Service Manual RK1
Contents
1. 6 Cylinder Head Valve Cylinder Head Disassembly Remove the adjustment hole cap for the EX amp IN valve clearance bolt x 6 Firstly remove the camshaft stopper and then drive a 6mm bolt into camshaft Finally remove the camshaft and rocker arm Use a valve compressor to press the valve spring After removed valve split locks release the compressor and then take out spring retainer valve spring and valves A Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve split locks in which can be removed Special Service Tool Valve spring compressor Or with the valve spring remover installer to compress the valve spring directly Then remove the valve and valve spring A Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly Special Service Tool Valve spring remover installer 6 6 Remove valve valve stem and valve spring Cylinder Head Inspection Camshaft Inspect cam lobe height for damaged Service Limit IN Replacement when less than 26 702mm EX Replacement when less than 26 152mm Inspect the camshaft bearing for looseness or wear out If any replace whole set of camshaft and bearing Rocker Arm Measure the cam rocker ar2. 8 3 8 Driving System Remove the clutch weight with special tool Special tool number 1120100 G5 INSTALL Install according to the reverse procedure of remove A Caution Install clutch weight with lubricating oil on the crank shaft otherwise the crankshaft will be damaged Clutch lining Measure each clutch lining thickness Replace it if exceeds service limit Service limit 2 0 mm Clutch Block Replacement Remove snap and washer and the remove clutch block and spring from driving plate Check if spring is damage or insufficient elasticity 8 4 5 TOOL special tool Spring n plate Clutch block 8 Driving System Check if shock absorption rubber is damage or deformation Replace it if necessary Apply with grease onto setting pins Apply with grease onto setting pins But the clutch block should not be greased If so replace it Install new clutch block onto setting pin and then push to specified location Caution Grease or lubricant will damage the clutch block and effect the block s connection capacity Install the spring snap into groove with pliers Install snap ring and mounting plate onto setting pin Shock absorption rubber Spring Shock absorption rubber 8 5 8 Driving System NOTE 8 6 9 Alternator Starting Clutch Mechanism Illustration Starting Clutch Precautions
3. 9 5 9 Alternator Starting Clutch Check the starting driven gear for wear or damage Measure the ID of the starting clutch gear Service Limit ID 32 06 mm or less Check the starting idle gear and shaft for wear or damage Measure the ID of the starting idle gear Service Limit ID 10 05 mm or less Measure the OD of the starting idle gear Service Limit OD 9 94 mm or more Disassembly Remove the hex blots bolt x 3 inside the starting clutch Separate the clutch body and the clutch cover Remove the rollers plugs and springs on the one way clutch Check each rollers and plugs for wear or damage Install rollers plugs and springs Measure the OD of the starting clutch cover Service Limit OD 27 94 mm or more 9 6 Installation Install the components in the reverse procedures of removal Caution Add adhere seal onto the thread of hex socket bolt Torque value 1 0 1 4 kgf m Starting clutch Installation Install idle gear shaft and idle gear Install starting clutch Install the starting driven gear onto the starting clutch Hold the starting driven gear with the universal fixture Tighten the 22mm anti loosen mounting nut and gasket A Caution Add engine oil onto the thread of mounting nut Special service tools Anti loosen mounting nut socket Universal fixture Torque value 9 0 10 0 kgf m 9 Alternator Starting Clutch Moun
4. Pomar e es amaa e soso ESPEC EN 6 CTE Fonewayeuennx 1 80 100 favorema Crankcase bolts right crank 12 1 5 2 0 cover bolt Exhaust pipe bolts Exhaust pipe bolts bolts a 3 0 3 6 1 General Information Trouble Diagnosis The torque values listed in above table are for more important tighten torque values Please see standard values for not listed in the table Standard Torque Values for Reference Tighten Torque e Torus _ Torque 5mm bolt nut 0 45 0 60 kgf m 3mmscrew screw 0 05 0 08 0 05 0 08kgf m m 6mm bolt nut 0 80 1 20 kgf m 4mm screw 0 10 0 15 kgf m 8mm bolt nut 1 80 2 50 kgf m 5mm screw 0 35 0 50 kgf m a 20 300 kam Pt bot nt MEAT 1 10 1 General Information Trouble Diagnosis Troubles Diagnosis A Engine hard to start or can not be started Check and adjustment Fault condition Loosen carburetor drain bolt y to check if there is gasoline inside the carburetor Fuel supplied tom No fuel is supplied to carburetor sufficient carburetor Remove spark plug install it into spark plug cap and perform a spark test against engine ground Weak sparks no spark Check if sparks Perform cylinder compression pressure test Cylinder compression Low compression pressure pressure normal or no pressure Re start by following the at all starting procedures There are some signs of No ignition ignition nut engine can not be started Remove
5. The charging voltage can not exceed the voltage between two battery terminals and the charging current is in the discharging direction The charging voltage and current are too much higher than the standard values The following problems are not related to the charging system correct it if any by following steps indicate in the checking list The standard charging voltage and current can only reach when the revolution of the engine exceeds the specified rpm Bulbs used exceed their rate and consume too much power The replacement battery is aged and does not have enough capacity The charging voltage is normal but the current is not The replacement battery is aged and does not have enough capacity Battery used do not have enough electricity or is over charged The fuse of the ammeter is blown The ammeter is improperly connected The charging current is normal but the voltage is not The fuse of the voltmeter is blown 11 Electrical Equipment Starting switch Main switch 11 7 11 Electrical Equipment REGULATOR INSPECTION Disconnect the 3P connector of the regulator Measurement Main switch Battery voltage connection wire ON Battery Check the parts onto the abnormal wire circuit if the measured values are not within standards If the parts is OK then it is the wire circuit abnormal Replace the regulator if both checks are OK CHARGING COIL INSPECTION Caution The coi
6. Remove the flywheel with the flywheel puller Special service tools Flywheel puller Special tool number 3110000 Alternator Coil Set Removal Remove the couplers of the alternator and pulse generator Remove the 6 bolts for the pulse generator the alternator coil and cable guide Then remove the alternator assembly Caution Do not damage the alternator coil Right Crankcase Cover Removal Remove the right crankcase cover bolt x 7 Remove setting pin and gasket Remove the gasket or foreign materials on the connection surfaces of both the cover and crankcase A Caution Do not damage the connection surfaces ES Flywheel puller Cable guide Pulse generator 9 Alternator Starting Clutch Starting Clutch Starting Clutch Removal Mounting nut Hold the starting driven gear with the universal a fixture Remove the 22mm anti loosen mounting nut and gasket Special service tools lock nut socket Special tool number 9020100 Universal fixture Caution The mounting nut is left turn thread Remove the starting driven gear Remove starting clutch starting idle gear and shaft Starting Clutch Inspection Install the starting clutch onto the starting driven gear Hold the starting clutch and turn the starting driven gear The starting driven gear should can be turned in the motion of C W and can not be turned in C C W
7. Torque value 1 3 1 7 kgf m Fill out oil to the oil filler Oil viscosity SAE 10W 30 Recommended King Mate serial oils Engine oil quantity Replacement 800 c c After oil replaced insert ignition key into the re set bottom under instrument panel so that the oil indicator is changed from red to green and set oil replacement mileage to zero Install dipstick start the engine for running several minutes Turn off engine and check oil level again if within standard level after 3 5 minutes Check if engine oil leaks 3 Lubrication System 3 3 3 Lubrication System Oil Pump Removal Remove the alternator refer to chapter 10 the oil pump driving gear clamp and the gear Remove the engine right cover Remove oil pump body screws 3 screws Remove the one way clutch and starting gear nutx 1 Make sure that the pump axle can be rotated Oil Pump Disassembly freely Remove the screws on oil pump cover and Remove the oil pump cover screws x 2 disassemble the pump as illustration shown then screws x 2 Engine right Starting Starting clutch Oil pump shaft Outer rotor Inner rotor Oil pump outer cover Right crankcase cover 3 4 3 Lubrication System Oil Pump Inspection Check the clearance between oil pump body and outer rotor Limit below 0 12mm Check clearance between inner and outer rotors Limit below 0 12mm Check clearance between rot
8. Bookmark not defined Left Crankcase Cover8 Error Bookmark no Clutch Driven Pulley8 Error Bookmark no Mechanism Illustration 8 Driving System Maintenance Description PRECAUTIONS IN OPERATION e Driving pulley clutch and driven pulley can be serviced on the motorcycle e Driving belt and driving pulley surface must be free of grease Specification ID Inner Diameter OD Outer diameter Torque value Sliding pulley nut 5 0 6 0 kgf m Clutch jacket nut 5 0 6 0 kgf m driving pulley nut 5 0 6 0 kgf m Trouble Diagnosis Engine can be started but motorcycle can not be moved 1 Worn driving Belt 2 Worn tilt plate 3 Worn or damaged clutch lining 4 Broken driven pulley Shudder or misfire when driving 1 Broken clutch lining 2 Worn clutch lining Insufficient horsepower or poor high speed performance 1 Worn driving belt 2 Insufficient spring capacity of driven pulley 3 Worn roller 4 Driven pulley operation un smoothly 8 2 Unit mm Special Service Tools Clutch spring compressor Bearing puller inner type Clutch mounting nut wrench Universal fixture 8 Driving System Remove Installation Remove Remove 1 nut of the clutch outer comp Remove the clutch outer comp Remove the needle bearing and washer of the crank shaft Caution Needle bearing has to lubricate with lubricating oil once two hour or will cause damage Remove the special nut 24mm
9. Check ignition timing using ignition lamp Normal Abnormal Adjust the air screw of carburetor Air sucked through carburetor gasket Remove spark plug install spark plug into spark plug cap and perform spark test against engine ground D Engine runs sluggish High speed 1 Incorrect ignition timing malfunction of CDI or AC alternator _ OPOD o OPOD Rich mixture loosen the screw Lean mixture tighten the screw Poor heat insulation gasket Carburetor lock loose Poor intake gasket Poor carburetor O ring Vacuum hose crack Spark plug fouled Malfunction of CDI Malfunction of AC generator Malfunction of ignition coil Open or short circuit in spark plug leads Malfunction of main switch Check and adjustment and Check and adjustment Fault condition condition Probablecauses Probablecauses Check ignition timing Check for fuel supplying system in automatic fuel cup Check if carburetor clogged No clogged Clogged n Malfunction of CDI Malfunction of AC alternator Insufficient fuel in fuel tank Fuel filter clogged Restricted fuel tank vent Cleaning 1 13 1 General Information Trouble Diagnosis E Clutch driving and driving pulley FAULT CONDITIONS PROBABLE CAUSES can niet DeMnoued 2 Clutch weights broken Engine running and misfire as motorcycle initial forward moving or jumping suddenly 1 Clutch wei
10. Engine oil filter cover 1 3 1 7 kgf m Gear oil drain plug 0 8 1 2 kgf m Gear oil filling bolt 1 0 1 4 kgf m Oil pump connection screw 0 1 0 3 kgf m Trouble Diagnosis Low engine oil level Dirty oil e Oil leaking No oil change in periodical e Valve guide or seat worn out e Cylinder head gasket damage e Piston ring worn out e Piston ring worn out Low Oil Pressure e Low engine oil level e Clogged in oil strainer circuits or pipes Oil pump damage 3 2 Engine Oil Turn off engine and park the motorcycle in flat surface with main stand Check oil level with oil dipstick after 3 5 minutes Do not screw the dipstick into engine as checking If oil level is nearly low level fill out recommended oil to upper level Oil Replacement A Caution Drain oil as engine warmed up so that make sure oil can be drained smoothly and completely Place an oil pan under the motorcycle and remove oil strainer cap Make sure if the aluminum washer of the draining bolt is damaged If so replace it with new one Install the drain bolt and tighten it Torque value 3 5 4 5 kgf m Cleaning Engine Oil Strainer Remove the oil strainer cap Remove oil strainer and spring Clean oil strainer Recommended using compressed air to clean dirty foreign Check if the strainer and O ring of the oil strainer are broken Replace with new one if found Install the oil strainer and spring Install the oil strainer cap and tighten it
11. SYSTEM Installation Of Carburetor Install carburetor in the reverse order of removal Following adjustments must be made after installation Throttle valve cable clearance adjustment Idle speed adjustment Idle Speed Adjustment A Caution Fuel amount adjust screw was set at factory so no adjustment is needed Note the number of turns it takes to screw it all the way in for ease of installation Never screw in forcedly to avoid damaging the screw seat The main stand must be used to support the motorcycle to perform the Use a tachometer when adjusting engine RPM Screw in adjustment screw gently then back up to standard turns Standard turns 1 1 2 3 4 turns Warm up engine adjust throttle valve stopper screw to standard RPM Idle speed rpm 1700 100 rpm Connect the sampling hose of exhaust analyzer to exhaust front end Press test key on the analyzer Adjust the air volume adjustment screw and read CO reading on the analyzer CO standard value 1 0 1 5 Accelerate in gradual increments make sure both rpm and CO value are in standard values after engine running in stable If rom and CO value fluctuated repeat the procedures described above for adjusting to standard value 4 6 Throttle valve cable boltx2 5 REMOVAL OF ENGINE Mechanism Illustration Starting button Main switch CDI unit a Regulator a Plug cap _ Starting relay Battery re u
12. exceed standard value it means the spark plug cap is in not good Replacement Remove the ignition coil bolt to replace the ignition coil if necessary PULSATOR A Caution Checking pulsator can be done on engine But the spark plug must be installed onto the cylinder head and cylinder compression pressure must be in normal condition Check Remove the pulsator connector Measure the resistance between blue yellow terminal on engine side and frame ground Standard 50 2000 20 C Replace the alternator if the measured value exceeds standard value Exciting coil Remove the exciting coil connector Measure the resistance between black red wire on engine side and frame ground Standard 400 800N 20 C Replace the alternator if the measured value exceeds the standard value 11 Electrical Equipment 11 11 11 Electrical Equipment Starting System Starting Circuit Fuse 7A Battery Main switch Red Red Start motor Start relay Start switch pad mojjax Start Relay Inspection Turn main switch to on Then press start button to check if there a click sound It is normal if there is a click sound Disconnect the battery negative terminal Remove the battery positive connection and starting motor wires from the start relay large pin Remove the power control connector of the start relay Connect a Ohmmeter between the start relay l
13. front end of EXH Pipe Remove bolt of the EXH Pipe stay boltx1 NSTALL Install according to the reverse procedure of remove 5 4 throttle valve cable fuel hose Remove the connector between EXH Pipe and Muffler with spring springx2 Remove the ENG Seat fixed plate And remove the ENG boltx4 INSTALL Install according to the reverse procedure of remove 5 REMOVAL OF ENGINE 5 5 5 REMOVAL OF ENGINE NOTES 5 6 6 Cylinder Head Valve Mechanism Illustration Valve Stem Replacement Precautions In Operation Valve Seat Inspection And Service 6 10 Troubleshooting Cylinder Head Reassembly Cylinder Head Removal Cylinder Head Installation Cylinder Head Disassembly Valve Clearance Adjustment Cylinder Head Inspection Mechanism Illustration 1 0 1 4 kgf m 0 7 1 1 kgf m 2 0 2 4kgf m 1 0 1 4kgf m SS N 0 8 1 2kgf m 1 0 1 4kgf m 6 Cylinder Head Valve Precautions In Operation General Information e This chapter is contained maintenance and service for cylinder head valve and camshaft as well as rocker arm e Cylinder head service cannot be carried out when engine is in frame Specification Unit mm Compression pressure 12 2 kg cm Den 27 020 27 180 26 702 Camshaft Height of cam lobe l Rocker ID of valve rocker arm 10 000 10 015 10 100 arm OD of valve rocker arm shaft 10 966 10 984 10 910 OD of valve stem 4 9
14. if procedures are not A Caution followed Limits to use SAE 10W 30 API SG class oil Warranty will not cover D Engine oil the damage that caused by not apply with the limited engine oil Recommended oil KING MATE G 3 oil King Mate G 3 is recommended KING MATE G 3 U Gear cil King Mate gear oil HYPOID GEAR OIL is recommended SAE 85W 140 Apply sealant medium strength sealant should be used unless eo Locking sealant otherwise specified i Oil seal Apply with lubricant sten Special tools Special service tools L 1 correct Meaning correct installation Meaning wrong installation Indication of components dai Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid Indicates position and operation directions w MAS Components assembly directions each other Indicates where the bolt installation direction means that bolt cross through the component invisibility Replace with a new part before installation jm 1 General Information Trouble Diagnosis General safety Carbon monoxide If you must run your engine ensure the place is well ventilated Never run your engine in a closed area Run your engine in an open area if you have to run your engine in a closed area be sure to use an extractor Caution Exhaust contains toxic gas which may cause one to lose consciousness and even result in death Gasoline Gasoline is a low ignition point and explosive mate
15. plug with new one A Caution Make sure each wire connection is correct and test as required Even the wire connection is in correct sometimes it might not be tested occurred Connect the high voltage shunt with a multi meter or input a resistor in the 10M 10CV of voltage meter Connect ignition coil wires and connect a shunt between primary terminal black yellow and green and frame ground Press the starting motor button or starting lever to test the max primary voltage of ignition coil Connection connect terminal to green side and to black yellow side Min voltage Above 95 V A Caution Do not touch metal parts on the test probe with fingers to avoid electric shock Primary coil check Disconnect the primary coil connector and check the resistance between primary coil terminals Standard 0 210 10 Q at 20 C Primary coil is good if resistance within standard Primary coil is broken if resistance is infinite Replace the coil 11 10 I Secondary coil Attached the spark plug cap measure the resistance between plug cap side and green terminal Standard value 7 12 kQ 20 C Remove the spark plug cap measure the resistance between plug cap side and green terminal Standard value 3 5 kQ 20 C Secondary coil is good if resistance within standard Secondary coil is broken if resistance is infinite If the spark plug cap attached and the measured value is
16. seat If the valve and the valve seat still can not be matched sealing after grinded replace it with new one 6 10 Valve Seat Inspection If the valve seat is too width narrow or rough correct it Valve seat width Service limit 1 6 mm Check the contact condition of valve seat Valve Seat Grinding The worn valve seat has to be grinded with valve seat chamfer cutter Use 45 valve seat chamfer cutter to cut any rough or uneven surface from valve seat A Caution After valve guide had been replaced it has to be grinded with 45 valve seal chamfer cutter to correct its seat face Use 32 cutter to cut a quarter upper part out Use 60 cutter to cut a quarter lower part out Remove the cutter and check new valve seat Use 45 cutter to grind the valve seat to specified width A Caution Make sure that all roughness and uneven faces had been grinded Grind valve seat again if necessary 6 Cylinder Head Valve Rouahness N Old valve seat width Se Jaze so a E valve seat width N 60 TA 6 Cylinder Head Valve Coat the valve seat surface with red paint Install the valve through valve guide until the valve contacting with valve seat slightly press down the valve but do nat rotate it so that a seal track will be created on contact surface A Caution The contact surfaces of valve and valve seat are very impo
17. the right crankcase Remove the crankshaft from the left crankcase Remove the cam chain Remove the gasket and setting pin bolt x 2 Scrape gasket residues off the crankcase contact surface Caution e Check if the right amp left bearings are press in the crankshaft Do not damage contact surface of the crankcase Soap the gasket residues into solvent and the residues will be removed easily Remove oil seal from the left crankcase side cam chain 10 Crankcase Crankshaft Crankshaft Inspection Measure left and right clearance of connecting rod big end Service limit Replace when it is more than 0 55 mm Measure the radical clearance of the big end at the vertical directions Service limit 0 05 mm Place the crankshaft onto a V block and measure run out of the crankshaft with dial gauge Service limit 0 10 mm Bearing Inspection Rotate the bearing with fingers and make sure the bearing can be rotated smoothly and quietly Check if the inner ring is connected onto the crankshaft tightly Replace crankshaft as a set when noise or looseness is detected 10 4 a learance 10 Crankcase Crankshaft Assembly Of Crankcase Install cam chain into the chain hole of the left crankcase and then split out the cam chain Dowel pins Caution Do not damage the cam chain as installing the crankshaft Install crankshaft int
18. 50 4 975 4 900 Clearance between 0 010 0 037 0 080 valve stem and guide 0 025 0 062 0 100 Free length of valve spring 32 400 29 500 Valve seat width 1 000 1 600 Connection Flatness of cylinder head Fa 0 050 Torque Value Cylinder head bolt 1 0 1 4kgf m Cylinder head bolt LH 1 0 1 4kgf m Cylinder head Nut 1 8 2 2kgf m apply with oil on bolt thread amp seat Sealing bolt of timing chain auto tensioner 0 8 1 2kgf m Bolt of timing chain auto tensioner 1 0 1 4kgf m Timing gear cover bolts 0 7 1 1kgf m apply with oil on bolt thread amp seat Spark plug 1 0 1 4kgf m Tools Special service tools Valve reamer 5 0mm Valve guide driver 5 0mm Valve spring compressor 6 2 6 Cylinder Head Valve Troubleshooting Engine performance will be effected by troubles on engine top end The troubles usually can be determinated or by performing cylinder compression test and judging the abnormal noise generated Rough Idle Low compression pressure Low compression pressure 1 Valve Improper valve adjustment Burnt or bended valve Improper valve timing Valve spring damaged Valve carbon Poor sealing on valve seat Improper spark plug installation 2 Cylinder head e Cylinder head gasket leaking or damage e Tilt or crack cylinder surface 3 Piston e Piston ring worn out High compression pressure e Too much carbon deposit on combustion chamber or piston head Noise Improper valve clearance adjustment Burnt va
19. Forward This service manual contains the technical data of each component inspection and repair for the RK1 The manual is shown with illustrations and focused on Service Procedures Operation Key Points and Inspection Adjustment so that provides technician with service guidelines If the style and construction of the ENGINE OR ANYTHING are different from that of the photos pictures shown in this manual the actual vehicle shall prevail Specifications are subject to change without notice This manual that contains all data illustration indication and specifications is based on current production information We reserve the right to make changes at any time without notice and without incurring any obligation whatever No part of this manual can be duplicated by any means without written permission Service Department How to Use This Manual This service manual describes basic information of different system parts and system inspection service for RK1 In addition please refer to the manual contents in detailed for the model you serviced in inspection and adjustment The first chapter covers general information and trouble diagnosis The second chapter covers service maintenance and special service tools information The third to the eleventh chapters cover engine fuel systems and driving systems The twelfth to fifteenth chapters are contained the parts set of assembly body The sixteenth chapter is
20. ach of children Brake shoe Do not use an compressed air or a dry brush to clean components of the brake system use a vacuum cleaner or the equivalent to avoid asbestos dust flying Caution Inhaling asbestos dust may cause disorders and cancer of the breathing system Brake fluid A Caution Spilling brake fluid on painted plastic or rubber parts may cause damage to the parts Place a clean towel on the above mentioned parts for protection when servicing the brake system Keep brake fluid beyond reach of children 1 General Information Trouble Diagnosis Service Precautions Always use with RK1 genuine parts and recommended oils Using non designed parts for RK1 motorcycle may damage the motor Cycle Special tools are designed for remove and install of components without damaging the parts being worked on Using wrong tools may result in parts damaged When servicing this motorcycle use only metric tools Metric bolts nuts and screws are not interchangeable with the English system using wrong tools and fasteners may damage this vehicle Clean the outside of the parts or the cover before removing it from the motorcycle Otherwise dirt and deposit accumulated on the part s surface may fall into the engine chassis or brake system to cause a damage Wash and clean parts with high ignition point solvent and blow dry with compressed air Pay special attention to O rings or oil seals becaus
21. arge pins Connect the green yellow wire to battery positive terminal and the green yellow wire to battery negative terminal Check the continuity between the start relay large pins If it is not continuity then replace the start relay 11 12 11 Electrical Equipment START MOTOR REMOVAL Remove starting motor wire from the big terminal of start relay Remove the start motor mounting bolt x 2 Remove the starting motor Starting Motor Installation Install the motor and other components in reverse procedure of removal 11 13 11 Electrical Equipment Switch Main Switch Inspection Disconnect main switch leads connector Check connector terminals for continuity f Black esc pes mu Br oe Remove the main switch connector and nut Remove the main switch Install the main switch and other components in reverse procedure of removal STARING MOTOR BUTTON PUSH BUTTON 11 14 13 Wiring Diagram RK1 Wiring Diagram START MAIN SW START SW START MAG SW MOTOR BT el 1 y MO e Y E if N ao IE o dio a ii SX ook o El 7 ko CDI UNIT ACG REG REC IG COIL EARTH 13 1 13 Wiring Diagram NOTE 13 2
22. diameter Service Limit IN gt 4 90 mm EX 4 90 mm Valve Guide Caution Before measuring the valve guide clean carbon deposits with reamer Special Service Tool 5 0mm valve guide reamer Measure and record each valve guide inner diameters Service limit 5 03 mm The difference that the inner diameter of valve guide deducts the outer diameter of valve stem is the clearance between the valve stem and valve guide Service Limit 5 03 mm A Caution If clearance between valve stem and valve guide exceeded service limit check whether the new clearance that only replaces new valve guide is within service limit or not If so replace valve guide Correct it with reamer after replacement If clearance still exceeds service limit after replaced valve guide replace valve stem too A Caution It has to correct valve seat when replacing valve guide Valve Stem Replacement Heat up cylinder head to 100 150 C with heated plate or toaster A Caution e Do not let torch heat cylinder head directly Otherwise the cylinder head may be deformed as heating it Wear on a pair of glove to protect your hands when operating 6 Cylinder Head Valve 5 0mm valve guide reamer 5 0mm valve guide driver 6 9 6 Cylinder Head Valve Hold the cylinder head and then press out old 5 0mm valve valve guide from combustion chamber side 13mm LT guide driver Tool Valve guid
23. e driver 5 mm 0 15in 3 k LAA l P SAW A Caution ir e Check if new valve guide is deformation y N after pressed it in e When pressing in the new valve guide Y cylinder head still have to be kept in 100 1500 i i hy i i u Adjust the valve guide driver and let valve guide I height is in 13mm Press in new valve guide from rocker arm side Tool Valve guide driver 5 mm Wait for the cylinder head cooling down to room temperature and then correct the new valve guide with reamer A Caution e Using cutting oil when correcting valve guide with a reamer 5 0mm valve guide reamer e Turn the reamer in same direction when it be inserted or rotated Correct valve seat and clean up all metal residues from cylinder head Tool Valve guide reamer 5 mm Valve Seat Inspection And Service Clean up all carbon deposits onto intake and exhaust valves Apply with emery slightly onto valve contact face Grind valve seat with a rubber hose or other manual grinding tool A Caution Do not let emery enter into between valve stem and valve guide Clean up the emery after corrected and apply with red paint onto contact faces of valve and valve seat Remove the valve and check its contact face AN 3 AAA Caution eeM Valve seat ca a a a a a a E z LaL width Replace the valve with new one if valve seal is roughness wear out or incomplete contacted with valve
24. e most cleaning agents have an adverse effect on them Never bend or twist a control cable to prevent stiff control and premature worn out Rubber parts may become deteriorated when old and prone to be damaged by solvent and oil Check these parts before installation to make sure that they are in good condition replace if necessary When loosening a component which has different sized fasteners operate with a diagonal pattern and work from inside out Loosen the small fasteners first If the bigger ones are loosen first small fasteners may receive too much stress Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions depth distance or position Components not to be reused should be replaced when disassembled including gaskets metal seal rings O rings oil seals snap rings and split pins EA E 1 General Information Trouble Diagnosis The length of bolts and screws for assemblies cover plates or boxes is different from one another be sure they are correctly installed In case of confusion Insert the bolt into the hole to compare its length with other bolts if its length out side the hole is the same with other bolts it is a correct bolt Bolts for the same assemb
25. e wires as removing a connector or wires Hold the connector body O x A rE x Je PEN Secure wires and wire harnesses to the frame with respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire Make sure if the connector pins are bent h extruded or loosen A x X Insert the connector completely Wire band and wire harness have to be If there are two lockers on two connector sides clamped secured properly make sure the lockers are locked in properly Check if any wire loose Check if the connector is covered by the twin Do not squeeze wires against the weld or its connector boot completely and secured clamp x O x 1 General Information Trouble Diagnosis Do not let the wire harness contact with rotating moving or vibrating components as routing the harness Keep wire narnesses tar away trom tne hot parts F My Route wire harnesses to avoid sharp edges or corners and also avoid the projected ends of bolts and screws ia A i Route harnesses so that they neither pull too tight nor have excessive slack viL NEVER TOO k Protect wires or wire harnesses with electrical tape or tube if they contact a sharp edge or corner Thoroughly clean the surface where tape is to be applied e Secure the rubber boot firmly as applying it on wire harness gt A them l
26. el pump Starting motor Eng Set fixed plate a ee gt i i l i i i i ia j r Ignition coil i E p a Carburetor Throttle cable Eng Ass y fixed base 5 1 5 REMOVAL OF ENGINE Operational Precautions General Information Engine must be supported by a bracket or adjustable tool in height The following parts can be serviced with the engine installed on the frame 1 Throttle valve 2 Driving disk driving belt clutch and transporting disk 3 Final reduction gear mechanism Specification Engine Oil Capacity Gear Oil Capacity Torque Values Nut of rear wheel axle Nut of exhaust connection Bolt of exhaust fixed Bolt of rear bracket 9 2 Replacement Disassemble Replacement Disassemble Specification 800 c c 1000 c c 100 c c 110 c c 2 9 3 5 kgf m 11 0 13 0 kgf m 0 5 1 0 kgf m 3 0 3 6 kgf m 3 0 3 6 kgf m 5 REMOVAL OF ENGINE Engine Removal Remove the starting relay cable Remove the battery box and battery box nutx2 Remove the battery negative cable Remove the battery positive cable Remove the connector of CDI wire and regulator wire Remove the main switch and starting button wire starting button 5 REMOVAL OF ENGINE Remove the throttle valve cable Remove fuel hose vacuum hose Remove the connector of ACG wire and Ignition coil Remove the cap nut cap nut x 2 from the
27. electrical equipment The seventh chapter is for wiring diagram Please see index of content for quick having the special parts and system information Page Content Contents Index 1 1 1 14 2 1 2 10 3 1 3 8 4 1 4 14 5 1 5 10 6 1 6 16 7 1 7 8 8 1 8 14 General Information Trouble Diagnosis Maintenance Information Lubrication System Fuel System Engine Removal Cylinder Head Valve Cylinder Piston V Type Belt Driving System Foot Starter 2 W IN u o Y 0 9 1 9 6 10 1 10 10 Final Driving Mechanism Alternator Starting Clutch H O H H 11 1 11 6 12 1 12 14 13 1 13 12 14 1 14 8 15 1 15 4 16 1 16 22 17 1 17 2 Crankcase Crankshaft Body Cover Brake System Steering Front Wheel Suspension Rear Wheel Suspension Electrical Equipment Wiring Diagram i ESS ES IS E NE Ko Kun ES Kup EN 1 General Information Trouble Diagnosis Symbols And Marks General safety Service Precautions Symbols And Marks Symbols and marks are used in this manual to indicate what and where the special service are needed in case supplemental information is procedures needed for these symbols and marks explanations will be added to the text instead of using the symbols or marks A Means that serious injury or even death may result if procedures are Warning not followed Means that equipment damages may result
28. ghts spring broken 2 Clutch outer stuck with clutch weights 3 Connection parts in clutch and shaft worn out or burned 1 14 2 Maintenance Information Precautions In Operation Spark Plug Periodical Maintenance Driving System Schedule Battery Lubrication System Special Service Tools Catalogue Fuel System Precautions In Operation Specification wen 1000 c c E Oil F Mark in idling speed BTDC 132 1700 rpm Full timing advanced BTDC 27 8000 rpm Idling speed 1600 100rpm 2 1 3 Lubrication System Mechanism Illustration Connecting rod Cam Shaft Rock Arm Forcedly lubrication Inner passage Scoop lubrication Oil strainer Crankshaft Oil pump 3 Lubrication System Operational Precautions General Information e This chapter contains maintenance operations for the engine oil pump engine oil and gear oil Specifications Engine oil quantity Disassembly 1000 c c Replacement 800 c c Oil viscosity Oil viscosity SAE 10W 30 or equivalent Recommended King Mate SAF 30 40 serial oils n SEE Gear Oil Disassembly 110 c c SAE 10W 40 Replacement 100 c c SAE 10 30 Oil viscosity of gear oil SAE 85W 140 ee Recommended King Mate 20 F gear oil series HYPOID GEAR OIL unit mm E Oil pump Clearance between outer rotor and body Coa Be l Clearance between rotor side and body 0 05 0 10 Torque value Engine oil drain plug 3 5 4 5 kgf m
29. gs and place them respective into cylinder below 20mm of cylinder top Measure each piston ring gaps A Caution Push the piston rings into cylinder with piston top end in parallel motion Top ring replace if over 0 5 mm 2 ring replace if over 0 65 mm 7 Cylinder Piston Piston ring MN te e Tin in TR Feeler gauge Piston Piston rings 1 5 7 Cylinder Piston Measure the outer diameter of piston pin Service Limit 14 960 mm Measure the inner diameter of connecting rod small end Service Limit 15 060 mm Measure the inner diameter of piston pin boll 15 040 mm Measure piston outer diameter A Caution The measurement position is 10 mm distance from piston bottom side and 90 to piston pin Service limit 57 300 mm Compare measured value with service limit to calculate the clearance between piston and cylinder 7 6 7 Cylinder Piston Piston Ring Installation Clean up piston top ring groove and piston shirt Install the piston ring onto piston carefully Place the openings of piston ring as diagram shown A Caution e Do not damage piston and piston rings as installation All marks on the piston rings must be forwarded to up side Make sure that all piston rings can be rotated freely after installed Side ring Spacer Side ring Top groove 2 groove Oil groove Oil ri
30. harged less 12 3V at 20 C 11 4 Intermittent power supply Loose charging system connection Loose battery cables Loose connection or short circuit in discharging system Loose connection or short circuit in lighting system Charging system failure burn Fuse Loose broken or shorted wire or wire connection Faulty voltage regulator Faulty alternator Weak start motor Poor charging system The battery is not fully charged Poor connection in the windings The motor gear is jammed by foreign material Starter motor is working but engine does not crank Poor start motor pinion The start motor run in reverse direction Poor battery 11 Electrical Equipment Charging system Charging wire circuit HUM attery Alternator uat ij usa Charging Connect the battery charger s positive terminal to battery s positive post Connect the battery charger s positive terminal to battery s positive post Charging current 0 5A 5 0A Charging time 5 10H 0 5H A Warning Strictly keep flames away from a charging battery The charging ON OFF is controlled by the charger s switch Do not control the charging by battery jump wires A Caution e Quick charge a battery should be used only in an emergency Make sure the current and charging time of above description The battery will be damaged by to
31. in Operation Right Crankcase Cover Alternator Removal Installation Alternator Coil Set Removal Mounted Coil Set Installation Right Crankcase Cover Flywheel Installation Removal D 9 0 10 0 kgf m E 1 0 1 4 kgf m 1 5 2 0 kgf m 1 3 1 7 kgf m 9 Alternator Starting Clutch Precautions in Operation General information e Refer to chapter 5 Engine removal and installation e Refer to chapter 1 The troubleshooting and inspection of alternator e Refer to chapter 16 The service procedures and precaution items of starter motor Specification Unit mm ID of starting clutch gear 32 06mm OD of starting clutch flange 27 94mm ID of starting reduction gear 10 05mm OD of starting reduction gear shaft Torque value Flywheel nut 5 0 6 0 kgf m Bolt 8mm 1 5 2 0 kgf m Oil screen cover 1 3 1 7 kgf m Starting clutch mounting bolt 9 0 10 0 kgf m with oil on the thread Starting clutch hex socket bolt 1 0 1 4 kgf m with adhesive Special service tools Flywheel puller Universal fixture 9 2 9 Alternator Starting Clutch Alternator Removal Crankshaft position sensor Fan Fan shroud Bolt x 2 Cable guide Remove Remove the cooling fan cover screw x 2 bolt x 3 Remove the cooling fan bolt x 4 Hold the flywheel with the universal fixture Special service tool universal holder Special tool number 2210100 Universal holder 9 Alternator Starting Clutch
32. ing fuel level to increase and as a result fuel flooding A worn out or dirty float valve must be replaced with a new a new one 4 4 screw x 2 isu Float needle valve Float pin Float Remove main jet fuel needle jet holder fuel needle jet slow jet air and stop adjustment screw A Cautions e Take care not to damage jets and adjust screw Before removing adjustment screw turn it all the way down and note the number of turns Do not turn adjustment screw forcefully to avoid damaging valve seat face Clean jets with cleaning fluid Then use compressed air to blow dirt off Blow carburetor body passages with compressed air Installation Install main jet fuel needle jet seat fuel needle jet slow speed jet and air stop adjustment screw A Cautions Set the adjustment screw in according to number of turns noted before it was removed Install the float valve float and float pin Checking Fuel Level Cautions Check again to ensure float valve float for proper installation To ensure correct measurement position the float meter in such a way so that float chamber face is vertical to the main jet Fuel level 14 8 mm 4 FUEL INJECTION SYSTEM Fuel needle jet Main jet a lt i Fuel needle holder Slow jet we air adjustment Hid stop adjustment screw 4 FUEL INJECTION
33. install valve spring retainers onto the valve as assembling N Caution In order to avoid damaging the valve stem and the cylinder head in the combustion chamber place a rag between the valve spring remover installer as compressing the valve spring directly With the valve spring remover installer compress the valve spring directly Then remove the valve and valve spring Special Service Tool Valve spring remover installer Tap valve stem to make valve retainer and valve stem sealing properly A Caution Place and hold cylinder head on to working table and place a rag against onto the valve so that can prevent damage valve stem and cylinder head 6 Cylinder Head Valve 6 13 6 Cylinder Head Valve Install the camshaft onto the cylinder head and then the rocker arm and the rocker arm shaft Lock the lock plate after rotate the rocker arm shaft to properly position A Caution There is different shapes on the top end of rocker arm shaft The machined surface on the rocker arm shaft has to face toward exhaust side and then the larger surface has to align with the bolt hole of cylinder Cylinder Head Installation Install the lock pins and new cylinder head gasket onto the cylinder head Install the camshaft chain plate Install the cylinder head Tighten the 4 nuts onto the cylinder head top end and then the 2 cylinder head mounting bolts on its side Torq
34. ion Unit mm ICON INC Cylinder Cylindrical roundness Po Cylindrical roundness Clearance between 0 025 0 060 piston rings Piston Piston ring 0 015 0 050 Ring end gap 0 250 0 400 Oil ring side 0 200 0 800 rail OD of piston 57 370 57 390 Lower endup 9 Piston OD measurement position mm of piston skirt Trouble Diagnosis Low Or Unstable Compression Pressure e Cylinder or piston ring worn out High Compression Pressure Carbon deposit onto the piston amp combustion chamber Knock or Noise e Cylinder or piston ring worn out Carbon deposits on cylinder head top side e Piston pin hole and piston pin wear out 7 2 Smoking in Exhaust Pipe e Piston or piston ring worn out e Piston ring installation improperly Cylinder or piston damage Engine Overheat e Carbon deposits on cylinder head top side Cylinder Removal Remove cylinder head refer to chapter 6 Remove 2 bolts and then take out the cam chain auto tensioner Remove cam chain plate Remove cylinder Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase 7 3 7 Cylinder Piston Cover the holes of crankcase and cam chain with a piece of cloth Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase Caution To soap the residues into solvent so that the residues can be removed more ea
35. l need not be removed from engine as conduct this test At the alternator side from the regulator connector measure the resistor between green and white wires Standard value 0 16 0 80 11 8 regulator 11 Electrical Equipment Ignition System Ignition System Circuit Blue Yellow Green Black Yellow Black Red Exciter coil Black White Pulsator Main switch Ignition Coil Alternator CDI UNIT Removal Remove the battery cover then the CDI unit can be removed from the battery cover Check Disconnect the connector from the CDI unit Make the following inspection at each terminal of the harness side connector Continuity as main switch OFF Ignition Coil Green high voltage cable w o Cap 3 5KO Secondary Black yellow green 0 210 10 Green high voltage cable w Cap 7 12KQ 11 9 11 Electrical Equipment IGNITION COIL Removal Remove spark plug cap Remove the primary coil wire of ignition coil Remove the fix bolts for the ignition coil and remove the coil Install the coil in reverse order of removal A Caution Install primary coil with black yellow lead connected to black connector and green lead connected to green connector Spark plug confirmation Remove the spark plug and install a good plug into plug cap and then ground it to engine ground Make sure its spark condition If it is in not good or burnt spark plug replace the spark
36. le automatic by starter and air cut off valve arbitrarily Specification Tool Item Specification Special service tools Vacuum air pressure pump Carburetor diameter 22 100mm General service tools I D number 045 A Fuel level gauge Fuel level 14 8 mm Main injector 108 Idle injector 35 Idle speed 1600 100 rpm PuB patty 1 1 2 turns adjustment screw Torque value Fuel valve tightening nut 1 5 2 0 Kgf m 4 1 4 FUEL INJECTION SYSTEM Trouble Diagnosis Clogged fuel tank cap vent e Clogged fuel filter Obstructed fuel pipe Clogged air vent hose Air existing in intake system Poor engine start e No fuel in fuel tank e Clogged fuel tube Too much fuel in cylinder No spark from spark plug malfunction of ignition system e Clogged air cleaner Malfunction of automatic by starter e Malfunction of throttle valve operation Mixture too rich Clogged air injector Malfunction of float valve Fuel level too high in float chamber Stall after started Malfunction of automatic by starter e Malfunction of automatic by starter Dirty air cleaner e Incorrect ignition timing e Malfunction of carburetor e Dirty engine oil Air existing in intake system e Incorrect idle speed Rough idle e Malfunction of ignition system e Incorrect idle speed e Malfunction of carburetor e Dirty fuel Intermittently misfire as acceleration e Malfunction of igniti
37. linder Head Valve Install the cooling fan cover screw x2 bolt x 3 Valve Clearance Adjustment Loosen valve clearance adjustment nuts and bolts located on valve rocker arm Measure and adjust valve clearance with feeler gauge After valve clearance had been adjusted to standard value hold adjustment bolt and then tighten the Adjustment nut Standard Value IN 0 12 0 02 mm EX 0 12 0 02 mm Install the valve clearance adjustment hole cap bolt x3 Start the engine after assembly Remove the intake valve adjustment hole cap and make sure that engine oil flows onto the cylinder head Stop the engine after confirmed and then install the intake valve adjustment hole cap Install the seat cushion and the central cover N Caution The cylinder components will be serious wear out if lubricant did not flow onto the cylinder head So it has to be confirmed It has to be in idle speed when conduct this procedure Never increase engine speed in high RPM 6 16 7 Cylinder Piston Mechanism Illustration Piston Removal Precautions In Operation Piston Inspection Trouble Diagnosis Piston Ring Installation Cylinder Removal Piston Installation Cylinder Inspection Cylinder Installation Mechanism Illustration 0 8 1 2 kgf m 7 Cylinder Piston Precautions In Operation General Information Both cylinder and piston service cannot be carried out when engine mounted on frame Specificat
38. lve or damaged valve spring Camshaft wear out or damage Cam chain wear out or looseness e Auto tensioner wear out or damage of cam chain Camshaft sprocket wear out e Rocker arm or rocker arm shaft wear out White smoke e Valve guide or valve stem wear out e Valve stem seal wear out 6 3 6 Cylinder Head Valve Cylinder Head Removal Remove Remove the cooling fan cover screw x 2 bolt x 3 Remove the right cover of engine screw x 4 Remove the left cover of engine bolt x 1 Remove the cover of cylinder head Remove the spark plug Turn the flywheel in counter clockwise motion with T type wrench until the T mark on flywheel aligned with the mark on the crankcase so that the hole on the camshaft sprocket is forward up and piston is at TDC position Loosen the screw cap of camshaft chain tensioner and remove O ring With a flat screwdriver to tighten the screw of camshaft chain tensioner in a clockwise motion for release tensioner Remove the cam sprocket bolt x2 Remove the left bolt bolt x2 of cylinder head firstly and then remove the 4 nuts amp washers from the cylinder head top end Pry out the chain and take out the sprocket Then remove the cylinder head Caution Loosen the nuts diagonally by 2 3 sequences Do not let the chain fall into the crankcase after removed the sprocket 6 Cylinder Head Valve Bolt x 2
39. ly should have the same length Tighten assemblies with different dimension fasteners as follows Tighten all the fasteners with fingers then tighten the big ones with special tool first diagonally from inside toward outside important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated Bolts and fasteners should be kept clean and dry Do not apply oil to the threads When oil seal is installed fill the groove with grease install the oil seal with the name of the manufacturer facing outside check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal Manufacturer s name Remove residues of the old gasket or sealant before reinstallation grind with a grindstone if the contact surface has any damage hj 4 e Y m Be d q The ends of rubber hoses for fuel vacuum or coolant should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps Clamp Ne Groove Connector Rubber and plastic boots should be properly reinstalled to the original correct positions as designed Boots The tool should be pressed against two inner and outer bearing races when removing a ball bearing Damage may result if the tool is pressed against only one race either inner race or outer race In this case the bea
40. m 1 D Service Limit Replace when it is less than 10 100 mm Rocker Arm Shaft Measure the active O D of the cam rocker arm shaft and cam rocker arm Service Limit Replace when it is less than 10 910 mm Calculate the clearance between the rocker arm shaft and the rocker arm Service Limit Replace when it is less than 0 10 mm 6 Cylinder Head Valve 6 7 6 Cylinder Head Valve Remove cylinder head gasket and 2 lock pins Remove chain plate Clean up residues from the matching surfaces of cylinder and cylinder head A Caution e Do not damage the matching surfaces of cylinder and cylinder head Avoid residues of gasket or foreign materials falling into crankcase as cleaning Remove valve stem guide seal Clean carbon deposits in combustion chamber Clean residues and foreign materials on cylinder head matching surface A Caution Do not damage the matching surface of cylinder head Cylinder Head Check if spark plug and valve holes are crack Measure cylinder head plane with a straightedge and flat feeler gauge Service limit 0 5 mm Valve Spring Free Length Measure the free length of intake and exhaust valve springs Service limit 29 500 mm 6 8 Lock pin Valve Stem Check if valve stems are bend crack or burn Check the operation condition of valve stem in valve guide and measure amp record the valve stem outer
41. ng 7 7 7 Cylinder Piston Piston Installation Install piston and piston pin and place the IN marks on the piston top side forward to intake valve Install new piston pin snap ring N Caution Do not let the opening of piston pin snap ring align with the opening piston ring Place a piece of cloth between piston skirt section and crankcase in order to prevent snap ring from falling into crankcase as operation Cylinder Installation Clean up all residues and foreign materials on the matching surface of crankcase Pay attention to not let these residues and foreign materials fall into crankcase Caution To soap the residues into solvent so that the residues can be removed more easily Install 2 lock pins and new gasket Coat engine oil to inside of cylinder piston and piston rings Care to be taken when installing piston into cylinder Press piston rings in one by one as installation Caution Do not push piston into cylinder forcefully because this will cause the piston and the piston rings to be damaged Install the cam chain plate the cylinder gasket and lock pins Install cylinder head refer to Chapter 6 Install the cam chain auto tensioner 2 bolts 7 8 8 Driving System Mechanism Illustration Foot Starter8 Error Bookmark not defined Maintenance Description Drive Belt 8 Error Bookmark not defined Trouble Diagnosis Movable Drive Face8 Error
42. o much current or too rush charging After installing the battery coat the terminals with clean grease 11 5 11 Electrical Equipment Current Leakage Test Current Leakage Inspection Turn the main switch to OFF position and remove the negative cable terminal from the battery Connect an ammeter between the negative cable terminal and the battery negative terminal as shown on left diagram 4 Caution Inthe current leakage test set the current range at larger scale then gradually decrease to the lower scale as the test process goes to avoid possible damage to the ammeter and the fuse e Do not turn the main switch to ON position during test If the leaked current exceeds the specified value it may indicate a short circuit Allowable current leakage Less than 1mA Disconnect each cable one by one and take measurement of the current of each cable to locate the short circuit Charging Voltage Current Inspection A Caution Before conducting the inspection be sure that the battery is fully charged Use a fully charged battery having a voltage larger than 13 0 V If undercharged the current changes dramatically While starting the engine the starter motor draws large amount of current from the battery Thus do not start the engine with battery After the engine is warmed up replace original battery with a fully charged battery Connect a digital voltmeter to the battery terminals Connec
43. o the left crankcase and then install two dowel pins and new crankcase gasket Install the right crankcase and tighten the crankcase bolts bolt x 2 Torque value 1 5 2 0 kgf m Install the cam chain tensioner Install a new O ring onto the mounting bolt of the chain tensioner Apply some oil on the O ring and tighten the bolt Torque value 0 8 1 2 kgf m Caution The O ring must be installed into the bolt s groove 10 Crankcase Crankshaft Apply with some grease onto the oil seal lip and then install it onto the left crankcase Press fit the oil seal to specified position with the oil seal installer 25x40x8 Special service tools the oil seal installer 25x40x8 Special tools number 9121600 10 6 11 Electrical Equipment Mechanism Illustration Precautions In Operation Specification Ignition System Trouble diagnosis Starting System Mechanism Illustration Reg Rec Main Switch Start relay CDI unit Battery case Battery 11 Electrical Equipment Precautions In Operation C harging System When remove the battery the disconnection sequence of cable terminals shall be strictly observed First disconnect the negative cable terminal next the positive cable terminal MF Maintenance Free battery does not need to check add electrolyte or distilled water Battery must be taken out from scooter when charging the battery Bu
44. on system Late ignition timing e Malfunction of ignition system e Malfunction of carburetor Power insufficiency and fuel consuming e Fuel system clogged e Malfunction of ignition system Mixture too lean e Clogged fuel injector e Vacuum piston stick and closed e Malfunction of float valve e Fuel level too low in float chamber 4 2 4 FUEL INJECTION SYSTEM Carburetor Removal Throttle valve cable Remove Throttle valve cable Release the clamp strip of carburetor Remove air cleaner assembly Removal Remove the o chokes bracket screwx2 left handed the throttle cap Remove the compress spring and throttle valve Remove fuel needle and needle clamp from the throttle valve Check if the throttle valve for wear out crack or other damage 4 3 4 FUEL INJECTION SYSTEM Air Cut off Valve Remove of the air cut off valve and its cover screw x 2 Remove the spring and vacuum diaphragm Check if the diaphragm for deterioration or crack Installation Install the valve as reverse order of removal Cautions Do not damage the vacuum diaphragm or in opposite installation direction Float Chamber Disassembly Remove mounting screws and then the float screw x 3 Checking Check float needle valve and valve seat for drop difference damage wear out dirty or clogged Cautions In case of worn out or dirt the float valve and valve seat will not tightly close caus
45. or side face and pump body Limit below 2 0 mm Oil Pump Re assembly Install inner and outer rotors into the pump body Align the indent on driving shaft with that of inner rotor Install the driving shaft Install the oil pump cover and fixing pin properly and then tighten screw 1 screw 3 Lubrication System Install driving gear and clamp Caution Install the oil pump cover and fixing pin properly Oil Pump Installation Install the oil pump 3 screws A Caution The elliptical hole on the driving gear is not match with the screw hole Thus the elliptical hole has to align with the screw hoe before tightening it Install oil pump outer cover 2 bolts Install the starting gear and the alternator Refer to chapter 10 3 6 4 FUEL INJECTION SYSTEM Precautions In Operation Float Chamber Trouble Diagnosis Installation Of Carburetor Carburetor Removal Idle Speed Adjustment Precautions In Operation General Information A Warning Gasoline is a low ignition point and explosive materials so always work in a well ventilated place and strictly prohibit flame when working with gasoline A Cautions Do not bend or twist throttle valve cable Damaged cable will make unstable drive ability When disassembling fuel system parts pay attention to O ring position replace with new one as re assembly There is a drain screw in the float chamber for draining residual gasoline Do not disassemb
46. rankcase Crankshaft Mechanism Illustration Operational precautions Trouble diagnosis 10 Crankcase Crankshaft Operational precautions General Information e This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced Complete following operations before disassembling crankcase Engine Chapter 5 Cylinder head Chapter 6 Cylinder piston Chapter 7 Start motor Chapter 16 e Ifthe crankshaft bearing or timing sprocket need be replaced then the crankshaft set have to replaced Specification Unit mm Left right clearance of the big end of the connecting rod 0 100 0 300 Right angle clearance of the big end of the connecting rod 0 000 0 008 0 050 Torque value Bolts for crankcase f 1 5 2 0 kgf m Bolts for cylinder cylinder head 0 7 1 0 kgf m Engine oil draining plug 3 5 4 5 kgf m Bolts for cam chain tensioner 3 0 8 1 2 kgf m Special Service Tools Crankcase remover set Crankshaft installation puller Inner type bearing puller Outer type bearing puller Bearing pressing tools Oil seal pressing tools Trouble diagnosis Engine noise e Loose crankshaft bearing e Loose crankshaft pin bearing e Wear piston pin or piston pin hole 10 2 10 Crankcase Crankshaft Disassembly Of Crankcase Remove the cam chain tensioner hex socket bolt x 1 from the left crankcase side Remove the 2 bolts from the right side of crankcase and then remove
47. rial Work in a well ventilated place no flame or spark should be allowed in the work place or where gasoline is being stored Caution Gasoline is highly flammable and may explode under some conditions keep it away from children Used engine oil A Caution Prolonged contact with used engine oil or transmission oil may cause skin cancer although it might not be verdict We recommend that you wash your hands with soap and water right after contacting Keep the used oil beyond reach of children Hot components A Caution Components of the engine and exhaust system can become extremely hot after engine running They remain very hot even after the engine has been stopped for some time When performing service work on these parts wear insulated gloves and wait until cooling off Battery A Caution Battery emits explosive gases flame is strictly prohibited Keep the place well ventilated when charging the battery Battery contains sulfuric acid electrolyte which can cause serious burns so be careful do not be spray on your eyes or skin If you get battery acid on your skin flush it off immediately with water If you get battery acid in your eyes flush it off immediately with water then go to hospital to see an ophthalmologist If you swallow it by mistake drink a lot of water or milk and take some laxative such as castor oil or vegetable oil and then go to see a doctor Keep electrolyte beyond re
48. rical components in the voltage current regulator will be damaged The ignition switch must be turned OFF before performing any work Please do not replace with traditional type battery as replacement Please refer to the removal instruction when removing the alternator and the pulse generator Ignition System Please follow the procedure of trouble diagnosis chart to check ignition system The ignition system equipped with a auto advanced timing device in CDI unit Thus ignition timing need not to be adjusted In case of incorrect ignition timing occurred check the CDI unit or alternator system It has to check the ignition timing with the ignition timing lamp if replaced these components Do not hang or impact the CDI unit of ignition system because the major faulty of CDI unit is caused by impact Therefore take care when disassembling Most of ignition system problems were resulted from poor connecting connector Please check the connectors first when servicing Make sure that the heat range of spark plug is suitable Improper spark plug is the main cause of poor engine operation or combustion Inspection procedures in this manual are based on Max voltage This manual also contains methods of how to check ignition coil resistance and component operation Please follow the continuity chart to check ignition switch Starting System Starting motor can be removed directly from engine Please refer to chapter 10 for starting clutch remo
49. ring should be replaced To avoid damaging the bearing use equal force on both races Both of these examples can result in bearing damage Lubricate the rotation face with specified lubricant on the lubrication points before assembling Check if positions and operation for installed parts is in correct and properly 1 General Information Trouble Diagnosis Before battery removal operation it has to remove the battery negative cable firstly Notre tools like open end wrench do not contact with body to prevent from circuit short and create spark After service completed make sure all connection points is secured Battery positive cable should be connected firstly And the two posts of battery have to be greased after connected the cables Make sure that the battery post caps are located in properly after the battery posts had been serviced If fuse burned it has to find out the cause and solved it And then replace with specified capacity fuse lA Ebacity ca ificati y verificatio 1 General Information Trouble Diagnosis Before terminal connection check if the boot When separating a connector it locker has to is crack or the terminal is loose be unlocked firstly Then conduct the service operation See x Te n Ye Insert the terminal completely Check if the terminal is covered by the boot Do not let boot open facing up Do not pull th
50. rtant to the valve sealing capacity If the contact surface too high grind the valve seat with 32 cutter Then grind the valve seat to specified width If the contact surface too low grind the valve seat with 60 cutter Then grind the valve seat to specified width After the valve seat grinded coat valve seat surface with emery and then slightly press the grinded surface Clean up all emery coated onto cylinder and valve after grinded Cylinder Head Reassembly Lubricate valve stem with engine oil and then insert the valve into valve guide Install new valve stem oil seal Install valve springs and retainers A Caution The closed coils of valve spring should face down to combustion chamber 6 12 Contact surface too high Qld valve seat width Contact surface too high Old valve seat width E id hi 60 Valve split locks Spring retainer 9 Valve 8 Spring Valve stem Bil seal Valve Use valve spring compressor to press valve spring Install valve split locks and release the valve compressor N Caution In order to avoid loosing spring elasticity do not press the spring too much Thus press length is based on the valve split locks in which can be removed Special Service Tool Valve spring compressor Tool number 1471110 20 Or with the valve spring remover installer to install valve and spring Firstly
51. sily Cylinder Inspection Check if the inner diameter of cylinder is worn out or damaged In the 3 positions top center and bottom of cylinder measure the X and Y direction values respective in the cylinder Service limit 52 50 mm Calculate both the real roundness the difference between X and Y motion values and the cylindrical roundness the difference in the top center or bottom positions of X or Y motion values Then determinate by the max value Service limit Real roundness correct or replace as over 0 05 mm Cylindrical roundness correct or replace as over 0 05 mm Check Cylinder Wrapage Service limit correct or replace as over 0 05 mm 7 4 Piston Removal Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling Hold another snap ring with pliers Push out the piston pin from the side that not removed the snap ring Remove piston rings A Caution Pay attention to remove piston rings because they are fragile Disassemble the piston rings Check if the piston rings are damaged or its grooves are worn Clean out the carbon deposit around the piston ring groove Piston Inspection Install the piston rings and then measure clearance between piston ring and its grooves Service Limit Top ring replace if over 0 09 mm 2 ring replace if over 0 09 mm Take out the piston rin
52. speed can not 1 Poor fuel supply i increased 2 Lines in fuel tank evaporation system clogged 3 Exhaust pipe clogged be increased fs oedi 4 Fuel level too low in carburetor Check ignition timing j Using ignition lamp 5 Fuel nozzle clogged in carburetor Ignition timing correct Incorrect ignition timing 1 Malfunction of CDI 2 Malfunction of AC alternator Check cylinder compression pressure using compression pressure gauge Compression pressure correct No compression pressure Check if carburetor jet is Cylinder amp piston ring worn out Cylinder gasket leaked Sand hole in compression parts Valve deterioration Seized piston ring ar WD clogged No clogged Clogged 1 Remove foreign Remove spark plug No foul or discoloration Fouled and discoloration 1 Remove dirt 2 Incorrect spark plug heat range Piston and cylinder worn out Lean mixture Poor fuel quality Too much carbon deposited in combustion chamber Check if engine over heat 5 Ignition timing too advanced Continually drive in 6 Poor circuit on the cooling system acceleration or high speed 1 Too much carbon deposited in combustion chamber 3 Poor fuel quality IN 4 Ignition timing too advanced BhO0OoDn mM 1 12 1 General Information Trouble Diagnosis C En runs sluggish iu in low speed and er Check and Checkand adjustment Fault condition condition Probablecauses causes
53. t an ammeter between both ends of the main fuse A Caution When the probe is reversibly connected use a voltmeter having an indication that the current flows from the positive or the negative direction and the measurement should be at zero ammeter at one direction only 11 6 Battery terminal Digital meter pd Ammeter f A V A ay E 5 AS VK T ma jimi EN F J J 1 Fuse connector F A Caution Do not use short circuit cable e Itis possible to measure the current by connecting an ammeter between the battery positive terminal and the cable position terminal however while the starter motor is activated the surge current of the motor draws from the battery may damage the ammeter The main switch shall be turned to OFF position during the process of inspection Never tamper with the ammeter and the cable while there is current flowing through lt may damage the ammeter Comnect a tachometer Accelerate the engine gradually to the specified revolution per minute and measure the charging voltage current Charging Current 4 8A 1600 rpm Control Charging Voltage 12 0 0 5 V 1700 rpm A Caution To replace the old battery use a new battery with the same current and voltage The following problems are related to the charging system follow the instructions provided in the checking list to correct it if any one of the problems takes place
54. t do not open the battery caps Do not quick charge the battery unless in emergency A voltmeter must be used when checking battery charging condition Battery can be charged or discharged alternately To set a discharged battery idle for a prolonged period will shorten its service life and reduce its capacity Usually battery s capacity will reduce after 1 2 years After low capacity battery was charged its voltage will increase If it connects to an additional load the voltage will reduce suddenly and then go up again Over charged battery Usually the over charged battery can be seen externally If a short circuit occurred inside the battery there will be no voltage on the terminals of battery if voltage regulator does not operate Then the battery s voltage will be too high that may reduce battery s life The battery will be self discharged if it was set idle for a long time An idle battery must be charged about every 2months A new battery filled with electrolyte will generate a voltage after filled out electrolyte The voltage should be in 12 5V or more after 10 minutes When electrolyte is not enough the battery must be filled with electrolyte and then charged to prolong the battery s life span Please check electrical device according to the procedure of diagnosis chart Do not disconnect and connect the connector of electrical devices when current is passing these devices because this will generate high voltage and the elect
55. the spark plug again and check it Dry spark plug Wet spark plug Remove carburetor after 30 minutes and connect a hose onto fuel rich circuit Then blow the hose with air Blowing in normal Blowing clogged Probable causes 1 2 3 4 5 6 OW BD NOOR ONS No fuel in fuel tank Check if the pipes fuel tank to carburetor and intake vacuum are clogged Float valve clogged Lines in fuel tank evaporation system clogged Malfunction of fuel pump Loosen or damaged fuel pump vacuum hose Fuel filter clogged Malfunction of spark plug Spark plug foul Malfunction of CDI set Malfunction of AC generator Ignition coil is in open or short circuit Ignition coil leads open or short circuit Malfunction of main switch Piston ring seized Malfunction of cylinder valves Worn cylinder and piston ring Cylinder gasket leak Sand hole in compression parts 1 Malfunction of throttle valve operation 1 Air sucked into intake manifold Incorrect ignition timing Fuel level in carburetor too high Malfunction of throttle valve operation Throttle valve opening too wide Malfunction of automatic by starter 1 11 1 General Information Trouble Diagnosis B Engine run sluggish Speed does not pick up lack of power Check and adjustment Fault condition Probable causes V Try gradual acceleration and check engine speed 0 Air cleaner clogged Engine speed can be Engine
56. ting nut Plug Mounting nut socket 9 7 9 Alternator Starting Clutch Right Crankcase Cover Installation Install setting pin and new gasket on the crankcase Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip Install right crankcase cover onto the right crankcase bolt x 7 Torque value 1 5 2 0 kgf m Mounted Coil Set Installation Install the coil set onto right crankcase cover screw x 2 Install crankshaft position sensor screw x 2 Tighten the cable guide screw x 2 Torque 1 5 2 0 kgf m Tie the wire harness hose onto the indent of crankcase A Caution Make sure that the wire harness is placed under the crankshaft position sensor Connect the connectors of alternator and crankshaft position sensor Flywheel Installation Make sure that there is no magnetic powder If so clean up it Align insert on crankshaft with the flywheel groove and then install the flywheel Hold the flywheel with flywheel holder and tighten its nut Torque value 5 0 6 0 kgf m Special service tool Universal fixture 9 8 Cable guide ture Universal fix Install the cooling fan bolt x 4 Install the cooling fan shroud screw x 2 Install the rear bracket mounting bolts bolt x 3 9 Alternator Starting Clutch 9 Alternator Starting Clutch NOTE 9 10 10 C
57. ue value 2 0 2 4 kgf m A Caution This model is equipped with precious 4 valves mechanism so tighten torque can not be over the limited value and tightening the bolts diagonally by 2 3 sequences It can prevent from cylinder head deformation and then cause noise or leaking problems so that effect motorcycle s performance With T type wrench to turn crankshaft in a clockwise motion so that the T mark on the alternator flywheel aligns with the mark on crankcase piston is at TDC position Place the TDC marks of the cam sprocket at same level of the top end of cylinder head The other single hole of the cam sprocket is in upward Then install the cam chain onto the cam sprocket Install the spark plug and tighten it Torque value 1 0 1 2 kgf m 6 14 Chain plate nt a All Tw 6 Cylinder Head Valve ighten the cylinder head right side cover bolt x 2 With flat screwdriver turn the cam sprocket tensioner in counter clockwise motion so that the tensioner is pushed out to contact the cam chain plate tightly Apply with oil onto a new O ring and then install it onto the tensioner hole Tighten the bolt cap of the tensioner adjustment hole A Caution The O ring must be installed into glove Install the left side cover of the engine body bolt x 1 Install the right side cover of the engine body screw x 4 Screw x 4 6 Cy
58. val procedures 11 2 11 Electrical Equipment Specification Charging System oe Full charged 13 1V RPM for starting charging 1700 rpm headlamp ON Voltage controlled by regulator 12 0 0 5 V Resistance 20 C 20W5 90 7 0 8 00 Resistance 20 C 5W5Q 4 5 5 50 Battery Alternator Resistor lo ee S o System lem Po Specification Standard NGK C8E Recommended usage Spark plug Starting System Start motor Capacity 0 5 KW 11 3 11 Electrical Equipment Trouble diagnosis No power supply Dead battery e Disconnect battery cable Fuse burned out Faulty ignition switch Low voltage Weak battery Loose battery connection e Charging system failure Voltage current regulator failure Start motor does not work The fuse is blown The battery is not fully charge e Poor main switch Poor start switch The front and rear brake switches do not operate correctly e Starter relay is out of work The ignition coil is poorly connected open or short circuited The start motor is out of work Battery Removal Remove the rubber carpet Remove the battery cap screw x 3 Remove the battery mounting bracket bolt x 2 Firstly remove the negative post and remove the positive post Remove the battery Voltage Inspection Measure the voltage with a digital voltage meter Voltage Value Fully charged 13 0 13 2V at 20 C underc
59. y Se W ze 6 O Ss pS Never use wires or harnesses which insulation has been broken Wrap electrical tape around the damaged parts or replace Never clamp or squeeze the wire harness as installing other components Never clamp o squeeze the wire 1 General Information Trouble Diagnosis With sand paper to clean rust on connector pins terminals if found And then conduct connection operation later SS Before operating a test instrument operator should read the operation manual of the instrument And then conduct test in accordance with the instruction Do not let the wire harness been twisted as installation O Do you know how to set the instrument to its measurement position and the insert locations of its two probes 1 General Information Trouble Diagnosis Torque Values Engine Thread Dia Torque mm Value Kg m Cylinder head bolts Cylinder head bolts bolts Epa 1 0 1 4 Ze head nuts Be e bolts Cylinder head left bolts Cylinder head left bolts left bolts fa o6 twa fo vane causen nano a 8 oz Apollo mess Cer Spark plug ee connecting nuts Engine oil draining plug Engine oil draining plug draining plug a RIE IE PE wonna f 8 msn oearanmnann lm na foinumpscem pa 8 ones eronetenasecwernan e 6 10 18 reversa ESSE 1 e O CT Camshaft chain adjuster bolts ouenna 1 soso curada a m soso
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