mm Limit: 1.6 mm Exhaust: 0.8

1.2mm

Limit: 1.6 mm

4 - 23

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

CAUTION:

NOTE:

a. Apply Mechanic’s blueing dye (Dykem)

1

onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and

onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the

valve seat and valve face contacted one

another, the blueing will have been removed.

4. Lap:

valve face

valve seat

After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

a. Apply a coarse lapping compound

a

to the

valve face.

Do not let the lapping compound enter the gap between the valve stem and the valve guide.

b. Apply molybdenum disulfide oil onto the

valve stem. c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all of

the lapping compound.

For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand.

4 - 24

CAMSHAFT /VALVES AND VALVE SPRINGS

e. Apply a fine lapping compound to the valve

face and repeat the above steps. f. After every lapping procedure, be sure to

clean off all of the lapping compound from

the valve face and valve seat. g. Apply Mechanic’s blueing dye (Dykem)

b

onto the valve face. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-

sion. j. Measure the valve seat width

c

again. If the valve seat width is out of specification,reface and lap the valve seat.

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the valve springs.

1. Measure: valve spring free length

a

Out of specification Replace the valve spring.

Valve spring free length (intake and exhaust)

Inner spring

33.78 mm Limit: 32.5 mm

Outer spring

35.55 mm Limit: 34.0 mm

2. Measure: compressed spring force

a

Out of specification Replace the valve spring.

b

Installed length

Compressed spring force

Intake and exhaust inner spring

52

64 Nm at 22.45 mm Intake and exhaust outer spring

105

129

Nm

at

25.45 mm

3. Measure: valve spring tilt

a

Out of specification Replace the valve spring.

Spring tilt limit

Intake and exhaust inner spring

1.3

/0.8 mm

Intake and exhaust outer spring

1.35

/0.8 mm

4 - 25

CAMSHAFT /VALVES AND VALVE SPRINGS

NOTE:

CAUTION:

INSTALLING THE VALVES

The following procedure applies to all of the valves and related components.

1. Deburr: valve stem end (with an oil stone)

2. Lubricate: valve stem oil seal (with the recommended lubricant)

Recommended lubricant

Molybdenum disulfide oil

3. Install: valve

1

oil seal

2

valve springs

3

upper spring seat

4

(into the cylinder head)

Install the valve springs with the larger pitch a facing up.

4. Install: valve cotters

1

Install the valve cotters by compressing the valve springs with the valve spring compressor

2

and attachment3.

5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.

Hitting the valve tip with excessive force could damage the valve.

4 - 26

   

CYLINDER AND PISTON

Order Job / Part name Q’ty Remarks

1 PIN SHAFT,GUIDEROLLER 2 CAM CHAIN GUIDE ROLLER 3 CYLINDER BLOCK 4 GASKET,CYLINDER BLOCK 5 DOWEL PIN 6 RECTANGLE RING 7 CIRCLIP,PISTON PIN 8 PISTON PIN 9 PISTON

Remove the parts in the order listed.

For installation, reverse the removal procedure.

5

3

2

6

1

4

CYLINDER AND PISTON

7

NEW

7

8

1 1

1 1 1 1 1 2 1 1 1

NEW



9

10 PISTON RING

4 - 27

CYLINDER AND PISTON

NOTE:

REMOVING THE PISTON AND PISTON RINGS

1. Remove: piston pin circlip

1

piston pin

2

piston

3

Before removing the piston pin circlip, cover the crankcase opening with a clean towel or rag to prevent the circlip from falling into the crankcase cavity.

2. Remove: top ring 2nd ring oil ring

When removing the piston ring, open the end gap of the ring by fingers, and push up the other side of the ring.

CHECKING THE CYLINDER AND PISTON

1. Check: piston wall cylinder wall Vertical scratches

Rebore or replace the cylinder, and replace the piston and piston rings as a set.

2. Measure: piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinder

bore gauge.

Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find theaverage of themeasurements.

Cylinder bore “C”

54.00 54.015 mm

Taper limit ”T” 0.05 mm

Out of round “R” 0.005 mm

”C” = Maximum D

”T” = (Maximum D1 or D2)–

(Maximum D

5

or D6)

”R” = (Maximum D1, D3 or D5)

– (Minimum D

2

, D4 or D6)

4 - 28

CYLINDER AND PISTON

NOTE:

b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston rings as a set.

c. Measure piston skirt diameter “P” with the

micrometer.

1

7.0 mm from the bottom edge of the piston.

Piston size “P”

Standard 53.965 53.975 mm

d. If out of specification, replace the piston and

piston rings as a set.

e. Calculate the piston-to-cylinder clearance

with the following formula.

Piston-to-cylinder clearance =

Cylinder bore “C” – Piston skirt diameter “P”

Piston-to-cylinder clearance

0.025

0.05 mm

f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston rings as a set.

CHECKING THE PISTON RINGS

1. Measure: piston ring side clearance Out of specification

Replace the piston

and piston rings as a set.

Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

Piston ring side clearance

Top ring

0.04

0.08 mm

<Limit>: 0.12mm

2nd ring

0.04

0.08 mm

<Limit>: 0.12mm

4 - 29

CYLINDER AND PISTON

NOTE:

2. Install: piston ring (into the cylinder)

Level the piston ring in the cylinder with the piston crown as shown.

a

5.0 mm

3. Measure: piston ring end gap Out of specification

Replace the piston

ring.

The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.

Piston ring end gap

Top ring

0.10

0.25 mm

<Limit>: 0.60 mm

2nd ring

0.15

0.30 mm

<Limit>: 0.60 mm

Oil ring

0.2

0.5 mm

CHECKING THE PISTON PIN

1. Check: piston pin Blue discoloration / grooves

Replace the piston pin and then check the lubrication system.

2. Measure: piston pin outside diameter

a

Out of specification Replace the piston pin.

Piston pin outside diameter

13.994

14.000 mm

3. Calculate: piston-pin-to-piston clearance Out of specification Replace the piston pin and piston as a set.

4 - 30

CYLINDER AND PISTON

NOTE:

New

NOTE:

New

Piston-pin-to-piston clearance =

Piston pin bore size

b

–

Piston pin outside diameter

a

Piston-pin-to-piston clearance

0.002

0.019 mm

INSTALLING THE PISTON AND CYLINDER

1. Install: top ring

1

2nd ring

2

lower oil ring rail

5

upper oil ring rail

oil ring expander

Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.

2. Install: piston

1

piston pin

2

piston pin clip

3

Apply engine oil onto the poston pin. Make sure that the mark “IN” on the piston points towards the intake side ofthe cylinder. Before installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the clip from falling into the crankcase.

3. Install: gasket

1

dowel pins

2

4. Lubricate: piston piston rings cylinder (with the recommended lubricant)

Recommended lubricant

Engine oil

4

3

4 - 31

CYLINDER AND PISTON

NOTE:

5. Offset: piston ring end gaps

a

Top ring

b

Lower oil ring rail

c

Upper oil ring rail

d

2nd ring

6. Install: cylinder

1

While compressing the piston rings with one hand, install the cylinder with the other hand. Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.

4 - 32

! ! ! !

CLUTCH

Order Job / Part name Q’ty Remarks

1 DECORATE COVER,R CRANK CASE COVER 2 GASKET,DECORATE COVER 3 CLUTCHLEVER PIN 4 CLUTCHLEVER ASSY 5 CLUTCH CAM SHAFT SPRING 6 O-RING 7 CLUTCH SHIFTING PLATE 8 CLUTCH PRESSURE PLATE 9 OIL SEAL

Remove the parts in the order listed.

For installation, reverse the removal procedure.

CLUTCH

1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1

2

ˠ

ˡ

ˢ

ˣ

７

８

10

11

９

12

13

14

15

16

18

19

20

2122

17

23

24

25

26

27

28

10 OIL SEAL 11 R ,CRANK CASE COVER 12 GASKET,R ,CRANK CASE COVER 13 CLUTCH PUSH ROD 14 OIL TUBE 15 OIL THIMBLE SPRING 16 OIL THIMBLE 17 BEARING 18 CLUTCH END COVER

NEW

4 - 33

! ! ! !

CLUTCH

Order Job / Part name Q’ty Remarks

Remove the parts in the order listed.

For installation, reverse the removal procedure.

CLUTCH

1 1 1 1 1 1 1 1 1 1

19 GASKET,END COVER 20 NUT 21 WASHER 22 THURST WASHER 23 CLUTCH ASSY 24 DRIVER GEAR 25 SLEEVE 26 BUSH 27 CIRCLIP 28 DRIVEN GEAR CAM

1

2

ˠ

ˡ

ˢ

ˣ

７

８

10

11

９

12

13

14

15

16

18

19

20

2122

17

23

24

25

26

27

28

NEW

1 CIRCLIP 2 PLATE 3 CLUTCH DRIVE FRICTION PLATE 4 CLUTCH CENTER SLEEVE 5 DRIVE PLATE 6 CLUTCH CUSHION SPRING 7 CLUTCH SPRING 8 CLUTCH OUTER CASE

4 - 34

! ! ! !

CLUTCH

Order Job / Part name Q’ty Remarks

Remove the parts in the order listed.

For installation, reverse the removal procedure.

CLUTCH

1 3 3 1 1 1 1 1 1

１

２

３

４

３

５

６

8

7

２

３

4 - 35

CLUTCH

NOTE:

REMOVING THE CLUTCH

2. Straighten the lock washer tab ③

3. Remove:

clutch boss nut ①

While holding the clutch boss with the universal clutch holder , loosen the clutch boss nut.

CHECKING THE FRICTION PLATES

The following procedure applies to all of the friction plates.

1. Check: friction plate Damage/wear

Replace the friction plates

as a set.

2. Measure: friction plate thickness Out of specification

Replace the friction

plates as a set.

Measure the friction plate at four places.

Friction plate thickness

2.85

2.95 mm

<Limit>: 2.7 mm

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the clutch plates.

1. Check: clutch plate Damage

Replace the clutch plates as a

set.

1. Remove:

Screw

-

4. Remove:

snap spring ①

washer ②

4 - 36

CLUTCH

NOTE:

2. Measure: clutch plate warpage (with a surface plate and thickness gauge

1

)

Out of specification

Replace the clutch

plates as a set.

Clutch plate warpage limit

Less than 0.1

mm

CHECKING THE CLUTCH SPRINGS

The following procedure applies to all of the clutch springs.

1. Check: clutch spring Damage

Replace the clutch springs as a

set.

2. Measure: clutch spring free length Out of specification

Replace the clutch

springs as a set.

Clutch spring free length

20.5 mm <Limit>: 19.5 mm

CHECKING THE CLUTCH OUTER CASE

1. Check: clutch outer case dogs Damage/pitting/ wear

Deburr the clutch

outer case dogs or replace it.

Pitting on the clutch housing dogs will cause erratic clutch operation.

CHECKING THE CLUTCH CENTER SLEEVE

1. Check: clutch center sleeve splines Damage/pitting/ wear

Replace the clutch

center sleeve.

Pitting on the clutch sleeve splines will cause erratic clutch operation.

4 - 37

CLUTCH

NOTE:

2. Lubricate:

friction plates ③ upper plates ④

First, install a friction plate and then alternate between a upper plate and a friction plate.

(with the recommended lubricant)

Recommended lubricant

Engine oil

INSTALLING THE CLUTCH ASSY

1. Install:

put the clutch spring ① into the clutch outer case.

put the drive plate ② into the clutch outer case.

3. Install:

friction plates ③ upper plates ④

4. Install:

pressure plate and install clutch circlip ⑤

4 - 38

CLUTCH

NOTE:

60 Nm (6.0 m kg)

NOTE:

CHECKING THE CLUTCH PUSH RODS

1. Check: oil tube

1

oil thimble spring

2

oil thimble

3

Cracks/damage/ wear Replace the defective part(-s).

2. Measure:

oil thimble spring ② free length

Out of specification Replace the oil thimble spring.

Oil thimble spring free length

17.5 mm

INSTALLING THE CLUTCH

1. Install: clutch assy

1

thrust washer④,make sure the “OUT SIDE”

mark on the washer is upturned.

Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss.

2. Tighten: clutch boss nut

5

While holding the clutch boss with the universal clutch holder , tighten the clutch boss nut.

3. Bend the lock washer tab ③ along a flat side of the nut. 　

4 - 39

CLUTCH

NOTE:

6 Nm (0.6 m • kg)

4. Install: oil tube

1

oil thimble spring

2

oil thimble

3

screw ķĺ

5. Check clutch assy

Make sure that the teeth on the lock washer are correctly aligned with the grooves on the clutch boss.

4 - 40

! ! ! !

Order Job / Part name Q’ty Remarks

Remove the parts in the order listed.

For installation, reverse the removal procedure.

OIL PUMP

1 1 1

1 OIL PUMP 2 OIL FILTER SCREEN 3 GEAR

OIL PUMP

1

2

NEW

3

4 - 41

OIL PUMP

NOTE:

REMOVING THE OIL PUMP

2. Remove:

gasket of oil pump ①

Remove the gasket of oil pump and check the state.Replace if worn or if reuse if questionable.

1. Remove:

Screw ①　- ③．

gear of oil pump ②

3. Check: Remove the oil pump and inspect oil way for smoothness.clean oil way as necessary.

Check whether the gear is worn.

4 - 42

   

Order Job / Part name Q’ty Remarks

1 FRONT COVER, LEFT CRANKCASE 2 GASKET, LEFT CRANKCASE 3 STATOR , MAGNETO 4 NUT 5 COTOR , MAGNETO 6 CIRCLIP 10 7 DRIVEN SPROCKET, STARTING MOTOR 8 DRIVE SPROCKET, STARTING MOTOR 9 STARTING MOTOR DRIVE CHAIN

Remove the parts in the order listed.

For installation, reverse the removal procedure.

10 OIL SEAL 19×30×5 11 OIL SEAL 12 CHAIN PROTECT PLATE 13 CHAIN GUIDE PLATE 14 WOODRUFF KEY

1 1 1 1 1 1 1

1

1 1 1 1 1 1

MAGNETO AND STARTER GEAR

1

3

5

2

4

10

9

7

8

12

6

11

MAGNETO AND STARTER GEAR

13

NEW

14

4 - 43

MAGNETO AND STARTER GEAR

NOTE:

REMOVING THE GENERATOR ROTOR

1. Remove: bolt

1

(magneto)

Loosen the bolt (generator rotor) 1 while holding the rotor with a sheave holder

2

. Do not allow the sheave holder to touch the projection on the rotor.

2. Remove: generator rotor

1

woodruff key ②

CHECKING THE STARTER CLUTCH

1. Check:

1

starter clutch drive gear

2

starter clutch gear

Burrs/chips/ roughness / wear

Replace

the defective part(-s).

3. Remove: circlip

1

bolt ②

4 - 44

MAGNETO AND STARTER GEAR

30 Nm (3.0 m kg)

b. When turning the starter clutch gear clock-

wise

a

, the starter clutch and the starter clutch gear should engage. If the starter clutch gear and starter clutch do not engage, the starter clutch is faulty and must be replaced.

c. When turning the starter clutch gear counter-

clockwise

b

, it should turn freely. If the starter clutch gear does not turn freely, the starter clutch is faulty and must be replaced.

3. Inspect: dowel pins

1

compression springs

2

spring caps

3

Wear/Damage Replace.

4. Inspect: starter wheel gear (contacting surface) Pitting/Wear/Damage

Replace.

INSTALLING THE STARTER CLUTCH

1. Install: starter clutch assembly

1

2. Unloosen the starter clutch assembly by using the center punch.

3. Install: compression springs

1

spring caps

2

dowel pins

3

2. Check: starter clutch operation

a. Hold the starter clutch.

4 - 45

MAGNETO AND STARTER GEAR

NOTE:

50 Nm (5.0 m kg)

NOTE:

INSTALLING THE GENERATOR ROTOR

1. Install:

1

starter wheel gear

2

woodruff key

3. Install: generator rotor

1

Clean the tapered portion of the crankshaft and the rotor hub. When installing the rotor, make sure the woodruff key is properly seated in the key way of the crankshaft and turning the starter wheel gear

clockwise.

4. Tighten: generator rotor

2

Tighten the bolt while holding the generator rotor with the sheave holder .

2. Install:

starting motor drive chain ① drive gear ② cirlip ③ bolt ④ chain protect plate ⑤

4 - 46

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Order Job / Part name Q’ty Remarks

1 CLIP, VOLTAGE WIRE 2 LOWER PAN, OIL INSULATING 3 O-RING 4 OIL SEAL 5 BOLT M14×1.5 6 WASHER 7 SPRING, CHAIN TENSIONER PUSH ROD 8 CHAIN TENSIONER PUSH ROD 9 TIGHTENING ROD HEAD

Remove the parts in the order listed.

For installation, reverse the removal procedure.

10 TIMING CHAIN 11 TIGHTENING ARM SHAFT 12 TIGHTENING ARM 13 TIGHTENING IDLER WHEEL SET 14 OIL PUMP DRIVE SPROCKET

1 1 1 1 1 1 1

CAM CHAIN-TENSIOR

1

4

3

2

5

6

7

8

9

11

12

13

14

10

NEW

4 - 47

CAM CHAIN-TENSIOR

20 Nm (2.0 m • kg)

1. Remove:

bolt of cam chain tensior ①

roller of cam chain tensior

2

cam chain

3

2. Check:

aluminium washer ①

Pitting/Wear/Damage Replace.

INSTALLING THE CAM CHAIN TENSIOR

1. Install: bolt of cam chain tensior

1

spring of chain tensior push rod

Pitting/Wear/Damage Replace.

CAM CHAIN TENSIOR

4 - 48

! ! ! !

Order Job / Part name Q’ty Remarks

1 BOLT, LOCATING PLATE LOCATING PLATE GROUP 2 RETURN SPRING, LOCATING PLATE 3 RETURN SPRING, GEARSHIFT LEVER 4 BUSH 5 GEARSHIFT LEVER BODY ASSY 6 TENSION SPRING, GEARSHIFT LEVER 7 STOP PLATE 8 BOLT M8×11 9 CIRCLIP 16

Remove the parts in the order listed.

For installation, reverse the removal procedure.

10 SPRING 11 SPRING SHAFE SPRING BASE

1

1 1 1

1 1 1 1 1

CRANKSHAFT AND GEARSHIFT ARM

13

14

15

16

17

18

19

20

21

22

23

24

25

6

11

10

12

1

2

5

8

7

4

3

10

11

9

4 - 49

! ! ! !

Order Job / Part name Q’ty Remarks

13 CYLINDER STUD BOLT B M7 X 204 14 CYLINDER STUD BOLT A M7 X 212 15 OIL DRAIN PLUG M12×1.5 16 WASHER 12.5×1.5×20 17 BOLT M6×65 18 BOLT M6×60 19 BOLT M6×45 20 BOLT M6×60 21 BREATHER TUBE C100-2#

Remove the parts in the order listed.

For installation, reverse the removal procedure.

22 LEFT CRANKCASE 23 GASKET, CRANKCASE 24 RIGHT CRANKCASE 25 TIE-IN, BREATHER TUBE

1 2 2 1 1 3 1 1 1 1 1 1 1 1

CRANKSHAFT AND GEARSHIFT ARM

13

14

15

16

17

18

19

20

21

22

23

24

25

6

11

10

12

1

2

5

8

7

4

3

10

11

9

12 CONTACT, GEAR INDICATION

4 - 50

CRANKSHAFT AND GEARSHIFT ARM

DISASSEMBLING THE CRANKCASE

1. Gearshift arm ①:

bolt of locating plate ②

2. Remove:

cirlip ①

Remove:

bolt of locating plate ③

spring ② spring seat ③

4 - 51

CRANKSHAFT

NOTE:

CAUTION:

DISASSEMBLING THE CRANKCASE

1. Remove: crankcase bolts

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence.

2. Remove: right crankcase

Set the left crankcase half under then put in the flat head screw driver to the separating slit .

First check that the shift drum segment’s teeth and the drive axle circlip are properly positioned, then remove the right crankcase. Do not damage the crankcase mating surfaces.

1

5

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Orion AGB-21G Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual