troubleshooting - Honda Spree and Elite 50 Forums • Index page
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3. Y 3 Check the area around the manifold for air leakage 4 Check sparks Sparks normal POOR PERFORMANCE AT HIGH SPEED 1 Check ignition timing Correct 2 Remove the fuel tube from the fuel valve Fuel flows 3 Remove the carburetor and check for clogged jets Not clogged Abnormal gt Incorrect 752 Leaking gt Weak or intermittent gt sparks Incorrect CAUSE OF TROUBLE 1 Faulty CDI unit 1 Excessive fuel mixture Loosen screw to correct adjustment level 2 Lean fuel mixture Tighten screw to correct adjustment level 1 Faulty insulator packing 2 Loose carburetor 3 Faulty inlet pipe packing 4 Faulty insulator O ring 1 Carbon deposited on spark plugs or spark plugs contaminated 2 Faulty CDI unit 3 Faulty ignition coil 4 Faulty generator 5 Faulty main switch CAUSE OF TROUBLE gt 1 CDI unit 2 Faulty A C generator Insufficient fuel supply 1 Fuel tank empty Clogged 2 Fuel tube or fuel filter clogged 3 Fuel tank cap air hole clogged gt 1 Clean 18 3 TROUBLESHOOTING UNSATISFACTORY OPERATION CLUTCH DRIVE DRIVEN PULLEY CAUSE OF TROUBLE 1 Engine starts but motorcycle does not move gt 1 Drive belt worn or slips 2 Ramp plate damaged 3 Drive face spring damaged 4 Clutch lining came off 5 Driv
4. gt Check IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit Signal operates satisfactorily GAUGE NEEDLE SHAKES OR VERTICALLY WOBBLES Signal continuously operates dim or does not operate at all Needle not moving 2 Remove the tank and operate the float Needle moving 3 Move the float rapidly One up down motion per second Needle moving 4 Start the engine and measure the fuel level sensor resistance Resistance not changed 5 Check each joint Y Needle not moving Resistance changed gt significantly Unsatisfactory gt Satisfactory 18 6 CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Faulty ignition swtich 4 Faulty terminal connection 5 Wire harness damaged 1 Faulty float 1 Balance coil damaged or shorted 1 Terminal loose 2 Faulty terminal connection 1 Balance coil lead shorted damaged CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Ignition switch damaged or shorted 4 Terminal loose of faulty connection 5 Wire harness damaged 1 Faulty fuel level sensor connection 1 Damper oil inside the meter insufficient 1 Faulty connection between the sliding arm and the resistance 1 Terminal connection loose or faulty connection 1 Balance coil lead shorted or
5. REAR WINKER BULB REPLACEMENT Press the winker lens groove and open the winker lens using plain screwdriver Remove the bulb from the socket replace with new bulb Install in the reverse order of removal Pay attention not to damage the lens Do not apply excessive force when removing the lens TAILLIGHT BULB REPLACEMENT Loosen the 2 pan screws remove the tail light lens Replace the tail stop light bulb with the new one Pay attention not to damage the tail light lens when removing it METER BULB REPLACEMENT Remove the front handle cover 23 6 Remove the bulb socket replace with new bulb METERS REPLACEMENT Remove the front cover 43 5 Remove the front handle cover 23 6 Remove the front rear stop swtich wire Remove the speedometer cable from the meter Loosen the 4 steering handle tapping screws Remove the speedometer coupler connected to the wire harness Remove the speedometer wiring from the steering handle cable guide Remove the speedometer and the gear handle cover assemblied from the steering handle Roose the 3 tapping screws securing the speedometer and the rear handle cover Disconnect the R L wiring Remove the speedometer assembly Install in the reverse order of removal LIGHTS METER SWITCHES N NOTE Check the each switch for proper operation The wire and cable must be connected accurately
6. 3 Press the kick starter pedal to check the cylinder pressure Normal 4 Check the carburetor for clogging Not clogged 5 Remove spark plugs Not contaminated or discolored 6 Check for engine overheating Not overheated Y 7 Accelerate suddenly or run at Engine does not knock 18 2 Engine speed does not gt increase sufficiently Abnormal Low Clogged Contaminated or discolored Overheated gt Engine knocks gt CAUSE OF TROUBLE 1 Air cleaner clogged 2 Insufficient fuel supply 3 Fuel tank cap air hole clogged 4 Muffler clogged 1 Faulty CDI unit 2 Faulty A C generator 1 Cylinder and piston ring worn 2 Cylinder head gasket damaged 3 Cylinder and cylinder head cracked 1 Unsatisfactory carburetor maintenance 1 Unsatisfactory plug maintenance 2 Plugs with incorrect heat value used 3 Rich fuel mixture 1 Cylinder or piston worn 2 Lean fuel mixture 3 Poor quality fuel used 4 Carbon deposit inside the combustion chamber excessive 5 Ignition timing incorrect 1 Carbon deposit inside the combustion chamber excessive 2 Poor quality fuel used 3 Lean fuel mixture TROUBLESHOOTING POOR PERFORMANCE AT LOW SPEED AND IDLING 1 Check ignition timing Normal Y 2 Check the carburetor air screw Correct
7. Inspect with the spark plug assembled and while there is compression pressure Remove the CDI unit 14 7 Remove the coupler from the CDI unit and connect the peak voltage adaptor to the pulse generator wire blue yellow and green of harness coupler Operate the starter motor and measure the peak voltage of the pulse generator coil CONTACT POINTS BLUE YELLOW TERMINAL BODY EARTH PEAK VOLTAGE OVER 1 5V N CAUTION When measuring voltage do not touch the metal part of the handle rod as there is the danger of receiving an electric shock Perform the following inspections if measured peak voltage in the CDI unit coupler portion is abnormal Disconnect the AC generator cord coupler and connect When the measured value in the unit side is abnormal and normal in the pulse generator side the problem is either incorrect coupler connection or disconnection of the wire harness When both measurements are abnormal this indicates a problem with the pulse generator Refer to the malfunction diagnosis are go through each step IGNITION COIL REMOVAL INSTALLATION Remove the luggage box 3 3 Remove the plug maintenance cover Remove the spark plug cap Loosen the ignition coil fixing bolt Disconnect the ignition coil wire Remove the ignition coil Install in the reverse order of removal N CAUTION Arrange the cords in the right place INSPECTION RESISTANCE MEASUR
8. SERVICE LIMIT 2 0mm REAR WHEEL BRAKE SUSPENSION REAR BRAKE DISASSEMBLY Manually open the brake shoe and remove it BRAKE SHOE Remove the shoe spring from the brake shoe Se SHOE SPRING SHOE SPRING BRAKE SHOE Loosen the rear brake arm fixing bolt Remove the rear brake arm rear brake indicator brake cam dust seal Remove the rear brake cam gt TM 1 cor M 2 DUC au E a x Las 4 1 b nm REARBRAKECAM REAR BRAKE ASSEMBLY INSTALLATION Apply small amount of grease to the brake cam Install the brake cam Install the rear brake dust seal indicator rear brake arm Align the punch marks of the brake arm and the brake cam before assembly Remove the excessive grease after assembling the shoe Install the brake shoe and spring Install the rear brake shoe to the rear brake cam Install the rear wheel Install the washer and U nut N NOTE Check the brake for smooth operation REAR WHEEL BRAKE SUSPENSION REAR CUSHION REMOVAL Remove the luggage box 43 3 REARICUSHION Loosen the top and bottom rear cushion setting bolts NOTE Support the frame firmly prior to working DISASSEMBLY Install the compressor attachment as shown in the figure Install the cushion on the cushion compressor and compress the spring TOOLS COMPRESSOR A
9. damaged STARTER MOTOR STARTING MOTOR WILL NOT TURN 1 Apply the brake and check the brake Light not activated stop light for operation Light is activated 2 Operate the turn signal to check the Signal continuously gt battery circuit operates dim or does not operate at all Signal operates satisfactorily 60 120 signaling second 3 Press the starter switch to check the Unsatisfactory starter magnetic Satisfactory 4 Connect the starter to battery and Starter does not turn gt check operation Light not activated Starter turns STARTER MOTOR TURNS SLOW OR FAILS TO CRANK MOTOR 1 Operate the turn signal to check the Signal continuously 9 battery circuit operates dim or does not Signal operates satisfactorily operate at all 2 Connect the starter subwire to the Operates sitisfactory battery Turns slowly with speed not changing 3 Operate the kick starter Operates heavy Operates light STARTER ROTATE WITHOUT STOPPING Turn off the ignition switch Will not stop gt TROUBLESHOOTING CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Faulty stop switch 4 Faulty terminal connection 5 Ignition swtich damaged or shorted 1 Battery totally discharged 1 Faulty starter switch connection 2 Starter magnetic damaged or
10. 14 3 IGNITION TIMING INSPECTION 14 7 IGNITION SYSTEM INSPECTION 14 7 IGNITION COIL 14 5 CUT OFF SWITCH 14 8 SERVICE INFORMATION GENERAL SAFETY Refer to the malfunction diagnosis when inspecting ignition devices Because the ignition devices have installed electrical advancer devices it is impossible to adjust ignition timing Be careful when handling the ignition devices as they can become easily damaged if dropped or bumped Also do not disconnect or connect the connectors and couplers when the main swtich is turned ON as excessive electric current can cause damage in the unit Always perform maintenance work on the ignition devices with the main switch turned OFF Ignition devices can often appear to be malfuctioning when the couplers or connectors are disconnected Check these connections before working on Use recommended spark plug Using incorrect spark plug may make the engine run badly or damage the engine This manual gives explanations on inspections to receive peak voltage As inspections for coil resistance values are also included it may be difficult to make a correct determination Conduct inspection on the main swtich by referring to the wiring diagram continuity chart chapter 16 14 1 IGNITION SYSTEM IGNITION DEVICES LOCATION SPARK PLUG CDI UNIT A C GENERATOR GREEN BLACK YELLOW BLUE YELLOW BLACK RED BLACK WHITE A C GENE
11. 8 10h WARNING Do not let the electrolyte temperature rise above 45 C 113 If the electrolyte temperature becomes too high lower the charging current e Quick charging will shorten the battery life and cause battery damage It chould only be done in emergency slow charging is prefered 13 5 CHARGING SYSTEM AC GENERATOR HEADLIGHT VOLTAGE INSPECTION Remove the front cover 3 5 CAUTION Check voltage with the headlight coupler connected N After starting the engine place the dimmer switch to HI and check the voltage between blue green wires of the headlight coupler Measurement is performed in AC area CONTROL VOLTAGE 12 6 13 6V 5 000rpm If voltage is incorrect check the regulator rectifier REGULATOR RECTIFIER INSPECTION HARNESS CIRCUIT INSPECTION Remove the front cover 23 5 Remove the coupler of the regulator rectifier and inspect the wiring circuit in the main harness side terminal ITEM MEASUREMENT LOCATION LEVEL AREAS OF INSPECTION IF INCORRECT Voltage between red green There must be battery voltage Damaged disconnected main fuse harness CHARGING Resistance between white wire and 0 4 1 0 20C COIL earth wires Disconnect the starter AC generator charging lighting coil Resistance between yellow wire and coupler connection damage resister 6 7 SOIT ea
12. Ch Vel P VSS 5 7 NC GREEN WHITE GREEN FUSE A C GENERATOR ZI mE H gt an mr lt N hs lt 56 CC cc LLI 0 gt 0 YELLOW YELLOW DIMMER SWITCH BLUE HIGH RESISTER 5W 6 7 Q WHITE TAIL LIGHT 12V 5W SPEEDOMETER LIGHT LOW 12V 3Wx2EA 30W 5 9 0 HEADLIGHT 12V 35 35W 13 2 CHARGING SYSTEM AC GENERATOR TROUBLESHOOTING Battery is Overcharged Headlight bulb is out No headlignt beam wire Headlight register is damaged disconnected Lighting switch is connected incorrectly Regulator rectifier is not grounded or connected incorrectly Problems with the Charging System eee Inspect the body of the register rectifier NORMAL NORMAL Short circuited harness Y Damaged main switch ABNORMAL et OVER 15 Regulator rectifier is damaged UNDER 14V OVER 14 15 Battery is damaged Y Check the voltage of the regulator rectifier Wire harness is short circuited battery lines and the ground line Coupeler is connected incorrectly NORMAL Y Check the changing coil with the regulator rectifier coupler charging coil ABNORMAL gt ids the AC generator charging coil NORMAL gt AC gene
13. In case that charging the voltage is not controled properly the battery cannot be used due to the battery solution dried up by over charging and the deformation caused by the damage of the plates Battery control voltage 14 5 0 5 5 000 N NOTE If you have 1EA of tester measure current first CHARGING CURRENT CHECK Check the charging current passed through the generator assy regulator comp is normal with the discharged battery CHARGING CURRENT 1 5 2 4A 5 000rpm TOOL DIGITAL CIRCUIT TESTER BATTERY CHARGING Remove the battery from the frame and connect it to the battery charger Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal N NOTE Do not connect the charger to the battery coupler terminals Never open the sealed filler cap The battery generates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery easpecially while charging it Turn power ON OFF at the charger not at the battery terminals If the cable is disconnected or connected at the battery terminal during charging spark may jump and ignite the flammable gas Always remove the battery from the frame when charging it If the battery is charged while installed in the frame the electrolyte may spill and corrode the frame components CHARGING CURRENT 0 3A CHARGING TIME
14. generator Loosen the 2 stator fixing flange bolts Remove the grommet from the crankcase cover Remove the stator N NOTE Insert the puller shaft and remove the flywheel after inserting the ACG rotor puller and securing it with spanner The flywheel may easily removed if you rotate the puller while tapping the roller shaft with metal hammer Always use a holder and a puller to remove the flywheel Do not try to remove the flywheel by hammering directly on it The crankshaft or components could be damaged Remove the woodruff key with care not to lose it ACG ROTOR PULLER WOODRUFF KEY CRANKSHAFT 13 7 CHARGING SYSTEM AC GENERATOR P 4 4 M x 4 Ys WOODRUEF KEY Tz ELYW EEL y 13 8 Before installing the flywheel check that no nuts or STATOR INSTALLATION Note the direction of stator and install the stator on the crankcase Install the grommet to R crankcase cover Install AC generator wire coupler to wire harness Install the connector to starter motor then install the ground wire FLYWHEEL INSTALLATION Clean the tapered portion of the crankshaft If the flywheel is installed with dust or dirt on the taper the taper will not make secure contact with the flywheel and there will be excessive force on the woodruff key Insert the woodruff key into the key groove in the crankshaft Set the flywheel g
15. occurs thoroughly clean with water and if acid enters eyes flush with water and see a doctor If battery acid gets on clothing as it can seep through or make a hole through the clothing and make its way to the skin make sure to change clothing that has come into contact with battery acid and wash the battery acid from the clothes N CAUTION This vehicle has a maintenance free MF battery Because MF batteries use different charging equipment take special care when performing maintenance and especially when replacing parts Not all regular battery equipment is compatible with MF batteries When charging the battery remove the battery from the frame and do not open stopper There is the possibility of damaging the regulator rectifier etc if the terminal or coupler is separated connected when electricity 15 over flowing through the electrical devices Make sure to turn the main switch OFF when performing maintenance to the charging equipment If the battery is allowed to repeatedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to note here that the battery will naturally last 2 3 years of noromal use and although it will re charge its load is reduced leading to a loss in battery strength It is possible for the battery to become overcharged from battery body load
16. u ABNORMAL Starter motor rotates but crank shaft does t Incorrect starting clutch Incorrect starter gear Starting clutch slip Starter motor operates in free wheel Internal fault of starter motor Driven gear slips Remove the starter motor wire connect it to the battery terminal and check to CLICKS see if the starter motor rotates because large amount of current flows in this test do not use thin wire ROTATES DOES NOT ROTATE Y Y Incorrect starter Incorrect starter motor motor connecion Faulty starter switch NO CONTINUITY Incorrect connection with the switch terminals or harness disconnection NO VOLTAGE Damaged main or starter switch Incorrect connection with coupler connector Disconnection in starter switch wire Faulty brake stop switch NORMAL Loose or poor contact at starter relay switch connector Faulty starter relay switch Weak rotational power in starter motor Battery is insufficiently charged Incorrect connection of battery terminal cord Damaged starter motor Ground wire is connected incorrectly Brush is damaged or worn Starter motor and crank shaft rotate but does not turn engine over Incorrect starting system Faulty engine 15 3 STARTING SYSTEM ASHER SCRE Y STARTER MOTOR REMOVAL INSTALLATION Remove the luggage box 23 3 Remove the center cover 3 3 Remove the
17. 0minutes later TOOL DIGITAL CIRCUIT TESTER CHARGING SYSTEM INSPECTION LEAK TEST Trun off the main switch and remove the earth cable from the battery Connect an ampere meter between the battery terminal and the earth cable and check current when the main switch is turned off CAUTION Use an ampere meter while sequentially changing its measuring range from large to small If the current level greater than the measuring limit is measured the ampere meter fuse may be cut Do not turn on the main switch while current 1s being measured LEAK CURRENT Not to exceed 1mA BATTERY ADJUSTMENT VOLTAGE CHECK Connect the voltmeter between the battery terminals Connect the amperemeter between the main fuse termanals Start the engine and measure the charging voltage and ampere while incresae the rpm gradually CONTROL VOLTAGE CHARGING SIDE 14 5 0 5V 5 000rpm LAMP SIDE 13 1 0 5V 5 000rpm N NOTE Check with fully charge the battery which has the voltage between terminal of 12 8 13 0V In case that the engine is started by the starter motor measurement must be performed after accelating charging for 10 seconds 13 4 CHARGING SYSTEM AC GENERATOR VOLT METER AMPERE METER SAFETY VENT FILTER FILLER CAP SEPARATOR CPLATE BATTERY CHARGER CHARGING VOLTAGE CHECK Use the full change battery 12 8 13 2V
18. 33 3 Remove the body cover Loosen the bolt jointed with the fuel tank Remove the wire of oil level switch Remove the oil level switch from the oil tank Install in the reverse order of removal N NOTE Disassemble after adjusting the oil level INSPECTION Move the float to farthest extreme up and down and check the continuity of the terminals Its normal state if there is no continuity when the float is up but continuity when it is down MAIN SWITCH REMOVAL INSTALLATION Remove the front cover 33 5 Remove the inner box 33 5 Disconnect the main switch coupler Remove the seat lock cable Loosen the 2 screws and remove the main switch Install in the reverse order of removal INSPECTION Inspect continuity of each terminal TERMINAL IG E BA1 BA2 ON 0 0 OFF O LOCK O O COLOR BLACKWHITE GREEN RED BLACK 16 3 LIGHTS METER SWITCHES HANDLE SWITCH INSPECTION Remove the front handle cover 3 6 Remove the handle switch coupler connector and inspect continuity of each terminal If abnormal inspect the switch LIGHTING SWITCH STARTER SWITCH ST E ms PUSH C3 z STARTER SWITCH DIMMER SWITCH WINKER SWITCH HI LO HL N HI COLOR BROWN WHITE BLUE COLOR SKYBLUE ORANGE GRAY HORN SWITCH HO BAT FREE W
19. E SYSTEM MECHANICAL DRUM BRAKE Poor brake performance Improperly adjusted brake Worn brake linings Worn brake drum Worn brake cam Improperly installed brake linings Brake cable sticking needs lubrication Contaminated brake linings Contaminated brake drum Worn brake shoes at cam contact areas Improper engagement between brake arm and camshaft serrations Brake lever hard or slow to return Worn broken return spring Improperly adjusted brake Sticking brake drum due to contamination Worn brake shoes at cam contact areas Brake cable sticking needs lubrication Worn brake cam Improperly installed brake linings Brake squeaks Worn brake linings Worn brake drum Contaminated brake linings Contaminated brake drum 12 2 BRAKE SYSTEM master BRAKE FLUID BLEEDING BRAKE FLUID CHANGE N CAUTION A contaminate disk or pad reduces braking power Do not allow the disk or pad to be contaminated by oil Replace contaminated pads and remove pollutants from the disk completely Check the brake fluid level often and replenish new fluid as required Do not spill fluid on painted plastic or rubber parts Remove the front handle cover 43 6 Remove the master cylinder cap master cylinder holder and diaphragm from the master cylinder Connect the bleeder hose to the bleeder valve Loosen the bleeder valve and pump the brake lever repeatedly When there is no more fluid flowing out of the ble
20. EMENT Remove the luggage box 3 3 Measure primary coil resistance between the green and black yellow terminals STANDARD VALUE 0 1 0 5 Q 20 C the adaptor 2 In the same manner as with the unit coupler side IGNITIONICOIL measure peak voltage and compare with the first peak voltage TM 4 NT x n SC AU 3 LM T 14 5 IGNITION SYSTEM Measure the secondary coil resistance between the plug cap and green wire terminals RESISTANCE VALUE SPARK PLUG CAP CONNECTION 6 5 9 5 20 C The coil which the resistance value indicate disconnection remove the plugcap and measure the resistance of secondary coil Measure the resistance between the high tension code and green code terminals RESISTANCE VALUE 2 6 1 25 Ko 20 C EXCITE COIL INSPECTION N NOTE Assembly the spark plug to the cylinder head and inspect in an state having compression pressure Remove the luggage box 23 3 Remove the connection of the AC Generator wire connector black red measure the resistance between the terminal of AC generator and body earth STANDARD VALUE 500 2 20 20 PULSE GENERATOR INSPECTION N NOTE The inspection of pulse generator is performed in a state assembling to the engine Remove the luggage box 53 3 Remove the connection of the AC generator coupler and measure the resistance b
21. HORN INSPECTION Remove the front cover 33 5 Remove the horn wiring and connect a fully charged 12V battery Check the sound quality for any abnormalities LICENCE LAMP Loosen 2 screws Remove the lamp cover Replace the lamp 12V 4W Install in the reverse order of removal 16 7 MEMO IL ON MYVW GNNOYD AVH9 HD ALIHM M d N33H9 91 N33H9 9 37789 AAS 8S 1 MOTIA A 8 109 i 9 ES 2533211 cE NO MOL H3MNIM HTJH mm A D 9 mm mm m ud mm mm MLZ MS AZL dOLS IIVL E MOL H3MNIM HH JH m LINN A 8 13441 INVHOVIG
22. INKER PUSH SWITCH COLOR LIGHTGREEN BLACK FRONT STOP SWITCH INSPECTION Remove the front handle cover 23 6 Remove the black wire and green yellow wire terminals inside the speedometer assembly and check the following When the brake lever is pulled continuity When the brake lever is released no continuity FRONTISTOP SWITCHIE 4 16 4 LIGHTS METER SWITCHES BULBS REPLACEMENT HEADLIGHT BULB Remove the front cover 3 5 Remove the headlight rubber cover Push down on the socket and turn to the left Replace with new bulb HEADLIGHT RUBBER COVER HEADE IGEHTIBUEB Before replacing the bulb be sure to check the swtiches for loose connection of the connectors Install in the reverse order of removal WARNING Headlight bulbs become very hot while the headlight is ON and remain hot for a while after they are turned OFF Be sure to turn the ignition switch OFF and let the bulb cool down before replacement If you touch the bulb with your bare hands clean it with a cloth moistened with denatured alcohol to prevent early bulb failure Be sure to install the dust cover after replacing the bulb FRONT WINKER BULB Remove the front cover 33 5 Remove the bulb from the socket replace with new bulb Install in the reverse order of removal 16 5 LIGHTS METER SWITCHES 16 6
23. ION CORD ATTACH THE PLUG CAP 6 3 10 3K 2 20C DETACH THE PLUG CAP 3 3 000 TESTING BY CDI TESTER Check the CDI unit spark performance by using a CDI tester N NOTE Read tester manual carefully prior to using the tester SIDE STAND IGNITION CUT OFF SWITCH INSPECTION Remove the plug maintenance cover center cover 53 3 Remove the coupler of side stand switch Check for continuity between the terminal as shown below 14 7 IGNITION SYSTEM SIDE STAND SWITCH SWITCH COUPLER EAN SCREW i 14 8 ITEM TERMINAL SPECIFICATION ON B Side stand is BLACK WHITE N Retracted AND GREEN CONTINUITY OFF BLACK WHITE Side stand is CONTINUITY Lowered AND GREEN REMOVAL Remove the floor side cover 33 4 Remove the plug maintenance cover center cover 33 3 Remove the side stand switch mounting 2 bolts Release the wire clamps and remove the side stand switch INSTALLATION Install in the reverse order of removal 15 STARTING SYSTEM SERVICE INFORMATION 15 1 STARTER MOTOR 15 4 STARTING DEVICES LOCATION 15 2 STARTER RELAY INSPECTION 15 7 TROUBLESHOOTING 15 3 STARTER PINION GEAR INSPECTION 15 7 SERVICE INFORMATION GENERAL SAFETY WARNING When performing maintenance on the starter motor and related parts turn the main switch to OFF There is the danger of the starter motor
24. If a battery cell becomes short circuited and if a state develops where voltage is not created between the terminals the regulator will not operate and excessive voltage will develops where voltage is not created between the terminals the regulator will not operate and excessive voltage will develop in the battery and normal cell electrolytes will decrease If the vehicle is not used for a long period make sure to chage the battery every three months If not so the battery ability to store electricity is reduced A new MF battery will not necessarily be ready for use in the vehicle with only the adding of battery acid Make sure to charge battery after the adding of battery water in the following instances When open voltage voltage between terminals does not reach 12 4V after the adding of battery water charge until open voltage reaches at least 12 8V When battery acid temperature is under C charge normally for 2 3 hours See the part location drawing for the location of charging system parts gt 13 2 Follow trouble shooting for charging equipment inspection 213 3 The charging equipment may ofter appear to be malfunctioning if the couplers or connectors are incorrectly attached Make sure to check these connections before starting maintenance work on the charging equipment 13 1 CHARGING SYSTEM AC GENERATOR CHARGING DEVICE LOCATION RESISTER LG P X 7 lt 2 i
25. RATOR 90000000 IGNITION COIL CDI UNIT 1 PULSE GENERATOR MAIN SWITCH oc o oc o SIDE STAND SWITCH 14 2 TROUBLESHOOTING Spark plug does not emit sparks IGNITION SYSTEM ASIVIAPHId TOO NOLLINDI ABNORMAL STATE Maximum voltage is low No or almost no peak voltage Spark plug peak voltage is normal but spark plug does not emit sparks POSSIBLE CAUSES START FROM 1 AND GO THROUGH LIST IN ORDER 1 Using a tester with a low internal resistance 2 Cranking speed is low Battery is low or kick power is weak 3 Influence of tester sampling time normal state if measured a number of times and shows over the set voltage 4 Problem in ignition system wiring disconnected damaged 5 Ignition coil is damaged 6 Excite coil is damaged measure peak voltage 7 CDI unit is damaged when no porblems in 1 6 and spark plug does not emit sparks 1 Adaptor is connected incorrectly 2 Main switch damaged 3 CDI unit coupler is connected incorrectly 4 CDI unit ground wire disconnection 5 Damage to excite coil measure peak voltage 6 Pulse generator is damaged measure peak voltage 7 Peak voltage adaptor is damaged 9 CDI unit is damaged when no problems in 1 7 and no sparks emitted from spark plug 1 Damage to spark plug or leakage of ignition coil secondary current 2 Damaged ignition coil 1 Using a tester with a low internal
26. REAR WHEEL BRAKE SUSPENSION TROUBLESHOOTING Wobble or vibration in motorcycle Tire pressure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorber rod Suspension noise Loose fasteners Worn shock REAR WHEEL BRAKE SUSPENSION REAR WHEEL REMOVAL Support the motor cycle on the main stand Loosen the rear brake adjuster and remove the brake cable Remove the brake arm joint B Remove muffler 3 7 Remove the rear wheel mud guard Loosen the rear wheel U nut Remove the washer Remove the rear wheel INSPECTION Turn the wheel and check the rim for wobbles SERVICE LIMIT Radical 2 0mm Axial 2 0mm INSTALLATION Insert the rear wheel over the final shaft REAR WHEEL BRAKE SUSPENSION Insert the washer and tighten with the U nut TORQUE VALUE 6 0 8 0kgf m Install the brake arm joint B Install the rear brake cable Install the rear brake rod adjusting nut Install the rear wheel mud guard Install the muffler Check the free play of the brake after the rear wheel assemblying REAR BRAKE Remove the rear wheel 511 3 INSPECTION Measure the brake drum of inner diameter SERVICE LIMIT 111mm Measure the thickness of the brake lining
27. TART 1 Open the drain screw and check fuel flow to the carburetor Fuel is supplied Y 2 Check spark plugs Good spark 3 Test cylinder pressure Pressure normal 4 Start engine in the following procedure Engine will not start 5 Remove spark plugs Dry plugs Fuel not supplied to the carburetor Weak or no spark Low cylinder pressure Engine starts but stops immediately Plugs wet gt CAUSE OF TROUBLE 1 Fuel tank empty 2 Fuel tube up to the fuel tank clogged or the vacuum tube or fuel tube up to the inlet pipe clogged 3 Float valve clogged 4 Fuel tank cap air hole clogged 5 Fuel supply pipe frozen 6 Fuel strainer clogged 1 Faulty spark plug 2 Contaminated spark plug 3 Faulty CDI unit 4 Faulty A C generator 5 Disconnected or shorted high tension cord 6 Disconnected or shorted ignition coil 7 Faulty main switch 1 Piston ring seized 2 Cylinder and piston ring won 3 Cylinder and cylinder head cracked 4 Crank case air leaks 5 Cylinder head gasket damaged 1 Manifold air leaks 2 Inadequate ignition timing 1 Carburetor flooded 2 Faulty control box 3 Throttle valve excessively opened 18 1 TROUBLESHOOTING ENGINE OUTPUT INSUFFICIENT 1 Gently accelerate engine Engine speed increases 2 Check ignition timing Normal
28. TTACHMENT REAR COMPRESSOR Fix the bottom metal and loosen the lock nut Remove the bottom metal Remove the stopper rubber spring from the damper component INSPECTION Measure the rear cushion spring free length SPRING Check the damper rod for deflection or damage cC FREE LENGTH REAR WHEEL BRAKE SUSPENSION REAR CUSHION ASSEMBLY INSTALLATION Assemble the spring spring guide and stopper rubber Apply thread locking agent to the lock nut and install the rear cushion compressor attachment on the damper rod Fix the upper joint and tighten the lock nut TORQUE VALUE 4 0kgf m TOOLS REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR ATTACHMENT INSTALLATION Install the rear cushion Tighten the top and bottom of the cushion with bolt REARICUSHION TORQUE VALUE UPPER SIDE 3 5kgf m LOWER SIDE 3 5kgf m s 7 i E paon 1 YY ty 7 4 M y Y E Ke E erem amp e 4 j SETTING Sons BRAKE SYSTEM 12 0 12 BRAKE SYSTEM SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID BLEEDING BRAKE PAD REPLACEMENT SERVICE INFORMATION GENERAL SAFETY 12 1 12 1 12 3 12 4 BRAKE DISK INSPECTION 12 6 BRAKE CALIPER 12 7 MASTER CYLINDER 12 9 Do not allow foreign material to enter the system when replenishing brake fluid To prevent ch
29. arrow were mark and the brake gt gt panel mark match with each other 2 Brake noise 3 3 Poor braking gt TROUBLESHOOTING Check tire pressure CAUSE OF TROUBLE 1 Cushion spring weak 2 Overloaded 3 Damper oil leaks 1 Fork pipe or cushion rod bent 1 Sliders stuck 2 Cushion stopper rubber damaged Check brake adjustment CAUSE OF TROUBLE 1 Brake shoe worn 2 Brake cam worn 3 Shoe and cam contact surface worn 4 Brake drum worn 1 Brake shoe worn 2 Foreign matter in the brake lining 3 Brake drum and shoe contact surface curved 1 Brake wire defective or expanded 2 Only part of the brake shoe makes contact with the brake drum 3 Clay or moisture inside the brake drum 4 Brake lining contaminated by grease or oil 18 5 TROUBLESHOOTING FUEL GAUGE GAUGE READING INACCURATE IGNITION SWTICH ON 1 Operate the turn signal to check the battery circuit Signal operates satisfactorily 2 Remove the fuel level sensor and move float to check the status of operation Float up Full position Float down Empty position Needle not moving 3 Short circuit the tank unit terminal on the wire harness side Needle not moving 4 Terminal joints loose or faulty connection Signal continuously gt operates dim or does not operate at all Needle moves Needle not moving Unsatisfactory
30. caliper Clean the piston and the inside of the caliper and remove the oil from the seal groove BRAKE CALIPER INSPECTION Caliper Cylinder Check the caliper cylinder bore for scoring scratches or other damage Measure the caliper cylinder I D in X and Y axis at serveral points Replace the caliper cylinder if the largest measurement is beyond the specified service limit SERVICE LIMIT 27 10 mm 12 7 BRAKE SYSTEM CALIPER PISTON MICROMETER LH BRACKET PSTON PIN BUSH DUSTSEAL SLIDE PIN Caliper Piston Measure the caliper piston O D in X and Y axis at several points Replace the caliper piston of the smallest measurement is less than the specified service limit SERVICE LIMIT 26 84 mm BRAKE CALIPER ASSEMBLY INSTALLATION Clean the piston seal and the dust seal with the brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad Make sure that each part is free from dust or dirt Replace the dust seals and piston seals as a set When cleaning with the brake fluid use the specified before reassembly whenever they are removed brake fluid 12 8 Apply the silicone grease to the pin bush Connect the pin bush to the portion of the caliper Install the pad spring in the caliper Install the caliper pin bolt and the slide pin in the caliper Install the brake pad and
31. eder valve stop pumping the brake lever AIR BLEEDING Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level S pes 94 nh N CAUTION To prevent chemical changed do not use different types of brake fluid Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this operation until the brake fluid flows out of the brake bleeder WV z N 2 NOTE Check fluid level often and replenish fluid if the amount of fluid is reduced to the lower level Read the user s manual carefully prior to disassembling or using the brake bleeder Protect the bleeder valve with tape to prevent air from entering the bleeder valve Repeat the above operation until there is no air flowing out of the bleeder hose Squeeze the bleeder valve and operate the brake lever to check the ingress of air Add brake fluid 12 3 BRAKE SYSTEM If the brake bleeder is not used do the following First fill the brake fluid up to the upper limit line Connect the hose to the bleeder valve to receive brake fluid Squeeze the brake lever completely loosen the bleeder valve 1 2 turn and tighten it again Do not release the brake lever unitl the bleeder valve is tightened Release the brake lever slowly to its fullest extent and leave it unattended for a few seconds Repeat the proces
32. emical changes do not mix different types of brake fluid Do not use the old brake fluid again Brake fluid can cause damage to painted plastic and rubber surfaces Take precaution not to allow parts to be contaminated by the brake fluid Do not reuse sealing washers Clean the disassembled parts with brake fluid and check for any clogged passage with compressed air Bleed the brake hose after removing it TROUBLESHOOTING HYDRAULIC DISK BRAKE Braking power unsatisfactory Air in the brake system Moisture in brake fluid Brake pad and disk contaminated Caliper piston seal worn Master cylinder piston seal worn Brake pad worn Caliper inside contaminated Unsatsfactory caliper sliding part operation Lopsided wear of brake pad and disk Low brake fluid level Clogged brake fluid line Disk bent or distorted Caliper piston seized or worn Master cylinder piston seized or worn Disk worn Master cylinder inside contaminated Brake lever bent Hard brake lever movement or unsatisfactory return Brake system clogged Caliper piston seized or worn Unsatisfactory caliper sliding part operation Brake fluid line clogged Caliper piston seal worn Master cylinder piston seized or worn Brake lever bent Brake drag Brake pad and disk contaminated Improper wheel alignment Lopsided wear of brake pad and disk Disk bent or distorted Unsatisfactory caliper sliding part operation Hydraulic system contaminated with dust 12 1 BRAK
33. en pulley shaft spline damaged 6 Faulty transmission 7 Transmission seized Y 2 Vehicle moves slow engine starts but stops gt 1 Shoe spring damaged immediately 2 Clutch outer and weight seized 3 Pivot seized 3 Engine weak at start gt 1 Drive belt worn or slips 2 Weight roller worn 3 Drive pulley bearing seized 4 Weak drive face spring 5 Drive pulley bearing worn or seized Y 4 Engine weak at high speed 1 Drive belt worn or slips 2 Weight roller worn 3 Drive pulley bearing worn 5 Abnormal noise or odor gt 1 Oil or grease spilled on the drive belt and inside pulley 2 Drive belt worn 3 Weak drive face spring 4 Driven pulley bearing worn or seized POOR MECHANICAL PERFORMANCE Check tire pressure CAUSE OF TROUBLE 1 Steering is heavy gt 1 Steering head adjuster excessively tightened 2 Steering cone race or steel ball damaged 2 Wheels wobbling gt Excessive wheel bearing play 2 Rim bent 3 Axle nut loose 3 Motorcycle pulls to one side 1 Front wheel and rear wheel not aligned 2 Front fork bent 18 4 POOR FRONT RE AR SUSPENSION PERFORM ANCE nm 1 Suspension excessively soft c 2 Suspension excessively hard gt 3 Noise from the suspension 1 If the
34. etween the blue yellow of starter and green code STANDARD VALUE 100 Q 20 20 IGNITION TIMING INSPECTION As a CDI device is used this vehicle there is no need for adjusting ignition timing If ignition timing problems occur inspect the CDI unit and the AC generator and replace if any malfunctions are found in the devices Ignition timing inspection well read the instruction manual of timing light or revolution indicator and handle it exactly INDEX SIDE STAND SWITCH IGNITION SYSTEM Warm up the engine Remove the center cover Remove the floor panel Remove the fan cover Connect timing light to the high tension cord When engine rpms are at 1 800 ignition timing is correct if the F mark and crank case index mark are aligned IGNITION TIMING 17 DEGREES 2 BTDC 1 800 rpms N NOTE Index mark must face the spark plug CDI UNIT REMOVAL INSTALLATION Remove the luggage box 3 3 Disconnect the coupler from the CDI unit and remove CDI Unit Install in the reverse order of removal CIRCUIT INSPECTION Remove the coupler from the CDI unit and check the ignition system circuits from the wiring coupler side INSPECTION ITEM CHECKPOINT STANDARD VALUE PULSE GENERATOR BLUEYELLOW AND GREEN 50 2000 20 IGNITION COIL PRIMARYCOIL BLACK YELLOW AND GREEN 0 1 0 5 2 20 C SECONDARY COIL GREEN AND HIGH TENS
35. fficiently charged Main swtich damaged Meter damaged Oil level switch damaged Loose connector Harness disconnection Oil indicator does not turn off when oil is out Oil level switch damaged Green red wire joined 16 1 LIGHTS METER SWITCHES FUEL UNIT REMOVAL Remove the luggage box 43 3 Remove the fuel unit wire from the wire harness Turn the fuel unit fixing unit set cap comp to the left and remove it Remove the fuel unit from the fuel tank Be careful of prevention the fuel unit wire from damaging When disassembling be careful of prevention the float arm from damaging Remove the base packing N NOTE Check for damage INSTALLATION Install the base packing to the fuel tank Install the fuel unit NOTE Install it aligning the part of the fuel unit with the loop part of fuel tank Check the fuel leakage INSPECTION Move the float upward and downward and measure the resistance between the terminals WIRE TERMINAL FLOAT UPPER LINE FLOAT LOWER LINE GREEN AND YELLOW WHITE 22 400 750 GREEN AND BLUE WHITE 400 750 33 BLUE WHITE AND BLUE WHITE 450 750 450 750 16 2 When the measured value differs greatly from the standard value replace the fuel unit OIL LEVEL SWITCH OIL TANK LIGHTS METER SWITCHES OIL LEVEL SWITCH REMOVAL INSTALLATION Remove the luggage box
36. floor side RH cover 3 4 Disconnect the starter wire connector remove the wire from the wire fixing clamp Loosen the 2 starter motor fixing bolts Remove the starter motor Install in the reverse order of removal N NOTE Accurately tighten the earth wire Turn off the main switch prior to servicing the starter motor If power is connected the starter motor may be activated and damaged 15 4 DISASSEMBLY Remove the starter motor screws and remove the motor cover Record the order so the parts can be installed correctly later INSPECTION Check for continuity of the starter motor case Between cord terminal and bracket normal if no continuity Between cord terminal and brush black wire normal if there is continuity If abnormal replace with a new one Measure the brush length Replace the brush if it 1s worn beyond the service limit SERVICE LIMIT 3mm STARTING SYSTEM Check the commutator for Damage or abnormal wear Replace with a new one Discoloration of the commutator bar Replace with a new one Metallic debris between commutator bars Clean it off COMM TATOR Check for continuity between pairs of commutator bars Make a continuity check between individual commutator bars and the armature shaft There should be no continuity Check the bearings Do not rotate smoothly Replace with a new one Loose bea
37. is correctly connected to ensure correct measurement Inspect when there is cylinder compression pressure and with the spark plug cap securely connected to the spark plug Remove the luggage box 23 3 With the ignition coil wire connected contact the peak voltage adaptor to the initial wire adaptor terminal black yellow and ground on vehicle body Turn the main swtich ON operate the starter motor and measure the ignition coil initial side peak voltage CONTACT POINTS BLACK YELLOW TERMINAL BODY EARTH PEAK VOLTAGE OVER 120V N CAUTION When measuring voltage do not touch the metal part of the handle rod as there is the danger of receiving an electric shock EXCITE COIL N CAUTION Assemble the spark pug to the cylinder head inspect in a state having compression pressure Remove the luggage box 3 3 Remove the CDI unit 14 7 Remove the coupler from the CDI unit contact the peak voltage adaptor to the excite coil wire black red and green of the harness side coupler Operate the starter motor and measure the excite coil peak voltage CONTACT POINTS BLACK RED TERMINAL BODY EARTH PEAK VOLTAGE OVER 120V CAUTION When measuring voltage do not touch the metal part of the handle rod as there is the danger of recieving an electric shock 14 4 IGNITION SYSTEM PULSE GENERATOR UNIT COUPLER WIRE HANESS N NOTE
38. ke fluid MASTER CYLINDER INSPECTION Check the piston periphery for kink or scratch Check the primary and secondary cups for wear Measure the O D of the master pin SERVICE LIMIT 10 90 mm 12 9 BRAKE SYSTEM N NOTE If there is any leak of fluid when installing new piston it may indicate the side wear of the cylinder lt MASTER CYLINDER by the direction of the piston contacting face In this case the master cylinder must be replaced also Z N Check the master cylinder for scores scratches or nicks A S UI and replace if necessary SZ Measure the master cylinder I D in X and Y axis at several points E SERVICE LIMIT 11 08 mm CYLINDER GAUGE MASTER CYLINDER ASSEMBLY INSTALLATION MASTER CYLINDER PRIMARY CUP CAUTION SECONDARY CUP Replace the piston spring cups and snap ring as a 2 set Be sure that each part is free from dust or dirt before Uy SNAP RING reassembly E gt When cleaning with the brake fluid use the specified brake fluid VO Coat the piston cup with the fresh brake fluid and SPRING MASTER CYLINDER install it on the piston Install the spring with its larger diameter end toward the master cylinder N CAUTION SPRING MASTER PISTON When installing the cups do not allow the lips to turn inside out Refer to the drawing Note the installation direction of the snap ring Be certain that the sna
39. l STARTERIBINIONIGEAn ML 2 DRIVEIFACE INSPECTION Wear or damage to the pinion reduction gears STARTER PINION Replace with a new one Worn journals Replace with a new one REDUCTION GEAR PINION GEAR Check if the pinion gear moves smoothly along the axis Pinion gear does not move smoothly Replace with a new one 15 7 MEMO 16 LIGHTS METER SWITCHES SERVICE INFORMATION 16 1 HANDLE SWITCH INSPECTION 16 4 TROUBLESHOOTING 16 1 FRONT STOP SWITCH INSPECTION 16 4 FUEL 16 2 BULBS 16 5 OIL LEVEL 16 3 METER 16 6 MAIN SWITCH 16 3 HORN INSPECTION 16 7 SERVICE INFORMATION GENERAL SAFETY Refer to tester owner s manuals when performing continuity inspections Refer to wiring diagram chapter 17 for switch continuity After inspecting and or performing maintenance work make sure the wires and cables are properly placed and connected TROUBLESHOOTING Oil indicator light not operating Fuel meter indicator malfunctioning when there is oil Coupler separated Harness disconnected Float operation malfuction Fuel unit damaged Meter damaged Fuel meter needle unstable Coupler loose Fuel unit damaged Meter damaged Headlight hi lo not operating Bulb malfunction Dimmer switch damaged Burned out fuse Battery insu
40. p ring is seated firmly in the groove Install the rubber boot in the groove properly TOOL SNAP RING PLIERS PRIMARY CUP Install the master cylinder to the handle bar Install the holder with its UP mark facing upwards and align the holder joint with the punch mark on the handle bar Tighten the holder upper bolt first MASTER CYLINDER MASTER CYLINDER BRAKE SYSTEM Install the brake hose to the master cylinder with 2 new sealing washers and the hose bolt TORQUE VALUE 3 5kgf m Connect the brake stop swtich wire Hill the brake fluid and bleed air Install the rear handle cover 3 6 Install the front handle cover 3 6 Install the back mirror 12 11 MEMO 13 BATTERY CHARGING SYSTEM SERVICE INFORMATION 13 1 CHARGING SYSTEM INSPECTION 13 4 CHARGING DEVICES LOCATION 13 2 HEADLIGHT VOLTAGE INSPECTION 13 6 TROUBLESHOOTING 13 3 REGULATOR RECTIFIER INSPECTION 13 6 BATTERY REMOVALANSTALLATION 13 4 GENERATOR 13 7 BATTERY INSPECTION 13 4 13 9 SERVICE INFORMATION Do not place flammable materials near battery when charging This can be a fire hazard as hydrogen gas is created during charging battery Do not allow battery acid to come into contact with clothes skin or eyes Battery acid contact can cause burns or loss of eye sight If contact
41. rator coupler connected incorrectly NORMAL ABNORMAL Y Damaged charging coil Check the lighting coil at the regulator ABNORMAL Inspact the AC generator charging rectifier coupler lighting coil line lighting coil NORMAL gt NORMAL ABNORMAI AC generator coupler connected incorrectly Y Damaged charging lighting coil Check the headlight lighting control voltage ABNORMAL Damaged regulator rectifier darkened headlight NORMAL Y Inspect the headlight register ABNORMAL Damaged headlight register NORMAL Y Inspect the body of the register rectifier ABNORMAL Damaged regulator rectifier NORMAL o Damaged Battery 13 3 CHARGING SYSTEM AC GENERATOR SETTING BOLT EARTH CABLE BATTERY REMOVAL INSTALLATION Loosen the battery cover setting bolt Remove the battery cover After removing the negative terminal of battery firstly must remove the positive terminal of battery Install in the reverse order of removal BATTERY INSPECTION CHARGE LEVEL OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and disconnect the battery terminals Measure the voltage between the battery terminals FULLY CHARGED 13 0 13 2V INSUFFICIENTLY CHARGED Under 12 3V NOTE Use a digital voltmeter when measuring charge level Measure 3
42. resistance 2 Cranking speed is too low Battery is insufficiently charged or kick power is weak 3 Influence of tester sampling time normal state if measured a number of times and shows over the set voltage 4 Excite coil is damaged when 1 3 is okay 1 Peak voltage adaptor is damaged Im k voltage 2 Excite coil is damaged 1 Using a tester with a low internal resistance 2 Cranking speed is too low 2 Battery is insufficiently charged or kick power is weak t1 Maximum voltage is low A 3 Influence of tester sampling time normal state if measured a number of times and shows over the set voltage 2 g 4 Pulse generator is damaged when 1 3 is okay 5 1 Maxi It daptor is d d No or almost no maximum voltage MENU QU eter en rere 2 Pulse generator is damaged 14 3 IGNITION SYSTEM DIGITAL TESTER PEAK VOLTAGE ADAPTOR IGNITION COIL UNIT SIDE INITIAL TERMINAL T IA Lt 712 NN WIRE HARNESS UNIT COUPLER CDI UNIT EXCITE COIL IGNITION SYSTEM INSPECTION PEAK VOLTAGE MEASUREMENT NOTE When sparks are not emitted from spark plug after checking for disconnection in wires and looseness measure peak voltage for each wire Connect the peak voltage adaptor to the digital tester DAELIM PVA MULTI TESTER IGNITION COIL PRIMARY VOLTAGE N NOTE Make sure each wire
43. ring Replace with new one STARTER MOTOR ASSEMBLY Carefully insert the armature shaft into the front bracket Align the front bracket notch with the brush The sliding surcfaces of the brushes be damaged if they are not installed properly RONT ET 15 5 STARTING SYSTEM Insert the brush spring into the brush holder and install the front bracket N NOTE Insert the brush spring with care so that it does not lean in the holder Apply grease to both ends of the armature shaft Install the starter motor cover NOTE The coil may be damaged if the magnet pulls the armature against the case STARTER MOTOR CO ER Align the front bracket with the cover Tighten the washer screw y YT x fs j VS I t p ASHER SCRE 15 6 STARTING SYSTEM STARTER RELAY INSPECTION au STARTER RELAY Remove the luggage box 93 3 5 SWITCH i When battery voltage is applied between the starter relay green yellow wire and yellow red terminals there should be continuity between the red and red white terminals The terminals are distinguished by the corresponding wire color of the wire harness connector STARTER PINION GEAR INSPECTION Remove L side cover 27 2 Remove the drive face 7 6 Remove the starter pinion gear Install in the reverse order of remova
44. roove to the woodruff key and install the flywheel on the crankshaft N CAUTION bolts are magnetically attached to the flywheel Installing the flywheel with anything attached to it could damage the stator coil Hold the flywheel rotor with a holder and tighten the bolt nut to the specified torque Install the cooling fan Install the fan cover Install the luggage box 33 3 CHARGING SYSTEM AC GENERATOR A C GENERATOR CHARGING COIL INSPECTION NOTE This test is done with the starter mounted to the engine Remove the center cover Disconnect the AC generator coupler 23 3 Measure the resistance of the charging coil between the white wire and ground and the lighting coil between the yellow wire and ground STANDARD RESISTANCE 20 C BETWEEN WHITE WIRE AND GROUND 0 4 1 0 2 BETWEEN YELLOW WIRE AND GROUND 0 2 0 8 2 RESISTER INSPECTION Remove the front cover 33 5 Measure the resistance between the register lead wire and ground STANDARD VALUE 20 C RESISTER 6 7 2 5W GREEN BLACK BODY GROUND 6 3 7 1 Q RESISTER 5 9 0 30W PINK BODY GROUND 5 6 6 5 0 N NOTE Problems with the resister are caused by operational problems of the starter 13 9 MEMO 14 IGNITION SYSTEM SERVICE INFORMATION 14 1 EXCITE COIL INSPECTION 14 6 IGNITION DEVICES LOCATION 14 2 PULSE GENERATOR INSPECTION 14 6 TROUBLESHOOTING
45. rth wires Disconnect dimmer 0 2 0 8 20C 5W headlight lighting circuit switch connection Inspect after at least 10 minutes later REGULATOR RECTIFIER INSPECTION BATEERY TERMINAL LAMP TERMINAL B L If the inspection of the harness side proves to be TERMINAL ARRANGEMENT satisfactory check the regulator rectifier coupler for faulty connection and measure the resistance between the terminals of regulator rectifier RESISTANCE VALUE CHARGING TERMINAL EARTH TERMINAL 13 6 CHARGING SYSTEM AC GENERATOR A C GENERATOR REMOVAL Remove the luggage box 3 3 Remove the plug maintenance cover 43 3 Remove the center cover 33 3 Remove the floor side cover 3 4 Remove the floor panel 43 4 Remove the engine hanger side RH cover 23 5 Remove the plug cap Loosen the 3 washer screws remove the fan cover and the fan cover element A B Remove the fan cover rubber Loosen the 2 flange bolts remove the fan cover Loosen the 4 cooling fan fixing flange bolts remove the cooling fan Hold the flywheel with a universal holder TOOL UNIVERSAL HOLDER Remove the flywheel with a ACG rotor puller TOOL ACG ROTOR PULLER 0750 00004 Remove the connector coupler on the wire harness or starter motor Remove the ground wires FLYWHEEL zs o 2 D Loosen the 2 pulse generator fixing flange bolts remove the pulse
46. s specified in item and until there is no more air bubbles coming out of the bleeder valve Check the fluid level often and add fluid 1f the fluid level is near the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Assemble the bleeder valve TORQUE 0 6kgf m Add brake fluid up to upper level Install diaphragm and mater cylinder cap TORQUE VALUE 1 0kgf m BRAKE PAD REPLACEMENT N NOTE When replacing brake pads replace whole set Do not remove the brake hose when replacing brake pads Loosen the hanger pin Loosen the 2 front brake caliper fixing bolts from the front fork Remove the front caliper FIXING BOLTS 12 4 PAD SPRING BRAKE SYSTEM To install a new brake pad into the brake press the piston to return to the original position Remove the hanger pin pad shim and brake pad Verify that the pad spring 15 installed in specific position Install a new brake pad pad shim and hanger pin Install the brake caliper into the left front fork Be careful not to damage the brake pad Tighten the caliper braket bolt TORQUE 2 7kgf m 12 5 BRAKE SYSTEM Tighten the hanger pin HANGER PIN De BRAKE DISK INSPECTION Measure the thickness of the disk SERVICE LIMIT 3 0mm Measure the brake disk thickness at the several points and replace if the smalles
47. shorted 3 Connector and terminals loose 1 Worn brush worn 2 Faulty connection between the rotor and brush 3 Faulty the starter motor subwire connection 4 Terminal loose 1 Wire harness damaged CAUSE OF TROUBLE 1 Battery totally discharged 1 Connector terminal loose 2 Faulty starter relay connector 1 Engine seized 1 Faulty connection between the rotor and brush CAUSE OF TROUBLE 1 Pinion seized Starter relay connection seized 18 7 MEMO
48. t measurement is less then the specified service limit Check the brake disk for bent and twist SERVICE LIMIT 0 4mm Replace the brake disk if the disk for damage or cracks BRAKE CALIPER REMOVAL Remove the brake oil bolts and the brake hose from the brake caliper Remove the caliper from the L front fork and remove the pad spring hanger pin and brake pad 12 6 CYLINDER GAUGE BRAKE SYSTEM Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface Wind the hose joint with cloth to prevent the brake fluid from leaking Clean the removed parts with the brake fluid and make sure that the each port isn t clogged with the compressed air Keep the removed parts in order to avoid dust from adhering DISASSEMBLY Remove the slide pin the L bracket the pin bush the boot and the pin boot and the pin bolt from the caliper If there is any wear or damage in the boot replace it with the new one Wind the caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the brake hose Never use the high pressure air or bring the air gun too close Never touch the inside of the caliper Disassemble the piston seal and the dust seal Pay attention not to damage the inner surface of the
49. the hanger pin in the caliper Connect the brake hose to the caliper and install 2 sealing washers and the brake hose bolt TORQUE 3 5kgf m Install the slide pin cap Fill the brake fluid and bleed air MASTER CYLINDER MASTER CYLINDER SWITCH FRONT STOP MASTER CYLINDER SET MASTER CYLINDER MICROMETER BRAKE SYSTEM MASTER CYLINDER REMOVAL Remove the back mirror Remove the front handle cover 3 6 Remove the rear handle cover 23 6 Disconnect the front brake switch wire Drain the brake fluid Remove the brake hose from the master cylinder N CAUTION Brake fluid causes damage to the painted plastic or rubber parts Do not spill fluid on these parts If contaminated gently wipe off the fluid with a piece of cloth or wash in water Close hose joints properly to prevent leakage of brake fluid Clean the disassembled parts with brake fluid and use compressed air to verify each passage is not clogged Do not allow the disassembled parts to be contaminated by waste material or dust Remove the master cylinder holder and lift out the master cylinder DISASSEMBLY Remove the front stop switch Remove the piston boot cir clip from the master cylinder TOOL SNAP RING PLIERS Remove the washer piston spring from the master cylinder Clean the master cylinder reserve master piston with the recommended bra
50. unexpectedly operating if the main switch is not turned to OFF First check connection with battery and battery charge level before beginning maintenance on the starter motor It is possible for the starter motor coil to become damaged if the starter is operated when the engine does not turn over 15 1 START SWITCH STARTING DEVICES LOCATION STARTING SYSTEM GREEN SWITCH D a uj gt amp C5 2 L A gt na c5 2 rl Kyl SAR Et 77 LS RE WHITE STARTER SWITCH fe YELLOW RE 0 A er i xe 2 1 fa START RELAY STARTER MOTOR GREEN GREEN YELLOW 15 2 TROUBLESHOOTING STARTING SYSTEM Starter motor does not rotate No response from starter motor Check to see if the fuse is burned out Check to turn on the lamp of stop switch With the main switch turned to ON squeeze the brake lever In this state push the starter button and check if a clicking noise then an operating noise is emitted from the starter relay NO CLICK Remove the coupler from the starter replay and inspect the relay coil ground wire CONTINUITY Check starter relay voltage in starter relay coupler with the coupler connected VOLTAGE MEASURED Y Check the operation of the starter relay
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