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(Thumpstar) Service Manual

1. 6 2 SERVICE INFORMATION GENERAL During engine removal and installation support the motorcycle securely using a hoist or equivalent Support the engine using a jack or other adjustable support for ease of engine hanger bolts removal The following components can be serviced with the engine installed in the frame alternator cam chain tensioner section 10 clutch section 9 cylinder piston section8 cylinder head valves section 7 gearshift linkage section9 oil pump section4 The crankshaft transmission and kickstarter require engine removal for service section1 1 SPECIFICATIONS mem SPECIFICATIONS Engine dry weight 21kg 46 3lbs TORQUE VALUES Drive sprocket fixing plate bolt 12N m 1 2kgf m 9lbf ft Engine hanger nut upper 31N m 3 2kgf m 23lbf ft lower 31N m 3 2kgf m 23lbf ft 6 ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Drain the engine oil page3 9 Remove the following exhaust system page2 5 left crankcase cover page10 2 Disconnect the following spark plug cap crankcase breather tube Remove the following from the clamp carburetor drain tube Loosen the rear axle nut and drive chain adjusters to loosen the drive chain page 3 12 PLATE Remove the following fixing plate bolts fixing plate drive sprocket SPROCKET intake manifold bolts 0 ring brake pedal return spring four bolts and foot peg bar support the motorcyc
2. 8 7 PISTON REMOVAL 8 3 SERVICE INFORMATION GENERAL The cylinder and piston service can be done with the engine installed in the frame Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head cylinder and crankcase sure that orifice is not clogged and that the O ring and dowel pins are in lace before installing the cylinder SPECIFICATIONS w T T saa Cylinder HD 89 005 39 015 1 5356 1 5360 Outofround see wen een e nce n cece e cee ce cee Taper nnn nnn nn Warpage nnn nnn nnn nnns Piston mark direction IN mark facing toward the intake side piston rings Piston O D measurement point 8mm 0 3in from bottom of shirt Piston pin bore I D 13 002 13 008 0 5119 0 5121 Piston pin O D 12 994 13 000 0 5116 0 5118 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 groove clearance Piston ring en gap Top 0 05 0 15 0 002 0 0016 Second 0 05 020 0 002 0 0016 Oil side rai 0 3 0 9 0 01 0 04 Cylinder to piston clearance o 0 010 0 040 0 0004 0 0016 13 016 13 034 0 5124 0 5131 Connecting rod to piston pin clearance 0 016 0 040 0 0006 0 0016 TORQUE VALUES Cam chain guide roller in bolt 10N m 1 0kgf m 7Ibf ft CYLINDER PISTON TROUBLESHOOTING If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Cylinder c
3. W_e t Flooded carburetor Choke valve closed G o o d Air cleaner dirty 4 Start by following normal Engine starts but Improper choke operation Carburetor incorrectly adjusted EngIne does not Intake pipe leaking Improper ignition timing faulty ignition coil or ignition pulse generator Fuel contaminated 5 Test cylinder L O w Valve clearance too small Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Seized valve Improper valve timing TROUBLESHOOTING ENGINE LACKS POWER 1 Raise wheel off the ground and spin by hand Wheels spins freely Y 2 Check tire pressure 4 Pressure normal j 3 Accelerate rapidly from low to second Engine speed reduced Y 4 Accelerate lightly increase Engine speed increase 5 Check ignition timing Correct 6 Test cylinder compression Normal 7 Check carburetor for clogging Not clogged 8 Remove spark plug Not fouled or discolored 9 Check oil level and condition Correct 10 Remove cylinder head cover and inspect lubrication Valve train lubricated properly 11 Check for engine overheating Not overheating 12 Accelerate or run at light speed Engine dose not knock _________ Fouled or discolored _ gt gt Possible cause Wheels
4. www thumpstar us IMPORTANT SAFETY NOTICE WARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of equipment damage if instructions are not followed NOTE Gives helpful information Detailed descriptions of standard workshop procedures safety principles and service operations are not included It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could not cover all conceivable ways in which service whether or not recommended by manufacturer might be done or of the possibly hazardous consequences of each conceivable way nor could manufacturer investigate all such ways Anyone using service procedures or tools whether or not recommended by manufacturer must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected HOW TO USE THIS MANUAL CONTENTS This service manual describes the service procedures for the Thumpstar Off Road Range GENERAL INFORMATION Follow the Maintenance Schedule Section 3 recommendations to FRAME BODY PANELS EXHAUST SYSTEM ensure that the vehicle is in peak operation condition and the emission levels are within the standards set by the Californi
5. SERVICE INFORMATION WARNING Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion This section covers removal and installation of the body panels fuel tank and exhaust system Always replace the exhaust pipe gasket after removing the exhaust system from the engine When installing the exhaust system loosely install all of the fasteners Always tighten the exhaust pipe joint nuts first then tighten the mounting If you tighten the mounting fasteners first the exhaust pipe may not seat properly Always inspect the exhaust system for leaks after installation TORQUE VALUES Side stand pivot bolt see page2 5 Muffler mounting bolt 26N m 2 7kgf m 20lbf ft TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler FRAME BODY PANELS EXHAUST SYSTEM SEAT REMOVAL Remove the two bolts Remove the two screws and bolts Pull the seat assembly back and remove it INSTALLATION BOLTS Install the seat assembly by inserting the prongs into the SEAT ASSEMBLY retainers on the frame Install the bolts and lock them pom SCREW
6. 5 11 CARBURETOR DISASSEMBLY 5 5 SERVICE INFORMATION GENERAL WARNING Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind resulting in loss of vehicle control Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion Refer to section 2 for fuel tank removal and installation When disassembling fuel system parts note the location of the O ring Replace them with new ones on reassembly Before disassembling the carburetor place a suitable container under the carburetor drain tube Loosen the screw and drain the carburetor After removing the carburetor wrap the intake port of the engine with a towel or cover it to prevent any foreign material from dropping into the engine NOTE If the vehicle is to be stored for more than one month drain the float bowl Fuel left in the float bowl may cause clogged jets resulting in hard starting or poor drivability COVER OIL PUMP FUEL SYSTEM TROUBLESHOOTING Engine will not start Too much fuel getting to the engine Air cleaner clogged Flooded carburetor Intake air leak Fuel contaminated or deteriorated No fuel to carburetor Fuel strainer clogged Fuel tube clogged Float level maladjusted Fuel tank bre
7. Spark plug page3 7 Muffler page 2 4 Camshaft see below CAMSHAFT INSTALLATION Apply clean engine oil to the camshaft lobes and bearings Install the camshaft into the cylinder head with its cam lobos facing the combustion chamber while holding the rocker arms CYLINDER HEAD VALVES Turn the crankshaft counterclockwise and align the T mark with the index notch on the left crankcase Install the dowel pin and cam sprocket NOTE Install the cam sprocket with its O mark with the index notch on the cylinder head Install and tighten the cam sprocket bolts to the specified torque TORQUE 9N m 0 9kgf m 6 5lbf ft Install the cylinder head left side cover onto the cylinder head with a new gasket Set the tab on the side cover against the left side of the stopper on the cylinder head Install the 6mm bolt with a new sealing washer into the cylinder head tighten it Tighten the two right side cover bolts if the cylinder head was disassembled Install the spark plug cap TORQUE 10N m 1 0kgf m 7Ibf ft CYLINDER HEAD VALVES Install the tensioner push rod spring and sealing bolt page 10 5 Adjust the valve clearance pages3 7 Pour the recommended engine page 3 9 DOWEL CYLINDER PISTON 8 CYLINDER PISTON SERVICE INFORMATION 8 1 CYLINDER PISTON INSPRCTION 8 4 TROUBLESHOOTING see 8 2 PISTON INSTALLATION 8 7 CYUNDER REMOVAL m 8 3 CYLINDER INSTALLATION
8. a wa STANDARD SERVICE LIMIT Engine oil capacity 0 6L 0 6US qt 0 5Imp at JAtdisassembly 0 8L 0 8US qt 0 7Imp at Recommended engine oil 4 stroke oil or equivalent motor oil APL service classification SF or SG Viscosity SAE 10W 30 Oil pump rotor 0 15 0 006 0 20 0 008 Body clearance 0 02 0 07 0 001 0 003 0 12 0 005 0 10 0 15 0 004 0 006 0 20 0 008 TORQUE VALUES Oil pump mounting screw 8N m 0 8kgf m 5 8lbf ft Oil pump cover screw 5N m 0 5kgf m 3 6lbf ft TROUBLESHOOTING Engine oil level too low or high oil consumption Oil contamination Normal oil consumption Oil not changed often enough External oil leak Worn piston ring or incorrect piston ring installation Worn piston ring or incorrect piston ring installation Worn valve guide or stem seal Worn cylinder Clogged oil strainer screen Worn valve guide or stem seal Oil pump worn or damaged LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the clutch assembly page9 4 When the oil pump is ready to be disassembled loosen the pump cover screws Remove the three screws and oil pump assembly DISASSEMBLY Remove the three screws and oil pump cover Remove the oil pump shaft then remove the inner and outer rotors from the oil pump body INSPECTION Temporarily install the outer and inner rotors into the oil pump body Install the oil pump shaft Measure the tip clearance between If any portion of the oil the inner and outer rotors pump is worn beyo
9. Remove the following Upper bearing inner race Upper bearing Steering stem Lower bearing FRONT WHEEL BRAKE SUSPENSION STEERING BEARING REPLACEMENT Drive out the upper and lower bearing outer races using the special tool TOOL Ball race remove07944 1150001 Always replace the bearing and races as a set Drive new upper and lower bearing outer races into the steering head pipe using the special tools as shown TOOLS Driver 07749 0010000 Attachment 37x 07746 0010200 Temporarily install the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem Remove the lower bearing inner race with a chisel or equivalent tool being careful not to damage the stem Remove the dust seal and washer 1 Steering Column Comp 12 Bottom Cone Race 2 Upper Panel 13 Dust Seal 3 Lower Holder Handle Pipe _ 14 Flange Bolt M6x12 4 Upper Holder Handle Pipe 15 Flange Bolt M8x25 5 Front Cover 16 Flange Bolt M8x25 6 Nut 17 Bolt M8x30 7 Adjusting Nut 8 Dust Cap 9 Upper Cone Race 10 Ball 11 Rall Race INSTALLATION ee HREAD UPPER INNER al E ______ UPPER amp a Af gt UPPER OUTER aug RACE Be j a if LOWER OUTER a LOWER LOWER INNER DUST SEAL Sao S WASHER Apply grease to upper and lower bearings and races Install the lower bearing onto the lower bearing race Insert the steering stem into the steering
10. Attachment 37x40mm 07746 0010200 11 12 Pilot 12mm 07746 0040200 12 13 Pilot 17mm 07746 0040400 11 Bearing remover shaft 07746 0050100 NOTE1 12 13 Bearing remover head 12mm 07746 0050300 NOTE1 12 13 Drive 07749 0010000 11 12 13 Valve spring compressor 07757 0010000 7 Valve seat cutter NOTE1 7 Seat cutter 24mm 45 IN 07780 0010600 Seat cutter 20 5mm 45 EX 07780 0011000 Flat cutter 24mm 32 IN 07780 0012500 Flat cutter 21 5mm 32 EX 07780 0012800 Interior cutter 22mm 60 IN EX 07780 0014202 Cutter holder 5mm 07781 0010400 Flywheel puller 07933 GE0000 NOTE2 3 07933 0010000 10 Valve guide driver 5 0mm 07948 MA60000 7 Ball race remover 07944 1150001 12 Steering stem driver 07946 GC40000 NOTE3 07946 MBO00000 12 Valve spring compressor attachment 07946 GC4000A U S A only Valve guide reamer 5 0mm 07959 KM30101 7 07984 MA60001 NOTE3 07984 MA6000C 7 Peak voltage adaptor 07HGJ 0020100 NOTE3 Peak voltage tester 14 LUBRICATION AND SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Cylinder bore surface Engine oil Valve adjuster hole cap threads Connecting rod small end bearing Pour 1 2cm Connecting rod small end inner surface Piston outer surface piston pin hole and ring grooves Piston pin outer surface Valve stem sliding surface Camshaft lobes Cam chain Cam chain guide roller inner surface Rocker arm inner and slipper surfaces Cam chain tensioner push rod inside Fill
11. Install the bolts and screws and tighten them o by pushing the centre pin flush DISASSEMBLY ASSEMBLY RETAINERS BOLTS A Ve a PRONGS CC USA A al ae j ha te a ys a ENa TANK SHROUDS SCREWS aA 4 o d Aer a uj 2 N _ i Be i m a NS i iz J T sy ey a a Ma j i A So a lt 7 x a T 5 k _ 1 jim a er as a se y AA af ETA N pN F ia re ik kS f y Fad i F gi tS r Cul i is 7 REAR FENDER FRAME BODY PANELS EXHAUST SYSTEM FUEL TANK WARNING BOLT AND COLLAR Gasoline is extremely flammable and is explosive H under certain conditions KEEP OUT OF REACH OF CHILDREN Remove the seat assembly page2 2 Remove the breather tube from the number plate E It UT A Turn the fuel valve OFF and disconnect the fuel tube from Balt AA the fuel valve Remove the two bolts washer and collar Remove the fuel tank Installation is in the reverse order of removal For fuel strainer service see page3 4 NUMBER PLATE Remove the breather tube from the number plate ar a ae Remove the fender mounting bolt if IM Remove the number plate from the steering stem nut and j front fender FUEL TANK rns NUMBER PLATE Installation is in the reverse order of removal FRONT FENDER Remove the three bolts and the front fender Installation is in the reverse order of removal FRAME BODY PANELS EXHAUST SYSTEM EXHAUST SYST
12. Replace the fuel line if necessary FUEL STRAINER SCREEN WARNING Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Smoking where the gasoline is stored can cause a fire or explosion Wipe spilled gasoline at once Turn the fuel valve OFF and disconnect the fuel tube Place a drain pan under the fuel tube and turn the fuel valve ON to drain the fuel tank After the tank has drained completely remove the two bolts and collars and remove the fuel valve and strainer screen Wash the fuel strainer screen in non flammable or high flash solvent Check the O ring is in good condition reinstall the fuel valve Tighten the fuel valve mounting bolts to the specified torque TORQUE 9N m 0 9kgf m 6 5lbf ft After installation check for fuel leaks O RING STRAINER SCREEN AIR FILTER FUEL LINE FUED VALVE THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions Check the throttle cable and replace it if it is deteriorated kinked or damaged Lubricate the throttle cable if throttle operation is not smooth Measure the free play at the throttle grip flange FREE PLAY 2 0 4 0mm 1 16 3 16 in MAINTENANCE Throttle grip free play can be adjusted at the upper end of the throttle cable Remove the dust cover from the adjuster Adjust the free play by loosening the lock nut and turning the adj
13. U nut 07708 0030100 Equivalent commercially available in U S A 077087 0030400 or 07908 KE90200 U S A only 07701 0020100 Equivalent commercially available in U S A 12N m 1 2kgf m 9ibf ft 47N m 4 8kgf m 35ibf ft U nut MAINTENANCE MAINTENANCE SCHEDULE Perform the PRE RIDE INSPECTION in the Owner s Manual at each scheduled maintenance period 1 Inspect and Clean Adjust Lubricate or replace if necessary C Clean R Replace A Adjust L Lubricate FREQUENCY ITEMS Refer to page 3 4 FUEL LINE 3 4 THROTTLE OPERATION 3 5 AIR CLEANER 3 6 SPARK PLUG 3 7 VALVE CLEARANCE 3 8 ENGINE OIL 3 10 ENGINE OIL STRAINER SCREEN 3 10 ENGINE OIL CENTRIFUGAL FILTER 3 11 ENGINE IDLE SPEED 3 12 DRIVE CHAIN 3 14 DRIVE CHAIN SLIDER 3 14 BRAKE SHOES WEAR 3 14 BRAKE SYSTEM 3 14 CLUTCH SYSTEM 3 16 SIDE STAND 3 16 SUSPENSION 3 17 SPARK ARRESTER 3 18 NUTS BOLTS FASTENERS 3 18 WHEELS TYRES 3 19 STEERING HEAD BEARINGS WHICHEVER COMES FIRST NOTE NOTE1 NOTE1 INITIAL MAINTENANCE MI 100 KM 150 MONTH 1 C Every 1000mi 1600km or Every 100 operating hours Should be serviced by your dealer unless the owner has proper tools and service data and is mechanically qualified In the interest of safety we recommend these items be serviced only by your dealer NOTE Service more frequently when ridden in wet or dusty conditions MAINTENANCE FUEL LINE Check the fuel line for deterioration damage or leakage
14. Wheel Rim Comp Flap FR Wheel Inner Tire 2 50 10 Outer Tire 2 50 10 Bearing Distance Collar Bush A i Bush B FR Wheel Axle 10 Grip Nut M12 11 Bolt 12 FR Brake Disk 13 FRONT WHEEL ASSY 14 Spoke Apply grease to the brake cam spindle Install the brake cam into the brake panel NOTICE need check the brake liquid every times when you drive it Master Cylinder Body Oil Pipe Brake Clamp Assembly Friction Pad FR Brake lever FRONT BRAKE SWITCH Holder Master Cylinder Lid Master Cylinder Gasket 10 Fixing Bolt 11 Bolt M6 25 12 Nut M6 13 SCREW 14 Screw 15 FRONT BRAKE ASSY CONAN KWDHND FRONT WHEEL BRAKE SUSPENSION STEERING NOTICE need check the Friction Pad when you drive it FR L Shock Absorber FR R Shock Absorber Bolt Holder FR Pipe RR Shock Absorber Rubber Cap Fi Flange Bolt M6 12 fo 7 Flange Bolt M8 25 REAR SHOCK ABSORBER 10 RFRONT SHOCK ASSY 11 LFRONT SHOCK ASSY INSTALLATION Install the front wheel page12 8 FORK DISASSEMBLY Remove the front wheel page 12 5 Loosen the brake cylinder bolt and remove the brake cylinder from the fork stem Remove front wheel axle from the fork Remove the front wheel Remove the fork top bolt and washer and pull the fork slider down to remove the fork assembly FRONT WHEEL BRAKE SUSPENSION STEERING Drive out the bolt Remove the following from the fork s
15. never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine EXCITER COIL CONNECTOR in an open area or with an exhaust evacuation system in an enclosed area Warm up the engine Stop the engine and remove the left crankcase cover page 10 2 Connect the timing light to the spark plug wire Start the engine and let it idle IDLE SPEED 1 700 100rpm Read the instructions for timing light operation The ignition timing is correct the F mark aligns with the index notch on the left crankcase Increase the engine speed by turning the throttle stop screw and make sure the F mark begins to move clockwise Install the left crankcase cover page 10 8 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1 Check the flue flow to carburetor _Not reaching carburet Clogged fuel line and strainer Clogged fuel tank breathe tube Reaching carburetor j 2 Perform a spark test _ Weak or no spark Faulty spark plug Fouled spark plug Good spark Faulty ignition control module Broken or shorted spark plug wire Faulty ignition pulse generator Faulty engine stop switch or ignition switch Loose or disconnected ignition system wires 3 Remove and inspect spark
16. the cam lobes for scoring chipping or flat spots SERVICE LIMIT IN EX gt 10 10mm 0 398 in Inspect the rocker arm shafts for wear or damage Measure the O D of the rocker arm shaft SERVICE LIMIT IN EX 9 91mm 0 390 in VALVE SPRING Measure the free length of the inner and outer valve springs SERVICE LIMITS IN EX 31 8mm 1 25 in Replace the springs if they are shorter than the service limits VALVE Inspect each valve for bending burring or abnormal stem wear Check valve movement in the guide Measure and record each valve stem O D SERVICE LIMIT IN EX 4 92mm 0 194 in 7 CYLINDER HEAD VALVES Ream the guides to remove any carbon deposits before measuring the guide Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise TOOL Valve guide reamer 5 0 mm 07984 MA60001 or 07984 MA6000C U S A only Measure and record each valve guide D SERVICE LIMIT IN EX 5 03mm 0 198 in Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance SERVICE LIMITS IN 0 08mm 0 003in EX 0 10mm 0 004in If the stem to guide clearance is out of Reface the specification determine if a new guide with valve seats standard dimensions would bring the clearance whenever the within tolerance If so replace any guides as valve guides necessary and ream to fit If the stem to guide are replaced clearance is out of specification with a
17. 0 015 0 050 0 0006 0 0020 0 12 0 005 Groove clearance Top Second Piston ring end gap Top 0 05 0 015 0 002 0 006 0 5 0 02 Second 0 05 0 20 0 002 0 008 0 5 0 02 Oil side rail 0 3 0 9 0 01 0 04 1 1 0 04 Cylinder to piston clearance 0 010 0 040 0 0004 0 0016 0 15 0 006 Connecting rod small end I D 132 016 13 034 0 5124 0 5131 13 08 0 515 Connecting rod to piston pin clearance 0 016 0 040 0 0006 0 0016 0 12 0 005 CLUTCH GEARSHIFT LINKAGE Unit mm in ITEM STANDARD SERVICE LIMIT Clutch disc thickness A 2 52 2 68 0 099 0 106 2 3 0 09 B 3 32 3 48 0 131 0 137 3 0 0 12 Clutch plate warpage 0 20 0 008 Centrifugal clutch spring free length 22 4 0 88 19 4 0 76 Primary drive gear I D 21 000 21 021 0 8268 0 8276 21 05 0 829 Clutch centre guide I D 16 988 17 006 0 6688 0 6695 17 04 0 671 O D 20 930 20 950 0 8240 0 8248 20 90 0 823 Crankshaft O D at clutch centre guide 16 966 16 984 0 6680 0 6687 16 90 0 665 Unit mm in ALTERNATOR CAM CHAIN TENSIONER ITEM STANDARD SERVICE LIMIT Cam chain tensioner Push rod O D 11 985 12 000 0 4718 0 4724 11 94 0 470 Spring free length 111 3 4 38 100 3 9 CRANKSHAFT TRANSMISSION KICKSTARTER ITEM STANDARD SERVICE LIMIT Crankshaft Side clearance 0 010 0 350 0 0004 0 0138 0 60 0 024 Radial clearance 0 0 012 0 0 0005 0 05 0 002 Run out renew nn nnn nnn nn
18. Clutch plate A Remove the clutch center and drive gear outer Remove the four damper springs Remove the four screws and plain washers Remove the drive plate assembly and clutch springs Remove the clutch weight stopper ring Remove the clutch weight center ring INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and freely without excessive play Also check that bearing fits tightly in the clutch outer cover If necessary replace the bearing Clutch spring Measure the clutch spring free length SERVICE LIMIT 19 4mm 0 76in Clutch disc Replace the clutch discs if they show signs of scoring or discoloration Measure the disc thickness of disc SERVICE LIMITS Clutch disc A 2 3mm 0 09 in Clutch disc B 3 0mm 0 12 in Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20mm 0 008in Primary drive gear clutch center guide Check the primary drive gear and clutch center guide for excessive wear or damage Measure the I D of the primary drive gear SERVICE LIMIT 21 05mm 0 829 in Measure the O D and I D of the clutch center guide SERVICE LIMITS D 17 04mm 0 671 in O D 20 90mm 0 823in BEARING Crankshaft Measure the crankshaft O D at clutch center guide SERVICE LIMIT 16 90mm 0 665 in Drive gear outer clutch center Check the
19. FUEL LINEs 2e 2220 22522 THROTTLE OPERATION AIR FILTER 3 5 SPARK PLUG VALVE CLEARANCE ENGINE OIL ae 3 1 an 3 3 DRIVE CHAIN _ 4 12 3 4 DRIVE CHAIN SLIDER 3 14 pues 3 4 Beatese 3 6 3 7 SUSPENSION 3 17 3 8 WHEELS TYRES 3 1 8 ENGINE IDLE SPEED 3 11 BRAKE SYSTEN 3 16 CLUTCH SYSTEN 3 16 SIDE STAND 3 16 ENGINE OIL STRAINER SCREEN 3 10 STEERING HEAD BEARINGS 3 18 ENGINE OIL CENTRIFUGAL FILTER 3 10 SERVICE INFORMATION GENERAL WARNING Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion When the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Place the motorcycle on a level ground before starting any wor
20. RATCHET CRANKSHAFT TRANSMISSION KICKSTARTER INSTALLATION Install the kickstarter spindle by aligning its friction spring with the groove in the left crankcase as shown Assemble the crankcase halves CRANKCASE ASSEMBLY Clean the crankcase mating surfaces before assembling NOTE Dress the surfaces with an oil stone 1f necessary to Correct any minor roughness or irregularities Install the dowel pins and a new gasket onto the left crankcase Install the right crankcase over the left crankcase Make sure that the gasket stays in place Install the seven bolts with the clamp and tighten them in a crisscross pattern in 2 3 steps Apply engine oil to the cam chain and install it CRANKSHAFT TRANSMISSION KICKSTARTER Install the washer and bolt to the shift drum then tighten the bolt to the specified torque TORQUE 12N m 1 2 kgf m 9Ibf ft Install the rubber cap Install the return spring and retainer onto the kickstarter spindle Temporarily install the kickstarter pedal Install the spring ends onto the retainer and crankcase lug as shown and press the retainer to set its edge against the stepped part of the crankcase while turning the pedal counterclockwise Install the snap ring into the groove in the kickstarter spindle securely 12 FRONT WHEEL BRAKE SUSPENSION STEERING SERVICE INFORMATION GENERAL A contaminated brake drum or shoe reduces stopping power Discard contaminated shoes and
21. ai DRIVE GEAR OUTER FREE SPRING S a ON CLUTCH OUTER TS DRIVE i CLUTCH ae ws CLUTCH PLATE A CLUTCH DISC B CLUTCH GEARSHIFT LINKAGE Install the clutch weight center ring onto the drive plate by aligning the ring end with the plate hole Install the stopper ring by aligning the ring end with the plate groove rVPOIN e DI ATO ACCC AADI Install the clutch spring onto the clutch outer holes Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs Install the plain washers and screws Tighten the screws in a crisscross pattern in 2 3 steps TORQUE 6 N m 0 6kgf m 4 3 Ibf ft Install the damper springs as shown CLUTCH GEARSHIFT LINKAGE Install the drive gear outer and clutch center Install the following Clutch plate A _ Free springs Clutch disc A Clutch disc B Clutch disc A Clutch plate B NOTE ith its flat surface facing the chamfered side facing the clutch disc A Install the clutch set ring with its chamfered side facing the clutch plate B DISC A CLUTCH GEARSHIFT LINKAGE INSTALLATION Install the collar onto the crankshaft Install the primary driven gear onto the mainshaft and secure it with the snap ring Apply engine oil to the clutch center guide and install it onto the crankshaft Install the primary drive gear Install the clutch assembly onto the crankshaft In
22. dive gear outer and clutch center for excessive wear or damage ASSEMBLY CLUTCH SPRING STOPPER RING CLUTCH WEIGHT CENTER RING DRIVE GEAR OUTER FREE SPRING CLUTCH DISC A CLUTCH PLATE B y CLUTCH OUTER DRIVE PLATE e CLUTCH CENTER Pa CLUTCH PLATE A CLUTCH DISC B Install the clutch weight center ring onto the drive plate by aligning the ring end with the plate hole Install the stopper ring by aligning the ring end with the plate groove Install the clutch spring onto the clutch outer holes Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs Install the plain washers and screws Tighten the screws in a crisscross pattern in 2 3 steps TORQUE 6 N m 0 6kgf m 4 3 Ibf ft Install the damper springs as shown Install the drive gear outer and clutch center Install the following Clutch plate A _ Free springs Clutch disc A Clutch disc B Clutch disc A Clutch plate B NOTE Install the clutch disc A with its flat surface facing the clutch disc B Install the clutch plate B with its chamfered side facing the clutch disc A Install the clutch set ring with its chamfered side facing the clutch plate B PLATE B INSTALLATION Install the collar onto the crankshaft Install the primary driven gear onto the mainshaft and secure it with the snap ring Apply engine oil to the clutch center guide and install i
23. do not spin freely _ Brake dragging Worn or damaged wheel bearing low _ Faulty tire valve Punctured tire Engine speed doesn t change accordingly gt Clutch slipping Worn clutch discs plates Warped clutch discs plates Weak clutch spring Additive in engine oil Engine speed does 1 Choke valve closed Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather tube Faulty ignition control module Faulty ignition pulse generator Incorrect Valve clearance too small Worn cylinder and piston rings Leaking head gasket Improper valve timing Carburetor not serviced frequently enough Incorrect 2222 Clogged Plug not serviced frequently enough Spark plug are the incorrect heat range Oil level too high Oil level too low Contaminated oil Incorrect Valve train not lubricated _ Clogged oil passage properly Clogged oil control orifice Possible cause Overheating Excessive carbon build up in combustion chamber Use of poor quality fuel Clutch slipping Lean fuel mixture Wrong type of fuel Engine knocks Worn piston and cylinder Wrong type of fuel Excessive carbon build up in combustion chamber Lgnition timing to advanced faulty ignition control module Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check
24. head pipe Install upper bearing inner race and top thread Hold the steering stem and tighten the stem top thread to the initial torque TORQUE 25 N m 2 5 kgf m 18 Ibf ft move the steering stem right and left lock to lock several rimes to seat the bearings Loosen the top thread Retighten the top thread to the specified torque TORQUE 3N m 0 3kef m 2 2Ibf ft Install the top bridge Install the stem nut and fork top bolts with the washers and tighten them TORQUE stem nut 74 N m 7 5 kgf m 54 Ibf ft 2 Upper Panel 13 Dust Seal play or binding 3 Lower Holder Handle Pipe 14 Flange Bolt M6x12 4 Upper Holder Handle Pipe 15 Flange Bolt M8x25 5 Front Cover 16 Flange Bolt M8x25 Install the following B ene 6 Nut 17 Bolt M8x30 Front fender 7 Adjusting Nut Front wheel 8 Dust Cap 9 Upper Cone Race Handlebar 10 Ball Number plate 11 Ball Race REAR WHEEL BRAKE SUSPENSION SERVICE INFORMATION GENERAL AWARNING e When servicing the rear wheel support the motorcycle using a safety stand or hoist SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Minimum tire tread depth B0012 asign 25kgem aseo a 0 200 008 D 7 Wheel rimrunoyRadial oo e 2 00 08 S Axil aso 2 00008 Drive chain Sizefink DI MB88 JP Slack S25 COMM Brake Brake pedal free play 10 20 3 8 13 16 S o a E gt y Q Eyr _ _l Cold tire pressure Axle run out TORQUE VALUES Spoke nipple 2N m 0 2kgf m 1 41bf Rear axl
25. in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN GENERAL INFORMATION SERVICE RULES 1 Use genuine Manufacturer s recommended parts and lubricants or their equivalent Parts that do not meet Manufacturer s design specifications may cause damage to the motorcycle 2 Use the special tools designed for this product to avoid damage and incorrect assembly 3 Use only metric tools when servicing the motorcycle Metric bolts nuts and screws 4 Install new gaskets O ring cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown on pages 1 14 through 1 16 Cable and Harness Routing MODEL IDENTIFICATION ENGINE SERIAL VEHICLE NITNADED IDENTIFICATION 2 The engine serial number is stamped 3 The vehicle identification on the lower left of the crankcase number VIN is located on the right side of the steering head GENE
26. m 301bt ft Install the left crankcase cover and tighten the two bolts Install the gearshift pedal so that same height as the footpeg Install the pinch bolt and tighten it Connect the ignition pulse generator and alternator connectors 11 CRANKSHAFT TRANSMISSION KICKSTARTER SERVICE INFORMATION GENERAL The crankcase must be separated to service the crankshaft transmission and kickstarter The following parts must be removed before separating the crankcase Alternator cam chain tensioner Section 10 Clutch gearshift linkage Section 9 Cylinder head Section 7 Cylinder piston Section 8 Engine Section 6 Oil pump Section 4 SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT 0 010 0 350 0 0004 0 0138 0 6 0 024 Crankshaft Radial clearance 0 0 012 0 0 005 0 05 0 002 Runout 0 100 004 Shift fork 34 075 34 100 1 3415 1 3425 34 14 1 344 TORQUE VALUES Shift drum bolt 12N m 1 2kgf m 9lbf ft CRANKSHAFT TRANSMISSION KICKSTARTER TOOLS Driver 07749 0010000 Attachment 37 40mm 07746 0010200 Pilot 17mm 07746 0040400 TROUBLE SHOOTING Hard to shift Incorrect clutch adjustment Bent shift fork Bent fork claw Damaged shift drum cam groove Incorrect transmission oil weight Transmission jumps out of gear Worm gear dogs and slots Bent fork shaft Broken shift drum stopper Excessive noise Worn crankshaft big end bearing Worn crankshaft journal bearing
27. mounting nuts TORQUE 20N m 2 0kef m 1 41bf ft Clean the inside surface of the left handlebar grip and the outside surface of left handlebar Apply Manufacture Bond a or equivalent to the inside surface of the left handlebar grip and to the outside surface of the left handlebar Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive NOTE Allow the adhesive to dry for an hour before using Apply grease to the throttle grip pipe flange and install the throttle grip onto the right handlebar Connect the throttle cable to the throttle grip pipe flange Install the engine stop switch throttle housing onto the handlebar aligning the mating surface with the punch mark on the handlebar Tighten the forward screw first then the rear screw TORQUE 3N m 0 3kef m 2 21bf ft FRONT WHEEL BRAKE SUSPENSION STEERING Secure the engine stop switch wire with the wire bares properly Install the number plate over the steering stem nut and insert the breather tube into the hoe in the number plate Check the throttle grip operation and free play page 3 4 FRONT WHEEL REMOVAL ANN A contaminated brake drum or shoe reduces stopping power Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent Support the motorcycle securely using safety stand or a hoist Remove the axle nut axle and front wheel Remove the side collar from the
28. off the ground Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings are worn Check for worn or loose suspension pivot components by grabbing the swingarm and attempting to move the swingarm side to side Check each fastener on the swingarm and shock absorber if any looseness is noted Check the action of the shock absorber by compressing it several times Check the entire shock absorber assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 13 for shock absorber and swingarm service MAINTENANCE WHEELS TYRES RECOMMENDED TYRE PRESSURE AND TYRE SIZE pT FRONT REAR Tyre pieggpro dia 4 za75 15 175 1 75 18 sgtem ps Yr a Tyre pressure should be checked when the TYRES are COLD Check the tyres for cuts embedded nails or other damage Check the front and rear wheel for trueness refer to section 12 and 13 Measure the tread depth at the center of the tyres Replace the tyres when the tread depth reaches the following limits MINIMUM TREAD DEPTH FRONT REAR 3 0mm 0 12in Tighten any loose spokes BRAKE DISC TOOL Spoke wrench 4 1 4 5 mm 07701 0020100 STEERING HEAD BEARINGS Support the motorcycle securely and raise the front wheel off the ground Check that the handlebar moves freely from side to side If the handlebar moves unevenly binds or has
29. peak voltage Se 100 V minimum Ignition pulse generator peak voltage p07 V minimum E Alternator exciter coil peak voltage Loe 100 V minimum 0 Ignition timing F mark E a i idle a TORQUE VALUES lgnition coil mounting bolt 6N m 0 6 kgf m 4 31bf ft TOOLS Peak voltage tester U S A only or 07HGJ 0020100 not available in Peak voltage adaptor available digital multimeter impede TROUBLESHOOTING Inspect the following before diagnosing the system Faulty spark plug Loose spark plug cap or spark plug wire connections Water got into the spark plug cap leaking the ignition coil secondary voltage No spark at spark plug 1 Incorrect peak voltage adaptor connections system is normal if measured Ignition coil Low peak voltage voltage is over the specifications with reverse connections primary 2 The multimeter impedance is too low 10M DCV voltage 3 Cranking speed is too low operating force of the kickstarter is weak 4 The sampling timing of the tester and measured pulse were not synchronized system is normal if measured voltage is over the standard voltage at least once 5 Poorly connected connectors or an open circuit in ignition system 6 Faulty exciter coil Measure peak voltage 7 Faulty ignition coil 8 Faulty ICM in case when above no 1 7 are normal 1 Incorrect peak voltage adaptor connections System is normal if measured No peak voltage voltage is over the specifications with reverse con
30. shown Install the foot peg bar page6 4 Adjust the brake pedal free play page 3 15 Pour the recommended engine oil page 3 9 Adjust the clutch page 3 16 10 ALTERNATOR CAM CHAIN TENSIONER SERVICE INFORMATION 10 1 CAM CHAIN TENSIONER 10 4 TROUBLESHOOTING 10 1 STARTER FLY WHEEL INSTALLATION 10 6 FLYWHEEL STATOR REMOVAL 10 2 SERVICE INFORMATION GENERAL This section covers service of the flywheel alternator and cam chain tensioner All service can done with the engine installed the frame Refer to section 14 for alternator stator inspection SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Push rod O D 11 985 12 000 0 4718 0 4724 11 94 0 470 Cam chain tensioner Spring free length 111 7 4 40 100 3 9 TORQUE VALUES Flywheel nut 41N m 4 2kef m 301bf ft Cam chain tensioner sealing bolt 23N m 2 3kef m 171bf ft Cam chain tensioner pivot bolt 16N m 1 6kef m 121bf ft TOOLS Universal holder 07725 0030000 Flywheel puller 07933 GE0000 Only available in U S A or 07933 0010000U S A TROUBLESHOOTING Excessive engine noise Worn or damaged chain tensioner Clogged one way valve Weak or damaged cam chain tensioner spring Loose cam chain Weak or damaged cam chain tensioner spring Improper push rod operation Clogged one way valve Air in cam chain tensioner chamber ALTERNATOR CAM CHAIN TENSIONER FLY WHEEL STATOR REMOVAL Disconnect the alt
31. the gasket and dowel pins Remove the clutch adjusting nut washer and o ring Remove the clutch lifter adjusting bolt assembly Hard to shift Incorrect clutch adjustment Loose stopper plate bolt Damaged stopper plate bolt Damaged stopper plate and pin Transmission jumps out of gear Worn shift drum stopper arm Weak or broken shift arm return spring Loose stopper plate blot Gearshift pedal will not return Weak or broken gearshift spindle return Bent gearshift spindle CLUTCH GEARSHIFT LINKAGE Check the kickstarter oil seal for damage replace if necessary CLUTCH REMOVAL Remove the ball retainer and spring Remove the clutch lifer lever Remove the oil through and spring Remove the clutch lifter cam plate Remove the screws and clutch outer cover and bearing CLUTCH GEARSHIFT LINKAGE Straighten the tab of the lock washer Hold the clutch outer with the flywheel holder and remove the lock nut using the special tools as shown TOOLS 07725 0040000 Flywheel holder Lock nut wrench 20x24mm 07716 0020100 Extension bar 07716 0020500 Remove the lock washer B 14mm lock washer and clutch assembly Remove the primary dive gear Remove the drive gear Remove the snap ring and primary driven gear from the mainshaft Remove the collar from the crankshaft DISASSEMBLY Remove the following Set ring Clutch plate B Clutch disc A Clutch disc B Clutch disc A Free springs
32. too high on the valve the seat must be lowered using a 32 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner vutter Refinish the seat to specifications using a 45 degree finish cutter VALVE SEAT CUTTERS IN 07780 0012500 24 mm 30 EX 0778 0012800 21 5mm 32 IN 07780 0010600 24 mm 30 EX 0778 0011000 21 5mm 32 ge r IN 07780 0014202 22mm CONTACT TOO HIGH CONTACT TOO LOW a CYLINDER HEAD VALVES After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure Do not allow lapping compound to enter the guides After lapping wash all residual compound off the cylinder head and valve ASSEMBLY CYLINDER HEAD Gy RIGHT SIDE COVER GASKET EXHAUST VALVE ROCKER ARM SHAFT INTAKE VALVE VALVE GUIDE SPRING SEAT STEM VALVE VALVE yee COTTERS NO ane CAMSHAFT Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air Install the valve stems with engine oil and insert the valve into the valve guide To avoid damage to the stem seal turn the valve slowly when inserting Install the valve springs with the tightly wound coils facing the combustion chamber Install the valve spring retainer CYLINDER HEAD VALVES Install the valve cotters using the special tool as shown TOOL Valve spring compressor 07757 0010000 Va
33. vertical movement inspect the steering head bearing pages 12 15 Check that the control cables do not interfere with handlebar rotation LUBRICATION SYSTEM DIAGRAM PISTON MAINSHAFT OIL FILTER ROTOR OIL STRAINER KICKSTARTER 4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 0 TROUBLESHOOTING 00 4 1 SERVICE INFORMATION 4 1 ORUM E EN 4 2 SERVICE INFORMATION GENERAL WARNING When the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN The oil pump can be serviced with the engine installed in the frame The service procedures in this section must be performed with the engine oil drained If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks SPECIFICATIONS raf
34. 01 0 tenn nnn nnn cence ene Valve Valve guide EX 0 05 0 02 0 002 0 001 ff 1 Valve stemO D IN 4 970 4 985 0 1957 0 1963 4 92 0 194 EX 4 955 4 970 0 1951 0 1957 4 92 0 194 Valve guide D IN EX 5 000 5 012 0 1969 0 1973 5 03 0 198 Stem to guide clearance IN 0 015 0 042 0 0006 0 0017 0 08 0 003 EX 0 030 0 057 0 0012 0 0022 0 10 0 004 Valve seat width IN EX 1 0 1 3 0 04 0 05 2 0 0 08 Valve spring free length IN EX 33 34 1 313 31 8 1 25 Rocker arm Rocker arm I D IN EX 10 000 10 015 0 3937 0 3943 10 10 0 398 Rocker arm shaftO D IN EX 9 978 9 987 0 3928 0 3932 9 91 0 390 Camshatt Cam lobe height IN 20 003 20 123 0 7875 0 7922 19 66 0 774 EX 19 994 20 114 0 7872 0 7919 19 65 0 774 Unit mm in LUBRICATION SYSTEM ITEM STANDARD SERVICE ITEM Cylinder I D THUMPSTAR 47 05 1 8524 THUMPSTAR 52 45 2 650 Outofround nett n enn nn nce n cen 0 10 0 004 Taper enn n nnn nn none 0 10 0 004 Warpage tenn ne nnn n nen ce ns 0 05 0 002 Piston mark direction IN mark facing toward the intake side ween nnn nn wenn nae Piston Piston O D 38 975 38 995 1 5344 1 5352 38 90 1 531 Piston O D measurement point 8mm 0 3in from bottom of skirt Piston Piston pin bore D 13 002 13 008 0 5119 0 5121 13 06 0 514 rings Piston pin O D 12 994 13 000 0 5116 0 5118 12 98 0 511 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 08 0 003 Piston ring to ring
35. 04 in Calculate the C1 gear bushing to shaft clearance SERVICE LIMITS 0 10 mm 0 004 in CRANKSHAFT TRANSMISSION KICKSTARTER Gear sliding surface gear TRANSMISSION ASSEMBLY Assembly is in the reverse order of disassembly C3 GEAR 25T C2 GEAR 25T C3 GEAR 21T SS C2 GEAR 15T wy cranes aep E MAINSHAFT M1 11T a GEARSHIFT DRUM DISASSEMBLY Remove the guide pin clips Remove the guide pins then remove the shift forks Inspect the shift drum grooves for wear or damage Measure the O D of the shift drum SERVICE LIMIT 33 93mm 1 336 in CRANKSHAFT TRANSMISSION KICKSTARTER Measure the shift fork I D SERVICE LIMIT 34 14mm 1 344 in Measure the shift fork claw thickness SERVICE LIMIT 4 60mm 0 181 in SHIFT DRUM ASSEMBLY GUIDE PIN CRANKSHAFT TRANSMISSION KICKSTARTER Apply engine oil to the shift drum outer surface Install the shift forks onto the gearshift drum Install the guide pins and secure them with the clips If the washer has been removed Install a new washer and bend the tab to lock the washer TRANSMISSION BEARING REPLACEMENT Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the crankcase Remove and discard the bearing 1f the race does not turn smoothly quietly or fits loosely in the crankcase Remove the countershaft oil seal CRANKSHAFT TRAN
36. 5Ibf ft SWINGARM REMOVAL Remove the following Rear wheel page 13 3 Drive chain page 3 12 Remove the bolts and drive chain cover Remove the bolts nuts and drive chain guard Remove the shock absorber lower mounting nut and bolt Remove the swingarm pivot nut bolt and swingarm Remove the nut and bolt and the drive chain slider INSPECTION Inspect the swingarm for wear or damage Inspect the pivot bushings for wear or damage INSTALLATION Install the drive chain slider and tighten the nut TORQUE 12N m 1 2kgf m 9lbf ft Install the swingarm over the frame then install the pivot bolt from the right side and the shock absorber lower mounting bolt from the left side Apply grease to the seating surface of the swingarm pivot nut Install an tighten the nuts to the specified torque TORQUE swingarm 39N m 4 0kgf m 291bf ft Shock absorber 34N m 3 5kgf m 251bf ft BRAKE PEDAL REMOVAL Remove the rear brake adjusting nut Remove the cotter pin joint pin Unhook the brake pedal return spring from the spring holding pin Remove the cotter pin washer and brake pedal INSTALLATION Apply grease to the pivot groove and install the brake pedal Install the washer and a new cotter pin to secure the brake pedal Install the return spring as shown Install the spring onto the brake rod the joint pin into the brake arm Install the rod to the brake arm with the adjusting nut Connect the brake rod to
37. 5in Insert the piston rigs squarely into bottom of the cylinder and measure the ring end gap SERVICE LIMITS Top 0 5mm 0 02in Second 0 5mm 0 02in Oil side rail 1 1mm 0 04in Push the ring into the cylinder with the top of the piston to be sure they are squarely in the cylinder PISTON RING INSTALLATION iS x i i lt a i Pi r pas Clean the piston ring grooves thoroughly and install the Rael vA Aj piston rings Wo x jf NOTE SS Apply oil to the piston rings Avoid piston and piston ring damage during installation Install the piston rings with their marking facing up Do not confuse the top and second rings Space the piston ring end gaps 120 degrees apart Do not align the gaps in the oil rings side rails After installation the rings should rotate freely in the ring grooves PISTON INSTALLATION Apply oil to the piston pin outer surface Install the piston with its IN mark facing the intake side Install the piston pin and secure it with new piston pin clips NOTE Do not align the piston pin clips end gap with the piston cut out Do not let the piston pin clips fall into the crankcase CYLINDER INSTALLATION Clean off any gasket materials from the crankcase surface Install the dowel pins new gasket and new rubber packing Coat the cylinder bore piston outer surface and piston ring grooves with clean engine oil Route the cam chain through the cylinder and install the cylinde
38. ARK PLUG WIRE ENGINE STOP SWITCH WIRE THROTTLE CABLE ATT 2 Is f A ks j 4 li i CLAMP __ ALTERNATOR WIRE EMISSION CONTROL SYSTEMS The California Air Resources Board CARB requires manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life when operated and maintained according to the instructions provided SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Controlling hydrocarbon emissions is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Manufacturer Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting and no adjustments should be made except idle speed adjustment with the throttle stop screw The exhaust emission control system is separate from the crankcase emission control system 2 FRAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 1 NUMBER PLATE 2 3 TROUBLESHOOTING 2 1 FRONT FENDER 2 3 SEAT een 9 9 EXHAUST SYSTEM gt 2 4 FUEL TANK ee 2 3 SIDE STAN Daa 2 5
39. CM connector measure the peak voltage and compare it to the voltage measured at the ICM connector e If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal the wire harness has an open circuit or loose connection e If both peak voltages are abnormal follow the checks described in the troubleshooting chart page 14 2 ALTERNATOR EXCITER COIL PEAK VOLTAGE Avoid touching the spark plug and tester probes to prevent electric shock NOTE Check cylinder compression and check that the spark plug is installed correctly Remove the seat assembly page 2 2 IGNITION COIL _ _ NS ICM CONNECTOR EXCITER COIL CONNECTOR ICM CONNECTORS Disconnect the 3p and 2p connectors from the ICM Connect the peak voltage adaptor or peak voltage tester probes to the connector terminals of the wire harness side TOOLS Peak voltage tester Peak voltage adaptor 07HGJ 0020100 not available in us A with commercially available digital multimeter impedance 10M DCV minimum CONNECTION Black Red terminal Green Shift the transmission into neutral Crank the engine with kickstarter and read the peak voltage PEAK VOLTAGE 100v minimum If the peak voltage measured at ICM connector is abnormal measure the peak voltage at the alternator exciter coil connector Disconnect the alternator exciter coil connector black red and connect the pe
40. CRANKSHAFT TRANSMISSION KICKSTARTER CRANKCASE SEPARATION NOTE Refer to Service Information page 11 1 for removal of necessary parts before separating the crankcase Remove the snap ring from the kickstarter spindle Unhook the return spring and remove the retainer And return spring Remove the rubber cap Remove the shift drum bolt and washer Remove the cam chain Loosen the seven crankcase bolts in a crisscross Pattern in 2 3 steps and remove them CRANKSHAFT TRANSMISSION KICKSTARTER Place the crankcase with the left side down Separate the right and left crankcase halves Remove the gasket and dowel pins CRANKSHAFT REMOVAL Remove the crankshaft from the left crankcase If necessary remove the cam chain guide spindle And guide sprocket CRANKSHAFT TRANSMISSION KICKSTARTER INSPECTION Measure the connecting rod big end side clearance with a feeler gauge SERVICE LIMIT 0 6 mm 0 024 in Measure the connecting rod big end radial clearance at symmetrical points as shown SERVICE LIMIT 0 05mm 0 002in Turn the outer race of the crankshaft bearing with Your finger The bearing should turn smoothly and quietly Also check that the inner race of the bearing fits tightly on the crankshaft Check the timing sprocket for wear or damage If you replacing the timing sprocket aline the center of the sprocket teeth with the center of woodruff key groove as shown SPROCKET CRA
41. EM WARNING Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced REMOVAL Remove the seat assembly page2 2 INSTALLATION Install a new joint gasket into the exhaust port Set the exhaust pipe onto the engine by aligning the Remove the exhaust pipe joint nuts Remove the mounting bolt and the muffler Remove the exhaust pipe joint gasket Tighten the joint nuts For spark arrester maintenance refer to page3 17 exhaust pipe flange with the cylinder head studs then install the joint nuts and the mounting bolt Tighten the mounting bolt TORQUE 26N m 2 7kgf m 20lbf ft Install the seat assembly page2 2 MOUNTING BOLT pa 26N m 2 7kgf m 20Ibf ft i Sh GASKET JOINT NUTS FRAME BODY PANELS EXHAUST SYSTEM SIDE STAND REMOVAL Support the motorcycle securely with a hoist or equivalent Retract the side stand and remove the following return spring pivot nut pivot bolt side stand INSTALLATION Apply grease to the side stand pivot and sliding surfaces Install the side stand with the pivot bolt Tighten the pivot bolt TOROUE 10N m 1 0kgf m 7lbf ft Loosen the pivot bolt 45 90 Install the pivot nut and tighten it while holding the pivot bolt Install the return spring as shown Check the side stand operation for freedom of movement 3 MAINTENANCE SERVICE INFORMATION MAINTENANCE SCHEDULE
42. GINE REMOVAL INSTALLATION Engine hanger nut 2 8 31 3 2 23 FRONT WHEEL BRAKE SUSPENSION STEERING Handlebar mounting nut 2 8 20 2 0 14 Engine stop switch throttle housing screw 2 5 3 0 3 2 2 Brake lever pivot bolt 1 5 3 0 3 2 2 Brake lever pivot nut 1 5 3 0 3 2 2 Spoke nipple 28 BC2 3 2 0 2 1 4 Front axle nut 1 12 47 4 8 35 NOTE 3 Front brake arm pinch bolt 1 5 6 0 6 4 3 NOTE 4 Fork protector bolt 4 6 10 1 0 7 Steering stem nut 1 22 74 7 5 54 Steering stem top thread 1 22 Page 12 17 REAR WHEEL BRAKE SUSPENSION Spoke nipple 28 BC2 3 2 0 2 1 4 Rear axle nut 1 12 47 4 8 35 NOTE 3 Driven sprocket nut 4 8 32 3 3 24 NOTE 3 Rear brake arm pinch bolt 1 5 6 0 6 4 3 NOTE 4 Swingarm pivot nut 1 10 39 4 0 29 NOTE 2 3 Shock absorber mounting nut 2 10 34 3 5 25 NOTE 3 Drive chain slider nut 1 6 12 1 2 9 NOTE 3 IGNITION SYSTEM Ignition coil mounting bolt 1 5 6 0 6 4 3 TOOLS NOTES 1 Equivalent commercially available in U S A 2 Not available in U S A 3 Alternative tool DESCRIPTION TOOL NUMBER REMARKS REF SEC Carburetor float level gauge 07401 0010000 5 Spoke wrench 4 1x4 5mm 07701 0020100 NOTE1 3 12 13 Pin spanner 07702 0020001 12 Valve adjusting wrench 8x9mm 07708 0030100 NOTE1 3 Valve adjuster B 07708 0030400 NOTES 07908 KE90200 U S A only 3 Lock nut wrench 20x24mm 07716 0020100 9 Extension bar 07716 0020500 NOTE1 9 Universal holder 07725 0030000 10 Flywheel holder 07725 0040000 NOTE1 9 Attachment 31x35mm 07746 0010100 12 13
43. Measure the front brake lever free play at the tip of the lever FREE PLAY 10 20mm 3 8 13 16IN REAR BRAKE Check the brake pedal free play FREE PLAY 10 20MM 3 8 13 16IN Adjust the brake pedal free play by turning the adjusting nut Make sure the cutout on the adjusting nut seated on the joint pin MAINTENANCE CLUTCH SYSTEM If the clutch does not operate properly adjust by doing the following Loosen the clutch adjuster lock nut and turn the adjusting bolt one full turn counter clockwise SIDE STAND Support the motorcycle on level surface Check the side stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary LOCK SUSPENSION WARNING Loose worn or damaged suspension parts impair motorcycle stability and control Repair or replace any damaged components before riding Riding a motorcycle with faulty suspension increases your risk of an accident and possible injury FRONT SUSPENSION INSPECTION Check the action of the fork legs by operating the front brake and compressing the front suspension several times Check the entire assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 12 for fork service MAINTENANCE REAR SUSPENSION INSPECTION Support the motorcycle on safety stand or box and raise the rear wheel
44. NKSHAFT TRANSMISSION KICKSTARTER Place the crankshaft on a stand or V blocks and Measure the runout using a dial gauge The measuring locations are shown in the illustration SERVICE LIMIT 0 10mm 0 004 in INSTALLATION Install the guide sprocket and guide spindle Pour 1 2cm of engine oil into the connecting rod big end bearing Install the crankshaft into the left crankcase being careful not to interfere the connecting rod with the crankcase Assemble the crankcase halves page 11 14 TRANSMISSION REMOVAL Remove the kickstarter spindle page 11 12 Remove the mainshaft countershaft and shift drum as an assembly CRANKSHAFT TRANSMISSION KICKSTARTER TRANSMISSION DISASSEMBLY Disassemble the mainshaft countershaft and shift drum TRANSMISSION INSPECTION Check the gear dogs dog holes and teeth for abnormal wear or lack of lubrication Measure the I D of each gear SERVICE LIMITS M2 17 10mm 0 673 in C1 23 10mm 0 909 in C3 20 10mm 0 791 in Measure the I D and O D of Cl gear bushing SERVICE LIMIT O D 22 93mm 0 903in D 20 08MM 0 79 Lin Calculate the CI gear to bushing clearance SERVICE LIMIT 0 10mm 0 004in Check the shifter groove of the shifter gear for excessive wear or damage Measure the O D of the mainshaft and countershaft SERVICE LIMITS At M2 gear 16 95 mm 0 667 in At Cl gear 19 94 mm 0 785 in Calculate the M2 gear to shaft clearance SERVICE LIMITS 0 10 mm 0 0
45. OOL Carburetor float level gauge 07401 001000 The float cannot be adjusted Replace the float assembly if the float level is out of specification Install a new o ring into the carburetor groove properly Install the float chamber Install and tighten the flat chamber screws FUEL SYSTEM CARBURETOR INSTALLATION CARBURETOR BODY Install new o ring into the insulator and carburetor body grooves Install the carburetor body into the air cleaner connection tube and the insulator between the manifold and carburetor then install the mounting bolts Tighten the connecting tube band screw and mounting bolts TORQUE Connecting tube 1N m 01kgf m 0 7lbf t THROTTLE VALVE Install the needle clip on the jet needle STANDARD POSITION 3rd groove from top CR70 4th groove from top CR107 O RING INSULATOR FUEL SYSTEM Install the jet needle into the throttle valve and secure it with the needle clip retainer Check the seal ring is in good condition replace if necessary Install the throttle valve spring onto the throttle cable Connect throttle cable to the throttle valve while compressing the throttle valve spring Install the throttle valve into the carburetor body aligning its cut out with the throttle stop screw 6 ENGINE REMOVAL AND INSTALLATION 6 ENGINE REMOVAL AND INSTALLATION SERVICE INFORMATION 6 1 ENGINE INSTALLATION 6 4 ENGINE REMOVAL
46. RAL ITEM SPECIFICATIONS Overall Length 1 430mm 71 0 in Overall width 760mm 30 0 in Overall height 950mm 37 4 in Wheelbase 990mm 38 9in Seat height 700mm27 6 in Foot peg height 215mm 8 5 in Ground clearance 240mm 9 4 in Dry weight 60 kg 180 8 Ibs FRAME Frame type Back bone Front suspension Telescopic fork Rear suspension Swingarm Rear damper Conventional type oil damper Front tyre size 2 50 10 12 14 Rear Tyre 2 50 2 75 3 00 10 12 Caster angle Front Rear C 183A 3 Trail length Internal expanding shoe Fuel tank capacity Internal expanding shoe Fuel tank reserve capacity 26 35mm 1 4 in 3 0 amp 0 79 US gal 0 66 Imp gal 0 9 amp 0 24 US gal 0 20 Imp gal ENGINE Bore and stroke 90cc 47mmx49 5mm 110cc 52 4mmx49 5mm 125cc 52 4mmx57mm Displacement 90cc 86ml 110cc 107ml 125cc 122 7ml Compression ratio 90cc 9 0 1 110cc 9 7 1 125cc 9 0 1 Valve train Chain driven OHC with rocker arm Intake valve opens at 1mm 7 5 BTDC closes 0 04in 12 5 ABDC Exhaust valve opens lift 22 5 BBDC closes 2 5 BIDC Lubrication system Forced pressure and wet sump Oil pump type Trochoid Air filtration Foam Style Crankshaft type Oiled polyurethane foam Engine dry weight Assembled type Cylinder arrangement 21kg 46 3lbs GENERAL INFORMATION ITEM SPECIFICATIONS CARBURETOR Carburetor type Piston valve Throttle bore DRIVE TRAIN Clutch system Multi plate wet Clutch operation system Automatic centrifugal Transmissi
47. SHOOTING FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON MANUFACTURER S MOTORCYCLES INDEX MOTOR SCOOTERS OR ATVS SERVICE PUBLICATION OFFICE REAR WHEEL BRAKE SUSPENSION WIRING DIAGRAM SYMBOLS The symbols used through out this manual show specific service procedures If supplementary information is required it would be explained specifically in the text without the use of the symbols Replace the part s with new one s before assembly Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease in a ratio of 1 1 Use multi purpose grease Lithium based multi purpose grease NLG1 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLG 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLG 2 or equivalent Example Molykote G N paste manufactured by Dow Corning U S A Manufacture Moly 610 U S A only Rocol ASP manufactured by Rocol Limited U K Rocol Paste manufactured by Sumico Lubricant Japan Use silicone grease Apply a locking agent Use a middle strength locking agent unless otherwise specified Apply sealant Use DOT 4 brake fluid Use the recommended brake fluid unles
48. SMISSION KICKSTARTER Drive the mainshaft bearing out of the right crankcase Drive the countershaft bearing out of the left crankcase Drive new bearings into the crankcases using the special tools as shown TOOLS Drive 07749 001000 Attachment 37 40mm 07746 0010200 Pilot 17mm 07746 0040400 Apply engine oil to a new countershaft oil seal lip Install the countershaft oil seal TRANSMISSION INSTALLATION Apply clean engine oil to the transmission gears and shift drum Set the right fork into the M3 gear and the left fork into the C2 gear to assemble the mainshaft Countershaft and shift drum as shown Install the mainshaft countershaft and shift drum as an assembly into the left crankcase Rotate the shift drum to check the transmission operation Install the kickstarter spindle page 11 14 KICKSTARTER REMOVAL Remove the kickstarter spindle from the right crankcase DISASSEMBLY Remove the washer Remove the snap ring and starter ratchet spring CRANKSHAFT TRANSMISSION KICKSTARTER Remove the snap ring washer and starter pinion gear INSPECTION Check the kickstarter spindle for bending Check the friction spring for fatigue Check each part for wear or damage replace if necessary ASSEMBLY Assembly is in the reverse order of disassembly KICKSTARTER SPINDLE ae a ie ee Fi PINION GEAR S WASHER SNAP RING ad a J WASHER a SNAP RING FRICTION SPRING STARTER
49. SSION T3 CAMSHAFT INSTALLATION 7 15 SERVICE INFORMATION GENERAL This section covers service of the cylinder head valves and camshaft The cylinder head valves and camshaft services can be done with the engine installed in the frame When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original locations Clean all disassembled parts with cleaning solvent and dry them off with compressed air before inspection Camshaft lubricating oil is fed through oil passages in the cylinder head Clean the oil passages before assembling cylinder head Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head Refer to section 10 for cam chain tensioner service SPECIFICATIONS ITEM STANDARD Cylinder compression 981 1 177kpa 10 0 12 0kgf cm 142 17lpsi at 1 000 rom Cylinder head warpage Valve Valve clearance 0 05 0 02 0 002 0 001 valve guide 0 05 0 02 0 002 0 001 Valve stem O D 4 970 4 985 0 1957 0 1963 4 955 4 970 0 1951 0 1957 5 000 5 012 0 1969 0 1973 0 015 0 042 0 0006 00017 0 030 0 057 0 0012 0 0022 1 0 1 3 0 04 0 05 D IN EX D 35 55 Rocker arm I D Rocker arm shaft O D Camshaft Cam lobe height 90 110cc__ IN26 563 26 683 1 046 1 051 Cd EX26 326 26 446 1 036 1 041 SY H125ec___ IN26 507 26 637 1 044 1 048 Cd EX26 321 26 441 1 036 1 041 TORQUE VALUES Cylinder head nut Cyl
50. _ Clean Cam sprocket not installed properly Faulty ignition control module Faulty ignition pulse generator gt Faulty spring Possible cause gt Steering stem adjusting nut too tight Damaged steering head bearings Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bushing excessively worn Bent frame Faulty shock absorber Front and rear wheel not aligned Bent fork Bent swingarm Bent axle DAROOK spi STRATEGIES SOLUTIONS IN DESIGNS WWW THUMPSTAR US
51. a Air MAINTENANCE Resources Board LUBRICATION SYSTEM Performing the first scheduled maintenance is very important It ENGINE compensates for the initial wear that occurs during the break in period fe FUEL SYSTEM TRAIN Sections 1 and 3 apply to the whole motorcycle Section 2 illustrates ENGINE REMOVAL INSTALLATION what may be required to perform service described in the following sections Section 4 through 14 describe parts of the motorcycle grouped according to location CYLINDER HEAD VALVES CYLINDER PISTON Find the section you want on this page then turn to the table of contents on the first page of the section CLUTCH GEARSHIFT LINKAGE Most sections have an assembly or system illustration service ALTERNATOR CAM CHAIN TENSIONER information and troubleshooting for the section CRANKSHAFT TRANSMISSION KICKSTARTER The subsequent pages give detailed procedures If you don t know the source of the trouble go to section 16 troubleshooting FRONT WHEEL BRAKE SUSPENSION STEERING ALL INFORMATION ILLUSTRATIONS DIRECTIONS AND SPECIFICATION INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING ELECTRICAL IGNITION SYSTEM THUMPSTAR MOTOR INC RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION THIS MANUAL IS WRITTEN TROUBLE
52. a contaminated drum with a high quality brake degreasing agent When servicing the front wheel brake fork or steering stem support the motorcycle using a safety stand or ho SPECIFICATIONS Unit mm in Minimum tire tread depth e 3001D Cold tire pressure 100kpa 1 Okgf em 15psi f Axle runout e 0 200 008 Wheel rim to hub distance 63 1 0 0 25 0 04 Radial e 2 00 08 Mhel im runout Rg on Brake Brake Fever ee pay __J0 70mm 810169 o Fork Spring free length 373 5 14 7 TORQUE VALUES Handlebar mounting nut 20N m 2 0kef m 141bf ft Engine stop switch holder screw 3N m 0 3kegf m 2 21bf ft Brake lever pivot nut 3N m 0 3kef m 2 21bf ft Brake lever pivot nut 3N m 0 3kef m 2 21bf ft Spoke nipple 2N m 0 2kef m 1 41bf ft Front axle nut 47N m 4 8kegf m 351bf ft Front brake arm pinch bolt 6N m 0 6kef m 4 31bf ft Steering stem nut 74N m 7 5kef m 541bf ft Steering stem top thread See Page 12 17 FRONT WHEEL BRAKE SUSPENSION STEERING TOOLS Spoke wrench 4 1 4 5Mm Bearing remover shaft Bearing remover head 12mm 07707 0020100 07746 0050100 07746 0050300 Driver 07749 00 10000 Attachment 32 35mm Pilot 12mm Pin spanner Ball race remover Attachment 37 40mm Steering stem driver TROUBLESHOOTING Hard steering Faulty or damaged steering head bearings Insufficient tire pressure Steering stem top thread too tight Steers to one side or does not track str
53. aight Bent fork Bent axle Wheel installed incorrectly Faulty steering head bearings Bent frame Worn wheel bearing Worn swingarm pivot components Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel 07746 0010100 07746 0040200 07702 0020001 07944 1 150001 07746 0010200 07946 gc40000 or Steering stem driver 07946 MBO0000 wit Steering stem driver attachment 07946 GC4000a U S A only Wheel turns hard Faulty wheel bearing Bent front axle Brake drag Soft suspension Weak fork springs Tire pressure too low Hard suspension Bent fork tubes Front suspension noisy Damaged or bent fork tubes Loose fork fasteners Improper brake performance Incorrect adjustment of lever Contaminated brake shoes Worn brake shoes Worn brake cam Worn brake drum Improperly engaged brake arm serrations FRONT WHEEL BRAKE SUSPENSION STEERING ay HANDLEBAR REMOVAL Remove the fuel tank breather tube from the number plate and the number plate from the steering stem nut Remove the wire bands Remove the two screws and engine stop switch throttle housing from the handlebar Disconnect the throttle cable and remove the throttle grip Remove the left handlebar grip FRONT WHEEL BRAKE SUSPENSION STEERING Remove the two nuts and handlebar INSTALLATION Install the handlebar into the fork top bridge and tighten the
54. ain tensioner page 10 4 Disconnect the spark plug cap Loosen the cylinder head side cover 6 mm bolt Tap the head of the 6mm bolt and release the cylinder head left side cover from the cylinder head Remove the 6 mm bolt sealing washer and cylinder head left side cover Turn the crankshaft counter clockwise and align the O mark on the cam sprocket with the index notch on the cylinder head Remove the bolts cam sprocket and dowel pin Secure the cam chain with a piece of wire to prevent it from falling into the cylinder CAM SPROCKET 7 CYLINDER HEAD VALVES Loosen the valve adjusting screw fully to make a valve clearance maximum pages 8 Temporarily install the cam sprocket bolts into the camshaft and remove the camshaft from the cylinder head while holding the rocker arms CAMSHAFT INSPECTION Turn the outer race of each camshaft bearing with your finger The outer race should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly if the outer race does not turn smoothly and quietly or if it fits loosely on the camshaft Using a micrometer measure each cam lobe height SERVICE LIMITS 90 110 125cc IN 26 22mm 1 032in EX 25 98mm 1 023in CYLINDER HEAD REMOVAL Remove the following Muffler page 2 4 Camshaft page 7 3 Remove the intake manifold bolts 7 CYLINDER HEAD VALVES Remove the followin
55. ak voltage adaptor or tester probes to the connector terminal of the exciter coil side and ground In the sane manner as at the ICM connector measure the peak voltage and compare it to the voltage measured at the ice connector If the peak voltage measured at the ICM is abnormal and the one measured at the alternator exciter coil is normal the wire harness has an open circuit or loose connection If both peak voltages are abnormal follow the checks described in the troubleshooting chart page 14 2 IGNITION COIL REMOVAL INSTALLATION Disconnect the spark plug cap from the plug Disconnect the wires from the ignition coil Remove the bolt and ignition coil Installation is in the reverse order of removal TORQUE 6N m 0 6kgf M 4 3 Ibf ft IGNITION CONTROL MODULE REMOVAL INSTALLATION Remove the seat assembly page 2 2 Disconnect the Ignition Control Module ICM connectors Remove the ICM from the frame Install action is in the reverse order of removal ENGINE STOP SWITCH IGNITION SWITCH INSPECTION Disconnect he switch connectors Check for continuity between the black white and green write terminals of the switch side connectors There should be continuity with the switch OFF and there should be no continuity when the engine stop switch is RUN or the ignition switch is ON IGNITION TIMING AWARNING When the engine must be running to do some work make sure the area is well ventilated
56. ather tube clogged Lean mixture Fuel jets clogged Float valve faulty Float level too low Fuel line restricted Carburetor air vent tube clogged Intake air leak Throttle valve faulty Rich mixture Choke lever in CLOSED position Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetor FUEL SYSTEM AIR CLEANER HOUSING REMOVAL AND INSTALLATION NOTE Refer to page 3 5 for air cleaner element service Loosen the connection tube band screw Remove the bolt and the air cleaner housing assembly Installation is in the reverse order of removal At installation secure the ground eyelet with the air cleaner housing mounting bolt CARBURETOR REMOVAL Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN THROTTLE VALVE Loosen the carburetor top Remove the carburetor top and throttle valve from the carburetor Engine stall hard to start rough idling Fuel line restricted lgnition malfunction Fuel mixture too lean or too rich Fuel contaminated or deteriorated ldie speed maladjusted Float level maladjusted Fuel tank breather tube clogged Air screw maladjusted Slow circuit clogged After burn when engine braking is used Lean mixture in slow circuit Backfiring or misfiring during acceleration lgnition mixture in slow circuit Fuel mixture too lean Poor performance and po
57. ber the hose or other hand lapping tool Remove and inspect the valves CAUTION The valves cannot be ground If a valve face is burned or badly worn or if it contacts the seat unevenly replace the valve Inspect the width of each valve seat STANDARD 1 0 1 3 mm 0 04 0 05 in SERVICE LIMIT 2 0mm 0 08in If the seat is too wide too narrow or has low spots the seat must be ground CYLINDER HEAD VALVES VALVE SEAT REFACING Valve seat cutters grinders equivalent valve seat refacing equipment are recommended to correct worn valve seats NOTE Follow the refacing manufacturers operation instructions Use a 45 degree cutter to remove any roughness or irregularities from the seat Reface the seat with a 45 degree cutter whenever a valve guide is replaced Use a 32 degree IN 30 cutter to remove the top 1 4 of the existing valve seat material CYLINDER HEAD VALVES Use a 60 degree cutter to remove the bottom 1 4 of the old seat Remove the cutter and inspect the area you have refaced Install a 45 degree finish cutter and cut the seat to the proper width Make sure that all pitting and irregularities are removed Refinish if necessary Apply a thin coating of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern NOTE The location of the valve seat in relation to the valve face is very important for good sealing If the contact area is
58. carburetor air screw Incorrect adjustment Correct j 2 Check for leaking intake pipe Not leak j 3 Perform spark test Leaking 4 Check ignition timing Incorrect POOR PERFORMANCE AT HIGH SPEED 1 Disconnect fuel tube and check the fuel flow fuel flows freely 2 Remove the carburetor and check _ Clogged for clogging Not clogged 3 Check valve timing incorrect correct 4 Check ignition timing incorrect correct 5 Check valve spring ___ weak not weak POOR HANDLING 1 If steering is heavy 2 If either wheel is wobbling 3 If the motorcycle pulled to one side Weak or intermittent spark Possible cause See section 5 Loose carburetor mounting bolts Damaged insulator Faulty or fouled spark plug Faulty ignition control module Faulty ignition coil Broken or shorted spark plug wire Faulty engine stop switch or ignition switch Faulty ignition pulse generator Loose or disconnected ignition system wires Improper ignition timing faulty ignition control module Possible cause Fuel flow restricted _ _ _ Clogged fuel ling Clogged fuel tank breather tube Faulty fuel valve Clogged fuel strainer gt
59. ck each wheel bearing cavities with grease Drive each wheel bearing cavities with grease Drive in a new left bearing squarely with its sealed side facing out Install the distance collar and drive in a new right bearing using the same tools TOOLS Driver 07749 0010000 Attachment 32 35mm 07746 0010100 Pilot 12mm 07746 0040200 FRONT WHEEL BRAKE SUSPENSION STEERING Wheel center adjustment Place the rim on the work bench Place the hub with the right side down and begin lacing with new spokes Adjust the hub position so that the distance from the hub left end surface to the side of rim is 6 341mm 0 25 40 04 in as shown TOOL Spoke wrench 4 1 4 5mm 07701 0020100 Equivalent commercially available in U S A TORQUE 2N m 0 2kef 1 41bf ft Check the rim runout page 12 8 Apply grease to a new dust seal lips then install it into the right wheel hub Install the side collar into the right wheel hub FRONT WHEEL BRAKE SUSPENSION STEERING Install the front wheel between the fork legs Apply a thin layer of grease to the front axle surface Install the front axle from the right side Hold the axle and temporarily tighten the axle nut With the front brake applied pump the fork up and down several times to seat the axle and check brake operation Tighten the axle nut to the specified torque TORQUE 47N m 4 8kef m 351bf ft FRONT WHEEL BRAKE SUSPENSION STEERING FRONT BRAKE ASSEMBLY FR
60. e Axle runout 2 nnn n nnn nn nee 0 20 0 008 Wheel rim run out Radial nee nn nnn nnnnne 2 0 0 08 Drive chain Axial Tommee 2 0 0 08 Brake Size Link DID420MBK1 88 tenn nen nnn nn nnn Slack 15 25 9 16 1 0 net nnn nnn n nnn Brake pedal free play 10 20 3 8 13 16 0 etn n nnn nn nnn n ne nnee ITEM SPECIFICATIONS Spark plug Standard CR6EHSA NGk U20FSR U DENSO For cold climate below410F 50C CRS5HSA NGk U16FSR U DENSO For extended high speed riding CR7HSA NGk U22FSR U DENSO Spark plug gap 0 60 0 70mm 0 024 0 028in Ignition coil peak voltage 100Vminimum Ignition coil generator peak voltage 0 7Vminimum Alternator exciter coil peak voltage 100Vminimum Ignition timing F mark 15 BTDC at idle TORQUE VALUES STANDARD TORQUE TORQUE FASTENER TYPE N m kgf m ibf ft N m kgf m ibf ft 4 0 4 2 9 5mm hex bolt and nut 5 0 5 3 6 9 0 9 6 5 6mm hex bolt and nut 10 1 0 7 10 1 0 7 8mm hex bolt and nut 22 2 2 16 12 1 2 9 10mm hex bolt and nu 34 3 5 25 12 1 2 9 12mm hex bolt and nu 54 5 5 40 26 2 7 20 39 4 1 29 Torque specifications listed below are for important fasteners Others should be tightened to standard torque values listed above NOTES 1 Apply oil to the threads 2 Apply grease to the seating surface 3 U nut 4 ALOC bolt replace with a new one ENGINE on Q TY THREAD DIAMETER mm TOPOLE REMARKS N m kgf m lIbf ft MAINTENANCE S
61. e left dust seal Wheel bearing removal Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing remover head 12mm 07746 0050300 Equivalent Bearing remover shaft 07746 00501 00 Equivalent ASSEMBLY DISTANCE COLLAR DRIVEN SPROCKET ADJUSTER AXLE AND NUT DISTANCE COLLAR mae ee D z Af p pi BEARING a fy r E rl rr TAa T E wl HR TR DUST SEAL aff AE ERIE ay Pe Bet ee F Pe Lay jT wa ae 7 a E a EG a Fi 4 bao Fi W pe ENM lt r f he 5A tw ie ae IA Aa a ba T BOLT uaa en em WG aa DRIVEN w Wheel bearing installation CAUTION Never install the old bearings once the bearings has been removed the bearing must be replaced with new ones Pack each wheel bearing cavity with grease Drive in a new right bearing squarely with the sealed side facing up using the special tools as shown TOOLS Driver 07749 0010000 Attachment 32x35mm 07746 0010100 Pilot 12mm 07746 0040200 Install the distance collar and drive in a new left bearing using the same tools Wheel center adjustment Place the rim on the word bench Place the hub with the left side down and begin lacing with new spokes Adjust the hub position so that distance from the hub right end surface to the side of rim is 25 1mm 1 0 0 04
62. e nut 47N m 4 8kgf m 351bf ft U nut Driven sprocket nut 32N m 3 3kgf m 24lbf ft U nut 39N m 4 0kgf m 291bf ft Apply grease to the seating surface U nut 34N m 3 5kgf m 251bf ft U nut 12N m 1 2kgf m 91bf ft U nut Swingarm pivot nut Shock absorber mounting nut Drive chain slider nut TOOLS Spoke wrench 4 1x4 5mm Bearing remover shaft Bearing remover head 12mm Drive Spanner 32x35mm Pilot 12mm TROUBLESHOOTING Soft suspension e Weak shock absorber spring e Oil leakage from sampler unit e Tire pressure too low Hard suspension e Bent damper rod e Damaged swingarm pivot bushings e Bent swingarm pivot e Tire pressure too high Steers to one side or does not track straight e Bent rear axle 07701 0020100 07746 0050100 07746 0050300 07749 0010000 07746 0010100 07746 0040200 Equivalent commercially available in U S A Equivalent commercially available in U S A Rear wheel wobbling e Bent rim e Worn rear wheel bearings e Faulty tire e Unbalanced tire and wheel e Tire pressure too low e Faulty swingarm pivot bushings e Axle alignment chain adjustment not equal on both sides REAR WHEEL REMOVAL Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground P Fi ral l A mi Pal i H tes Y E Te We v m P eget _ k we a ay i J z Na f i j i Al Te pes i k ome 4 i Loosen the drive chain adjuster lock nuts and adjusting nuts Remov
63. e sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Warm up the engine Stop the engine and remove the oil filler cap dipstick and drain bolt Drain the oil completely Used oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis It is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN MAINTENANCE Check that the sealing washer on the drain bolt is in good condition replace if necessary Install and tighten the drain bolt TORQUE 25N m 2 5kgf m 18lbf ft Fill the crankcase with recommended engine oil page3 8 OIL CAPACITY 0 6L 0 6USaqt 0 5Imp qt at draining 0 8L 0 8USqt 0 7lmp qt at disassembly Install the oil filler cap dipstick Start the engine and let it idle for 2 to 3 minutes Stop the engine and recheck the oil level Make sure there are no oil leaks WASHER UPPER LOWE kat mi ms ENGINE OIL STRAINER SCREEN CLEANING Remove the right crankcase cover page9 3 Remove the oil strainer screen and the sealing rubber Check the screen for damage and the sealing rubber for da
64. e the axle nut and drive chain adjuster Push the rear wheel forward and derail the drive chain from the driven sprocket Remove the axle from the left side and remove the rear wheel Remove the left side collar the left wheel hub INSPECTION Axle Place the axle in V blocks and measure the run out Actual run out is 1 2 the total indicator reading SERVICE LIMI0 20mm 0 008 in Wheel bearing Turn the inner race of each bearing with your finger Bearings should turn smoothly and quietly Also check that the bearing outer race first tightly in the hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the hub replace the wheel bearings in pairs Wheel rim run out Check the rim run out by placing the wheel in a turning stand Spin the wheel slowly and read the run out using a dial indicator Actual run out is 1 2 the total indicator reading SERVICE LIMITS Radial 2 0 mm 0 08in Axial 2 0 mm 0 08in Driven sprocket Check the condition of the final driven sprocket teeth Replace the sprocket if worn or damaged NOTE e If the final driven sprocket requires replacement inspect the drive chain and drive sprocket e Never install a new drive chain on a worn sprocket or a worn chain on new sprockets Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rapidly DISASSEMBLY Remove the nuts bolts and driven sprocket Remove th
65. eak voltagg1 The multimeter impedance is too low 10MO DCV pulse 2 Cranking speed is too slow operating force of the kickstarter is weak Generator 3 The sampling timing of the tester and measured pulse were not synchronized system is normal if measured voltage is over the standard voltage at least once 4 Faulty ignition pulse generator in case when above no 1 3 are normal No peak voltage Faulty poak voltage adaptor 2 Faulty ignition pulse generator IGNITION SYSTEM INSPECTION NOTE If there is no spark at plug check all connections for loose or poor contact before measuring each peak voltage 17 N m 1 7kgf m 12lbf ft 13Nem 1 3kgf m Qlbf ft SS 42Nem 4 3kgi m 31lbf ft a SNe m 0 5kgf m 3 6lbf ft 9 CLUTCH GEARSHIFT LINKAGE SERVICE INFORMATION TOLG aa ee eee 9 4 TROUBLESHOOTING 9 2 GEARSHIFT LINKAGE 9 14 RIGHT CRANKCASE 9 3 RIGHT CRANKCASE 9 17 COVER REMOVAL COVER INSTALLATION SERVICE INFORMATION GENERAL This section covers service of the clutch and gearshift linkage All service can be done with the engine installed in the frame Use care not to allow dust or dirt to enter the engine Transmission oil viscosity and level have an effect on clutch disengagement When the clutch does not disengage or the motorcycle creeps with clutch disengaged inspect the transmission oi
66. ernator and ignition pulse generator connectors Remove the bolt and gearshift pedal Remove the three bolts and left crankcase cover Hold the flywheel using the universal holder and remove the flywheel nut TOOL Universal holder 07725 0030000 Remove the washer ALTERNATOR CAM CHAIN TENSIONER Remove the flywheel using the special tool TOOL Flywheel puller 07933 GE00000 Not available in U S A Flywheel puller 07933 0010000 U S A only Remove the woodruff key Remove the bolt and wire clamp Release the wire grommet from the crankcase groove Remove the four mounting bolts and wire clamp and the ignition pulse generator and stator as an assembly ALTERNATOR CAM CHAIN TENSIONER Drain the engine oil page 3 9 Remove the screws and stator base Remove the O rings CAM CHAIN TENSIONER REMOVAL Remove the stator base page 10 2 Remove the sealing bolt tensioner spring and push rod Remove the pivot bolt tensioner arm and tensioner roller ALTERNATOR CAM CHAIN TENSIONER INSPECTION Measure the tensioner spring free length SERVICE LIMIT 100mm 3 9in Check the push rod for wear or damage Measure the push rod O D SERVICE LIMIT 11 94 mm 0 470in INSTALLATION Install the cam chain tensioner roller tensioner arm and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 16N m 1 6kgf m 1 21bf ft Check the sealing washer is in good condition replace if nece
67. g Cap nuts seating washers Nut sealing washer Cylinder head cover Gasket Remove the cylinder head mounting bolt and cylinder head Remove the following Gasket Dowel pins Collar O ring DISASSEMBLY Remove the spark plug Remove the bolts and cylinder head right side cover Temporarily install a 8 mm bolt to the rocker arm shaft and remove the rocker arm shafts and rocker arms 7 CYLINDER HEAD VALVES Remove the valve springs using the special tools as shown TOOLS Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 CAUTION To prevent loss of tension do not compress the valve springs more than necessary to remove the cotters Remove the following Mark all parts during Spring retainer disassembly so they can Valve spring be placed back in their original Valve locations Stem seal Valve spring seat Cotters INSPECTION CYLINDER HEAD Remove carbon deposits from the combustion chamber Check the spark plug hole and valve areas for cracks Avoid damaging the gasket surface Check the cylinder head for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 05mm 0 002 in SPR O RING COLLAR SHAFI 7 CYLINDER HEAD VALVES ROCKER ARM Inspect the rocker arm slipper surfaces for wear or damage Also check that the oil holes are not clogged If either rocker arm requires Measure the rocker arm I D service or replacement inspect
68. he ignition coil primary wire terminal and found CONNECTION Black yellow terminal Body ground Turn the ignition switch ON and engine stop switch to RUN Shift the transmission into neutral Crank the engine with the kickstarter and read ignition coil primary peak voltage PEAK VOLTAGE 100V minimum If the peak voltage is abnormal follow the checks described in the troubleshooting chart page 14 2 IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check cylinder compression and check that the spark plug is installed correctly Remove the seat assembly page 2 2 Disconnect the 4P connector from the ICM Connect the peak voltage adaptor or peak voltage tester probes to the connector terminals of the wire harness side TOOLS Peak voltage tester Peak voltage adaptor O07HGJ 00210100 not available in U S A with commercially available digital multimeter impedance 10M DCV minimum CONNECTION Blue Yellow terminal Green Shift the transmission into neutral Crank the engine with the Kickstarter and read the peak voltage PEAK VOLTAGE 0 7V minimum If the peak voltage measured at ICM connector is abnormal measure the peak voltage at the pulse generator connector Disconnect the ignition pulse generator connector blue yellow and connect the peak voltage adaptor or tester probes to the connector terminal of the ignition pulse generator side and ground In the same manner as at the I
69. hift arm them pull out the gearshift spindle from the crankcase Remove the bolt and shift cam plate Remove and gearshift drum pins INSPECTION Check the gearshift spindle or bends or other damage INSTALLATION Install the four gearshift drum pins Install the cam plate and tighten the bolt to the specified torque TORQUE 17N m 1 7kgf m 12lbf ft Install the gearshift spindle into the crankcase by aligning the return spring ends with the spring pin while pushing down the gearshift arm and set the gearshift arm to the shift drum pins Install the return spring and stopper arm as shown and tighten the bolt to the specified torque TORQUe 13N m 1 3kgf m 9lbf ft Install the gearshift pedal so that it is same height as the foot peg Install the pinch bolt and tighten it Install the driven gear and clutch assembly page9 12 RIGHT CRANKCASE COVER INSTALLATION Install the clutch lifter plate adjusting bolt into the right crankcase cover by aligning is pin with the hole in the crankcase cover Coat a new O ring with engine oil and install it into the cover groove properly Install the washer and lock nut SPRING Install the dowel pins and a new gasket Install the right crankcase cover Install and tighten the eight cover bolts in a crisscross pattern several steps Install the kickstarter as shown and tighten the bolt Hook the return spring to ten brake pedal and spring holding pin as
70. ift spindle from the crankcase Remove the bolt and shift cam plate Remove the dowel pins and gearshift drum pins CLUTCH GEARSHIFT LINKAGE INSPECTION Check the gearshift spindle or bends or other damage INSTALLATION Install the four gearshift drum pins and two dowel pins Install the cam plate and tighten the bolt to the specified torque TORQUE 17N m 1 7kgf m 12lbf ft Install the gearshift spindle into the crankcase by aligning the return spring ends with the spring pinwheel pushing down the gearshift arm and set the gearshift arm to the shift drum pins CLUTCH GEARSHIFT LINKAGE Install the return spring and stopper arm as shown and tighten the bolt to the specified torque TORQUe 13N m 1 3kgf m Qlbf ft Install the gearshift pedal so that it is same height as the foot peg Install the pinch bolt and tighten it Install the driven gear and clutch assembly page9 12 RIGHT CRANKCASE COVER INSTALLATION Install the clutch lifter plate adjusting bolt into the right crankcase cover by aligning is pin with the hole in the crankcase cover Coat a new O ring with engine oil and install it into the cover groove properly Install the washer and lock nut CLUTCH GEARSHIFT LINKAGE Install the dowel pins and a new gasket Install the right crankcase cover Install and tighten the eight cover bolts in a crisscross pattern several steps Install the kickstarter as shown and tighten the bolt Ho
71. in as shown TOOL Spoke wrench 4 107701 0020100 equivalent TORQUE 2N m 0 2kef m 1 41bf ft Check the rim run out page 13 4 Apply grease to new dust seal and install it into the left wheel hub Install the driven sprocket bolts and nuts and tighten them TORQUE 32N m 3 3kgf m 24Ibf ft INSTALLATION Install the left side collar into the left wheel hub Place the rear wheel into the swingarm Install the drive chain over the driven sprocket Apply thin layer of grease to the axle Install the axle with the right drive chain adjuster from the right side Install the left drive chain adjuster and axle nut 251 a fw g tS uoa FE REAR SUSPENSION SHOCK ABSORBER REMOVAL Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground Remove the seat page 2 2 Remove the shock absorber lower mounting nut and bolt Remove the upper mounting nut and bolt and the shock absorber INSPECTION Visually inspect the following Spring for fatigue or damage Damper rod for bend or damage Damper unit for deformation or oil leaks Bump rubber for wear or damage Mounting bushings for damage Replace the shock absorber assembly if necessary INSTALLATION Install the shock absorber into the frame and swingarm Install the upper and lower mounting bolts from the left side install the nuts and tighten them to the specified torque TORQUE 34N m 3 5kgf m 2
72. inder head right side cover bolt Cam sprocket bolt 7 CYLINDER HEAD VALVES TOOLS Valve spring compressor Valve spring compressor attachment Valve guide reamer 5 0mm Valve guide reamer 5 0mm Valve seat cutters Seat cutter 24mm 45 IN Seat cutter 20 5mm 45 EX Flat cutter 24mm 32 IN Flat cutter 21 5mm 32 EX Interior cutter 22mm 60 IN EX TROUBLESHOOTING 11N m 1 1 kgf m 8 Ibf ft ft 10N m 1 0 kgf m 7 Ibf ft ft 9N m 0 9 kgf m 6 5lbf ft 07757 001000 07959 KM30101 07742 MA60000 07984 MA60001 or 07984 MA6000C U S A only These are commercially available in 07780 0010600 07780 001 1000 07780 0012500 07780 0012800 07780 0014202 07781 0010400 Engine top end problems usually affect engine performance These problems can be diagnosed by a compression gauge or by tracing engine noises to the top end with a sounding rod stethoscope If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Section 8 Compression too low hard starting or poor performance at low speed Valves Incorrect valve clearance Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Worn cylinder piston or piston rings section 8 Compression too high overheating or knocking Excessive carbon build up on piston crown or
73. ine place the motorcycle on its side stand and shift the transmission into neutral Check the slack in the lower drive chain midway between the two sprockets CHAIN SLACK 15 25mm 5 8 1in CAUTION Excessive chain slack 40mm 1 1 2in or more may damage the frame ADJUSTMENT Loosen the axle nut Loosen the adjuster lock nuts and turn both adjusting nuts an equal number of turns until the correct drive chain slack is obtained Make sure the index marks on both adjusters are aligned with the index lines on the swingarm Tighten the rear axle nut to the specified torque TORQUE 47N m 4 8kgf m 345ibf ft Tighten both lock nuts Recheck the drive chain slack and free wheel rotation Check the rear brake pedal free play page3 15 adjust if necessary Lubricate the drive chain Wipe off the excess oil CLEANING INSPECTION AND LUBRICATION If the drive chain becomes extremely dirty it should be removed and cleaned prior to lubrication Carefully remove the retaining clip with pliers Removed the link plate and then the master link and now the drive chain can be removed from the sprockets MAINTENANCE Clean the chain with non flammable or high flash point solvent and wipe it dry Be sure the chain has dried completely before lubricating Lubricate the drive chain with 80 90 gear oil Wipe off the excess gear oil Inspect the drive chain for possible damage or wear Replace any chain that has damaged rollers loose fit
74. k SPECIFICATIONS ITEM Standard Spark plug For cold climate below41 f 5C For extended high speed riding SPECIFICATIONS CR6HSA NGK U20FSR U DENSO CRS5HSA NGK U16FSR U DENSO CR7HSA NGK U22FSR U DENSO MAINTENANCE ITEM SPECIFICATIONS Engine oil capacity At draining 0 6L 0 6US qt 0 5Imp at At disassembly 0 8L 0 8US qt 0 7Ilmp qt Recommended engine oil MANUFACTURE GN4 4 stoke oil or equivalent motor oil APL service classification SF or SG Viscosity SAE 10W 30 Engine idle speed 1 500 100rpm Throttle grip free play 2 0 6 0mm 1 16 1 1 4in Valve clearance IN 0 05 0 02mm 0 002 0 001 in EX 0 05 0 02mm 0 002 0 001 in Drive chain slack 15 25mmmm 5 8 1in Drive chain size link DID420MBK1 78 Brake lever free play 10 20mm 3 8 1313 16in Brake pedal free play 10 20mm 3 8 1313 16in TORQUE VALUES Fuel valve mounting bolt Spark plug Valve adjuster hole cap Valve adjuster lock nut Oil drain bolt Clutch adjuster lock nut Rear axle nut TOOLS Valve adjusting wrench 8x10mm Valve adjuster B Spoke wrench 4 1x4 5mm Clutch adjuster lock nut Rear axle nut 9N m 0 9kgf m 6 5ibf tt 12N m 1 2kgf m 9ibf ft 12N m 1 2kgf m 9ibf ft Apply engine oil to the threads 9N m 0 9kgf m 6 5ibf ft 25N m 2 5kgf m 18ibf tt 12N m 1 2kgf m 9ibf ft 47N m 4 8kgf m 35ibf ft
75. l level before servicing the clutch system SPECIFICATIONS Clutch disc thickness A SUPER 1A 1 52 1 68 0 060 0 068 130 051 Coo T T eoo 3 210 126 2 67 2 83 0 105 0 114 2 45 0 096 2 558 0 195 0 141 3 200 126 B 3 32 9 48 0 191 0 137 3 00 12 Se Clutch platewarpage 0 20 0 008 po OD 20 930 20 950 0 8240 0 8248 20 9 0 823 TORQUE VALUES Clutch outer cover screw 5N m 0 5kgf m 3 6lbf ft Clutch lock nut 42N m 4 3kgf m 31bf ft Clutch assembly screw 6N m 0 5kgf m 3 6lbf ft Shift drum stopper arm bolt 13N m 1 3kgf m 9lbf ft Shift return spring pin bolt 29N m 3 0kgf m 22 bf ft Gearshift cam plate bolt 17N m 1 7kgf m 1 2lbf ft TOOLS Flywheel holder 07725 0040000 Lock nut wrench 20 24mm 07716 0020100 extension bar 07716 0020500 TROUBLESHOOTING Clutch slips when accelerating Incorrect clutch adjustment Worn clutch disc Weak clutch spring Faulty clutch weight Transmission oil mixed with molybdenum or graphite additive Motorcycle creeps with clutch disengaged Incorrect clutch adjustment Clutch plate warped Faulty clutch lifter Faulty clutch weight Incorrect engine oil weight RIGHT CRANKCASE COVER REMOVAL Drain the engine oil page3 9 Remove the foot peg bar page 6 3 Remove the bolt kickstarter pedal Unhook the brake pedal return spring Loosen the rear brake pedal adjusting nut and lower the brake pedal Remove the eight bolts and right crankcase cover Remover
76. le securely 6 ENGINE REMOVAL AND INSTALLATION engine hanger nuts and washers Place the floor jack or other adjustable support under the engine Remove the hanger bolts and the engine from the frame CAUTION During engine assembly removal hold the engine securely and be careful not to damage the frame and engine ENGINE INSTALLATION Install the engine into the frame in the reverse order of removal NOTE Note the installation of the hanger bolts All bolts are installed from left side The jack height must be continually adjusted to relieve stress from the hanger bolts Tighten the hanger nuts to the specified torque TORQUE 31N m 3 2kgf m 23lbf ft Install the removed parts from engine removal procedure page 6 2 to 6 3 in the reverse order of removal NOTE Replace the intake manifold o ring with a new one Note the installation of the brake pedal return spring TORQUE Fixing plate bolt 12N m 1 2kgf m 9lbf ft Install the following left crankcase cover page 10 8 exhaust system page 2 5 Adjust the drive chain slack page 3 12 Fill with the recommended engine oil page 3 9 CYLINDER HEAD VALVES 12 N m 1 2 kgf m 9 Ibf ft 11 N m 1 1 kgf m 8 Ibf ft 11 N m 1 1 kgf m 8 lbf ft 7 CYLINDER HEAD VALVES SERVICE INFORMATION 7a CAMSHAFT REMOVAL 73 TROUBLESHOOTING 72 CYLINDER HEAD 7 4 CYLINDER COMPRE
77. le in U S A Valve adjuster B 07708 0030400 or 07908 KE90200 TORQUE 9 N m 0 9kgf m 6 5lbf ft Recheck the valve clearance Check the valve adjuster hole cap O ring is in good condition replace if necessary Coat the O ring with clean engine oil and install them in the valve adjuster hole caps Apply clean engine oil to the threads Install and tighten the valve adjuster hole caps to the specified torque INDEX NOTCH T MARK SPARK PLUG LEAD ADJUSTER TORQUE 12N m 1 2kgf m 9Ib ft Install the left crankcase cover page 10 8 ENGINE OIL OIL LEVEL INSPECTION Support the motorcycle in an upright position on level ground Remove the oil filler cap dipstick and wipe it clean Check the oil level by inserting the oil filler cap dipstick into the oil filler hole without screwing it in MAINTENANCE The engine contains a sufficient amount of oil if the oil level is between the upper and lower level marks on the dipstick If the level is near or below the lower level mark fill with the recommended oil up to the upper level mark RECOMMENDED ENGINE OIL 4 stroke oil or equivalent motor oil APL service classification SF or SG Viscosity 10W 30 NOTE Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range Reinstall the filler cap dipstick ENGINE OIL CHANGE WARNING When the engine must be running to do some work mak
78. lider spring others parts FR L Shock Absorber FR R Shock Absorber Bolt Holder FR Brake Pipe RR Shock Absorber Rubber Cap Flange Bolt M6 12 Flange Bolt M8 25 REAR SHOCK ABSORBER 10 RFRONT SHOCK ASSY 11 L FRONT SHOCK ASSY INSPECTION Visually inspect each part for excessive wear or damage Measure the fork spring free length ASSEMBLY FRONT WHEEL BRAKE SUSPENSION STEERING Install the following onto the fork slider new dust seal apply grease to the lips stopper ring with the chamfered side facing up back up ring Slider guide apply 5 6g of grease to the slider guide sliding surface of the fork slider 1 FR L Shock Absorber 2 FR R Shock Absorber 3 Bolt 4 Holder FR Brake Pipe 5 RR Shock Absorber 6 Rubber Cap 7 Flange Bolt M6 12 8 Flange Bolt M8 25 9 REAR SHOCK ABSORBER 10 R FRONT SHOCK ASSY 11 L FRONT SHOCK ASSY Install the slider piston and fork spring holder as shown Align the pin holes in the piston fork slider and spring holder so that the locating pin on the upper spring holder is facing inside of the fork slider and drive the spring pin to secure them using a 4mm pin driver Be sure that the spring pin do not project out of the piston outer surface i ee S S i freer f Ferrer S eff n i a f g rot r f rf eee gh Raggi ew at Apply 5 6g of grease w tne siiuer guide our groove Pack the fork spring with 14g of grease Ins
79. lve spring compressor attachment 07959 KM30101 CAUTION Support the cylinder head above the work bench so that the valve heads will not contact anything that cause damage Apply engine oil to the rocker arm inner and slipper surfaces Install the rocker arms and rocker arm shafts Install the rocker arm shaft with is threaded end facing the right side Install a new gasket onto the cylinder head right side SIDE COVER cover Install the right side cover onto the cylinder head CYLINDER HEAD VALVES Install the right side cover bolts INSTALLATION Clean off the gasket material from the cylinder surface Install the following New O ring Collar Dowel New gasket Route the cam chain through the cylinder head and install the cylinder head Install a new gasket onto the cylinder head and then install the cylinder head cover Install the cylinder head cover with its arrow mark facing down CYLINDER HEAD VALVES Install the following CAP Cap nuts new sealing washers Nut new sealing washer NOTE Note the position of the washers and nuts Tighten the cylinder head cover nuts to the specified torque NUT TORQUE 11N m 1 1 kgf m 8ibf ft Install and tighten the cylinder head mounting bolt If the cylinder was removed tighten the cylinder mounting bolt Install a new O ring into the groove in the intake manifold Install and tighten the intake manifold bolts Install the following
80. mage or deterioration Reinstall the oil strainer screen and right crankcase cover page9 17 ENGINE OIL CENTRIFUGAL FILTER CLEANING Remove the right crankcase cover ball retainer and clutch lifter lever page9 3 Remove the four screws and clutch outer cover MAINTENANCE Clean the clutch outer cover and inside the clutch outer cover using a clean lint free cloth CAUTION Do not allow dust and dirt to enter the crank shaft oil passage Do not use compressed air Reinstall the clutch outer cover using a new gasket page9 13 ENGINE IDLE SPEED WARNING When the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area NOTE Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications The engine must be warm for accurate idle speed inspection and adjustment Warm up the engine for about ten minutes Connect a tachometer Turn the throttle stop screw as required to obtain the specified idle speed IDLE SPEED 1 700 100 rpm MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION WARNING Never inspect and adjust the drive chain while the engine is running Turn off the eng
81. mbly and clutch springs Remove the clutch weight stopper ring Remove the clutch weight center ring INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and freely without excessive play Also check that bearing fits tightly in the clutch outer cover If necessary replace the bearing CLUTCH GEARSHIFT LINKAGE Clutch spring Measure the clutch spring free length SERVICE LIMIT 19 4mm 0 76in Clutch disc Replace the clutch discs if they show signs of scoring or discoloration Measure the disc thickness of disc SERVICE LIMITS Clutch disc A 2 3mm 0 09 in Clutch disc B 3 0mm 0 12 in Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20mm 0 008in Primary drive gear clutch center guide Check the primary drive gear and clutch center guide for excessive wear or damage Measure the I D of the primary drive gear SERVICE LIMIT 21 05mm 0 829 in Measure the O D and I D of the clutch center guide SERVICE LIMITS 1 D 17 04mm 0 671 in O D 20 90mm 0 823in CLUTCH GEARSHIFT LINKAGE Crankshaft Measure the crankshaft O D at clutch center guide SERVICE LIMIT 16 90mm 0 665 in Drive gear outer clutch center Check the dive gear outer and clutch center for excessive wear or damage ASSEMBLY CLUTCH SPRING ap ry KiB OPPER RING as aAa CLUTCH WEIGHT CENTER RING 3
82. nd the specified service limit replace the oil pump as SERVICE LIMIT 0 20mm 0 008in an assembly Measure the pump body clearance between the outer rotor and pump body SERVICE LIMIT 0 12mm 0 005in LUBRICATION SYSTEM Measure the side clearance using a straight edge and feeler gauge SERVICE LIMIT 0 20MM 0 008in ASSEMBLY OUTER ROTOR OIL PUMP INNER ROTOR Install the inner and outer rotors into the oil pump body joo Install the oil pump shaft aligning the flat surfaces of the shaft and inner rotor ROTOR S Fill the oil pump with 0 5 1cm of engine oil LUBRICATION SYSTEM Install the oil pump cover and tighten the screws to the specified torque TORQUE 5N m 0 5kgf m 3 6lbf ft INSTALLATION Install the rotor shaft collar into crankcase Install a new gasket onto the oil pump body Install the oil pump into the crankcase while aligning the pump shaft groove with the cam chain guide spindle lug Install and tighten the three screws to the specified torque TORQUE 8N m 0 8kgf m 5 8ibf ft Install the clutch assembly page9 1 2 5 FUEL SYSTEM SERVICE INFORMATION 5 1 CARBURETOR ASSEMBLY 5 6 TROUBLESHOOTIONG 5 2 CARBURETOR INSTALLATION 5 8 AIR CLEANER HOUSING 5 3 AIR SCREW ADJUSTMENT 5 10 CARBURETOR REMOVAL 5 3 CRANKCASE BREATHER
83. nections 2 Short circuit in ignition switch wire or engine stop switch wire black white 3 Faulty ignition switch or engine stop switch 4 Loose or poorly connected ICM connectors 5 Open circuit or poor connection in ground wire green of the ICM 6 Faulty peak voltage adaptor 7 Faulty exciter coil measure peak voltage 8 Faulty ignition pulse generator measure peak voltage 9 Faulty ICM in case when above no 1 8 are normal Peak voltage is nori 1 faulty spark plug or leaking ignition coil secondary current ampere but spark jumps at 2 faulty ignition coil 1 the multimeter is too low LOM DCV Exciter coil Low peak voltage 2 cranking speed is too slow operation force of the kickstarter is weak 3 the sampling timing of the tester and measured pulse were dot synchronized system is normal if measured voltage is over the standard voltage at least once 4 Faulty exciter coil in case when above no 1 3 are normal 1 Faulty peak vollase adaptor 2 Faulty exciter coil Ignition 1 The multimeter impedance is too low 10M DCV pulse Low peak voltage 2 Cranking speed is too slow operation force of the kickstarter is weak Generator 3 the sampling timing of the tester and measured pulse were dot synchronized system is normal if measured voltage is over the standard voltage at least once 4 Faulty ignition pulse generator in case when above no 1 3 are normal No peak voltage 1 Fault
84. new guide page7 9 also replace the valve VALVE GUIDE REPLACEMENT Chill new valve guides in the freezer section of a refrigerator for about an hour Heat the cylinder head to 212 302 100 150 C with a hot plate or oven WARNING To avoid burns wear heavy gloves when handling the heated cylinder head CAUTION Do not use a torch to heat the cylinder head it may cause warping Support the cylinder head and drive out the valve guides out of the cylinder head from the combustion chamber side TOOL Valve guide driver 5 0mm 07492 MA60000 CYLINDER HEAD VALVES Coat new O ring with engine oil and install them onto new valve guides While the cylinder is still heated drive the guides in the cylinder head from the camshaft side until they are fully seated TOOL Valve guide driver 5 0mm07942 MA60000 Let the cylinder head cool to room temperature Ream the new valve guide after installation Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise TOOL Valve guide reamer 5 0mm 07984 MA600001 or 07984 MA60000C NOTE Use cutting oil on the reamer during this operation Clean the cylinder head thoroughly to remove any metal particles Reface the valve seat see below VALVE SEAT INSPECTION REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to the valve seats Lap the valves and seats using a rub
85. nnnnen 0 10 0 004 Gear I D M2 17 016 17 043 0 6699 0 6710 17 10 0 673 C1 23 020 23 053 0 9063 0 9076 23 10 0 909 C3 20 020 20 053 0 7882 0 7895 20 10 0 791 Transmission Bushing O D C1 22 979 23 000 0 9047 0 9055 22 93 0 903 Bushing I D C1 20 000 20 021 0 7874 0 7882 20 08 0 791 Gear to bushing clearance C1 0 020 0 074 0 0008 0 0029 0 10 0 004 Mainshaft O D M2 16 966 16 984 0 6680 0 6687 16 95 0 667 Countershaft O D C1 19 959 19 980 0 7858 0 7866 19 94 0 785 Gear to shaft clearance M2 0 032 0 077 0 0013 0 0030 0 10 0 004 Gear bushing to shaft clear C1 0 020 0 062 0 008 0 0024 0 10 0 004 Shift fork 1 D 34 075 34 100 1 3415 1 3425 34 14 1 344 Claw thickness 4 86 4 94 0 191 0 194 4 60 0 181 Shift drum O D 33 950 33 975 1 3366 1 3376 33 93 1 336 Unit mm in FRONT WHEEL BRAKE SUSPENSION STEERING ITEM STANDARD SERVICE LIMIT Minimum tyre tread depth 3 0 0 12 Cold tyre pressure 175kpa 1 75kgf cm 26 25psi Axle runout enn nnn nn 0 20 0 008 WheelrimrtRadial ne nnn n nnn nn nee Axial nen ne nne 2 0 0 08 Brake Brake lever free play 10 20 3 8 13 16 2 0 0 08 Fork Spring free length 376 14 8 373 5 14 70 REAR WHEEL BRAKE SUSPENSION Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tyre tread depth nnn nn nnn n nnn 3 0 0 12 Cold tyre pressure 175kpa 1 75kgf om 29 25psi ween nnn n nn nnnn
86. o OD 20 980 20 950 0 8240 0 8248 20 90 8238 Crankshaft O D at clutch center guide 16 966 16 984 0 6680 0 6687 16 9 0 665 TORQUE VALUES Clutch outer cover screw 5N m 0 5kgf m 3 6lbf ft Clutch lock nut 42N m 4 3kgf m 31 bf ft Clutch assembly screw 6N m 0 5kgf m 3 6lbf ft Shift drum stopper arm bolt 13N m 1 3kgf m 9lbf ft Shift return spring pin bolt 29N m 3 0kgf m 22 bf ft Gearshift cam plate bolt 17N m 1 7kgf m 12lbf ft TOOLS Flywheel holder 07725 0040000 Lock nut wrench 20 24mm 07716 0020100 extension bar 07716 0020500 CLUTCH GEARSHIFT LINKAGE TROUBLESHOOTING Clutch slips when accelerating Hard to shift Incorrect clutch adjustment Incorrect clutch adjustment Worn clutch disc Loose stopper plate bolt Weak clutch spring Damaged stopper plate bolt Faulty clutch weight Damaged stopper plate and pin Transmission oil mixed with molybdenum or graphite additive Transmission jumps out of gear Worn shift drum stopper arm Motorcycle creeps with clutch disengaged Weak or broken shift arm return spring Incorrect clutch adjustment Loose stopper plate blot Clutch plate warped Faulty clutch lifter Gearshift pedal will not return Faulty clutch weight Weak or broken gearshift spindle return Incorrect engine oil weight Bent gearshift spindle RIGHT CRANKCASE COVER REMOVAL Drain the engine oil pages 9 Remove the foot peg bar page 6 3 Remove the bolt kickstarter pedal Unhook the brake pedal return spring L
87. ok the return spring to ten brake pedal and spring holding pin as shown Install the foot peg bar page6 4 Adjust the brake pedal free play page 3 15 Pour the recommended engine oil page 3 9 Adjust the clutch page 3 16 14 IGNITION SYSTEM SYSTEM DIAGRAM 14 0 IGNITION COI ae eee ee ere eee eee cena res 14 6 SERVICE INFORMATION 14 1 IGNITION CONTROL MODULE 14 6 TROUBLESHOOTING a 14 2 ENGINE STOP SWITCH IGNITION SWITCH 14 7 IGNITION SYSTEM INSPECTION 14 3 IGNITONITIMING Z 14 7 SERVICE INFORMATION GENERAL WARNING When the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area When servicing the ignition system always follow the steps in the troubleshooting sequence on page 14 3 The CDI ignition system uses an electrically controlled ignition timing system No adjustments can be made to the ignition timing The ICM may be damage if dropped Also if the connector is disconnected when current is flowing the excessive voltage may damage the module A faulty ignition system is often related to poor connections Check those connections before proceeding Use spark plug of the cor
88. ompression is too low or engine is hard to start Blown cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder or piston Piston sounds Worn cylinder piston and or piston ring Worn piston pin hole and piston pin Worn connecting rod small end Cylinder compression is too high or engine overheats or knocks Carbon deposits on the cylinder head and or piston crown Excessive smoke Worn stuck or broken ring CYLINDER REMOVAL Remove the cylinder head page 7 4 Remove the cam chain guide roller bolt washer and guider roller Remove the mounting bolt and cylinder Remove the following Rubber packing Gasket Dowel pins PISTON REMOVAL Remove the piston in clip with pliers CIRCLIP Press the piston pin out of the piston and remove the piston Do not let the piston pin clips fall into the crankcase Remove the piston rings Do not damage the piston rings during removal CYLINDER PISTON INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D in X and Y axis at three levels Take the maximum reading to determine the cylinder wear SERVICE LIMIT 39 05mm 1 537in Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Refer to page 8 5 for measurement of piston O D TOP SERVICE LIMIT 0 15mm 0 006in MIDDLE Calculate the taper and out of round at three levels in X BOTTOM and Y axis Take the maxim
89. on combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal Worn cylinder piston or piston rings section 8 7 CYLINDER HEAD VALVES CYLINDER COMPRESSION Warm up the engine to normal operating temperature Stop the engine and remove the spark plug page 3 6 Install a compression gauge Shift the transmission into neutral and open the choke lever OFF Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising COMPRESSION PRESSURE 981 1 177kKPa 10 0 12 0kgf cm 2 142 1 71psi at 1 000 rpm Low compression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder High compression can be caused by Carbon deposits in combustion chamber or on piston head Excessive noise Cylinder head Incorrect valve clearance Sticking valve or broken valve spring Damaged or worn camshaft Loose or worn cam chain Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Worn rocker arm and or shaft Worn cylinder piston or piston rings section 8 Rough idle Low cylinder compression LEFT SIDE COVER 4 N CAMSHAFT REMOVAL Drain the engine oil page3 9 Remove the following Valve adjuster hole cap page 3 7 Left crankcase cover page 10 2 Sealing bolt tensioner spring and tensioner push rod to loosen the cam ch
90. on 4 speed Primary reduction 4 059 69 17 Final reduction 2 866 37 14 Final reduction 1 706 36 1 1 ELECTRICAL Ignition system Starting system CDI Capacitive Discharge Ignition Kickstarter and electric LUBRICATION SYSTEM STANDARD SERVICE LIMIT ITEM Engine oil capacity At draining 0 6 0 6US qt 0 5Imp gt wenn nn nnnenn At disassembly 0 8 0 8US gt 0 7imp qt wenn new nn nnn nnnne ene Recommended GN4 4 stroke oil or equivalent Motor oil wren nnn anna no ne2 engine oil APL service classification SF or SG Viscosity SAE 10W 30 Oil pump rotor _ Tip clearance 0 15 0 006 0 12 0 005 Body clearance 0 02 0 07 0 001 0 003 0 12 0 005 Side clearance 0 10 0 15 0 004 0 006 0 20 0 008 FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification number VM22 38 VM16 486B Main jet 125cc 95 95 110cc 85 90cc Jet needle clip positioning 4th groove from top Different in each country Air screw initial opening 1 1 2turns out Float level 19mm 0 75in Idle speed 1 500 100rpom Throttle grip free play 2 0 6 0mm 1 16 1 4in CYLINDER HEAD VALVES Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression 981 1 177kpa 10 0 12 0kgfiem 2 142 171jpsi at 1 000 rom Cylinder head warpage 0 05 0 002 Valve clearance IN 0 05 0 02 0 00240 0
91. onized system is normal if measured voltage is over the standard voltage at least once 5 Poorly connected connectors or an open circuit in ignition system 6 Faulty exciter coil Measure peak voltage 7 Faulty ignition coil 8 Faulty ICM in case when above no 1 7 are normal No peak voltage 1 Incorrect peak voltage adaptor connections system is normal if measured voltage is over the specifications with reverse connections 2 Short circuit in ignition switch wire or engine stop switch wire black white 3 Faulty ignition switch wire or engine stop switch wire black white 4 Loose or poorly connected ICM connectors 5 Open circuit or poor connection in ground wire green of the ICM gt 6 Faulty peak voltage adaptor 7 Faulty exciter coil measure peak voltage 8 Faulty ignition pulse generator measure peak voltage 9 Faulty ICM in case when above no 1 8 are normal Peak voltage is no 1 faulty spark plug or leaking ignition coil secondary current ampere but no spark jumpg 2 faulty ignition coil Exciter coil Low peak voltagg 1 the multimeter impedance is too low 10MO DCV 2 cranking speed is too slow operation force of the kickstarter is weak 3 the sampling timing of the tester and measured pulse were dot synchronized system is normal if measured voltage is over the standard voltage at least once 4 Faulty exciter coil in case when above no 1 3 are normal 1 Faulty peak voltage adaptor 2 Faulty exciter coil Ignition Low p
92. oosen the rear brake pedal adjusting nut and lower the brake pedal Remove the eight bolts and right crankcase cover Remover the gasket and dowel pins Remove the clutch adjusting nut washer and o ring Remove the clutch lifter adjusting bolt assembly CLUTCH GEARSHIFT LINKAGE Check the kickstarter oil seal for damage replace if necessary CLUTCH REMOVAL Remove the ball retainer and spring Remove the clutch lifer lever Remove the oil through and spring Remove the clutch lifter cam plate Remove the screws and clutch outer cover and bearing CLUTCH GEARSHIFT LINKAGE Straighten the tab of the lock washer Hold the clutch outer with the flywheel holder and remove the lock nut using the special tools as shown TOOLS 07725 0040000 Flywheel holder Lock nut wrench 20x24mm 07716 0020100 Extension bar 07716 0020500 Remove the lock washer B 14mm lock washer and clutch assembly Remove the primary dive gear CLUTCH GEARSHIFT LINKAGE Remove the clutch center guide Remove the snap ring and primary driven gear from the mainshaft Remove the collar from the crankshaft DISASSEMBLY Remove the following Set ring Clutch plate B Clutch disc A Clutch disc B Clutch disc A Free springs Clutch plate A Remove the clutch center and drive gear outer CLUTCH GEARSHIFT LINKAGE Remove the four damper springs Remove the four screws and plain washers Remove the drive plate asse
93. or fuel economy Fuel system clogged lgnition system malfunction TUBES FUEL SYSTEM Remove the throttle cable from the throttle valve while compressing the throttle valve spring Remove the jet needle retainer and jet needle Check the throttle valve and jet needle for scratches or wear or damage CARBURETOR BODY WARNING Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion Loosen the drain screw and drain the fuel from the float chamber into an approved gasoline container Disconnect the fuel tube and air vent tube and drain tube from the carburetor body Loosen the carburetor connecting tube band screw Remove the carburetor mounting bolts carburetor and insulator FUEL SYSTEM CARBURETOR DISASSEMBLY Remove the screws and float chamber Remove the float pin and float and float valve Inspect the float for deformation or damage Inspect the float valve seat for scores scratches clogging and damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Replace the valve if the tip is worn or contaminated Check the operation of the float valve Remove the following Main jet Needle jet Throttle stop screw and spring Turn the air screw in and carefully count the number of turns until it
94. park plug 1 10 12 1 2 9 Oil drain bolt 1 12 25 2 5 18 Valve adjuster hole cap 2 30 12 1 2 9 NOTE1 Valve adjuster lock nut 2 5 9 0 9 6 5 Clutch adjuster lock nut 1 8 12 1 2 9 LUBRICATION SYSTEM Oil pump mounting screw 3 6 8 0 8 5 8 Oil pump cover screw 3 5 5 0 5 3 6 ENGINE REMOVAL INSTALLATION Drive sprocket fixing plate bolt 2 6 12 1 2 9 CYLINDER HEAD VALVES Cylinder head nut 4 6 11 1 1 8 Cylinder head right side cover bolt 2 6 10 1 0 7 Cam sprocket bolt 2 5 9 0 9 6 5 CYLINDER PISTON Cam chain guide roller pin bolt 1 8 10 1 0 7 CLUTCH GEARSHIFT LINKAGE Clutch outer cover screw 4 5 5 0 5 3 6 Clutch lock nut 1 14 42 4 3 31 Clutch assembly screw 4 5 6 0 6 4 3 Shift drum stopper arm bolt 1 6 13 1 3 9 Shift return spring pin 1 8 29 3 0 22 Gearshift can bolt 1 6 17 1 7 12 ALTERNATOR CAM CHAIN TENSIONER Flywheel nut 1 10 41 4 2 30 Cam chain tensioner sealing bolt 1 14 23 2 3 17 Cam chain tensioner pivot bolt 1 8 16 1 6 12 CRANKSHAFT TRANSMISSION KICKSTARTER Shift drum bolt 1 6 12 1 2 9 FRAME ITEM QTY THREAD DIAMETER mm TORQUE REMARKS N m kgf m bf ft FRAME BODY PANELS EXHAUST SYSTEM Side stand pivot bolt 1 10 Page 2 5 Muffler mounting bolt 1 8 26 2 7 20 Exhaust pipe protector bolt 3 6 15 1 5 11 Exhaust pipe cover screw 4 5 6 0 6 4 3 MAINTENANCE Fuel valve mounting bolt 2 6 9 0 9 6 5 FUEL SYSTEM Connecting tube band screw 1 4 1 0 1 0 7 EN
95. r while compressing the piston rings NOTE Avoid piston ring damage during installation Do not let the cam chain fall into crankcase Apply engine oil to the guide roller inner surface Install the cam chain guide roller new sealing washer and pin bolt Tighten the cam chain guide roller pin bolt go the specified torque TORQUE 10N m 1 0kgf m 7Ibf ft Install the cylinder mounting bolt but do not tighten it yet Install the cylinder head page 7 14 9 CLUTCH GEARSHIFT LINKAGE SERVICE INFORMATION Sine LU elec 9 4 TROUBLESHOOTING 9 2 GEARSHIFT LINKAGE 9 14 RIGHT CRANKCASE 9 3 RIGHT CRANKCASE 9 17 COVER REMOVAL COVER INSTALLATION SERVICE INFORMATION GENERAL This section covers service of the clutch and gearshift linkage All service can be done with the engine installed in the frame Use care not to allow dust or dirt to enter the engine Transmission oil viscosity and level have an effect on clutch disengagement When the clutch does not disengage or the motorcycle creeps with clutch disengaged inspect the transmission oil level before servicing the clutch system SPECIFICATIONS J soan O O senveMm O A A 1 52 1 68 0 060 0 066 880 051 O pt BBA2B5elo135 0 141 8 200 126 S o O A267011 oo o 245006 pt B3 42 3 58 0 135 0 141 8 200 126 po B88 2 8 48 0 131 0 137 8 00 12 S Clutch platewarpage ee 0 200 008 p
96. rect heat range Using spark plug with an incorrect heat range can damage the engine For alternator and ignition pulse generator removal and installation see section 10 SPECIFICATIONS B a d id a a a e Spark plug Standard CR6HSA NGK U20FSR U DENSO Forcoldclimate below 41 F 5C _CR5HSA NGK U16FSR U DENSO For extended high speed riding _CR7HSA NGK U22FSR U DENSO 0 60 0 70mm 0 024 0 028in 100 V minimum 0 7 V minimum 100 V minimum Ignition timing F mark 27 BIDC at idle TORQUE VALUES Ignition coil mounting bolt 6N m 0 6 kgf m 4 3lbf ft TOOLS Peak voltage tester U S A only or 07HGJ 0020100 not available in U S A with commercially Peak voltage adaptor available digital multimeter impedance 10M DCV minimum IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system Faulty spark plug Loose spark plug cap or spark plug wire connections Water got into the spark plug cap leaking the ignition coil secondary voltage No spark at spark plug isual condition Probable cause Check in numerical order Ignition coil Low peak voltagq 1 Incorrect peak voltage adaptor connections system is normal if measured primary voltage is over the specifications with reverse connections voltage 2 The multimeter impedance is too low 10MO DCV 3 Cranking speed is too low operating force of the kickstarter is weak 4 The sampling timing of the tester and measured pulse were not synchr
97. rk plug wrench TORQUE 12N m 1 2kgf m 9lbf ft REPLACING A SPARK PLUG Set the plug gap to specification with a wire type feeler gauge see previous page CAUTION DO not over tighten the spark plug Install and hand tighten the new spark plug then tighten it about 1 2 of a turn after the sealing washer contacts the seat of the plug hole Install the spark cap VALVE CLEARANCE INSPECTION Remove the valve adjuster hole caps Inspect and adjust the valve Clearance while The engine is cold below 95 F 35C Remove the left crankcase cover page10 2 Turn the crankshaft counterclockwise and align the T mark on the flywheel with the index notch on the left crankcase Mark on the flywheel with the index notch on the left crankcase Make sure the piston is at TDC Top Dead Center on the compression stroke This position can be obtained by confirming that there is slack in the rocker arm If there is no slack rotate the crankshaft one full turn counterclockwise and match up the T mark again MAINTENANCE Check the valve clearance by inserting a feeler gauge between the valve adjusting screw and valve stem VALVE CLEARANCE IN EX 0 05 0 02MM 0 002 0 001IN ADJUSTMENT Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on a feeler gauge Hold the adjusting screw and tighten the nut TOOLS Valve adjusting wrench 8x9mm_ 07708 0030100 equivalent commercially availab
98. s otherwise specified Use Fork or Suspension Fluid 1 GENERAL INFORMATION GENERAL SAFETY 1 1 SERVICE RULES 1 2 MODEL IDENTIFICATION 1 3 SPECIFICATIONS 1 4 TORQUE VALUES 1 10 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area WARNING The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area GASOLINE Work in a well ventilated area Keep cigarettes flames or sparks away from the work area or where gasoline is stored WARNING Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN eh 0 aooaa maaana aaa 1 12 LUBRICATION amp SEAL POINTS 1 13 CABLE amp HARNESS ROUTING 1 14 EMISSION CONTROL SYSTEMS 1 17 HOT COMPONENTS WARNING Engine and exhaust system parts become very hot and remain hot for some time after the engine is run Wear insulated gloves or wait until the engine and exhaust system have cooled before handing these parts USED ENGINE OIL WARNING Used engine oil may cause skin cancer if repeatedly left
99. seats lightly Make a note of this to use as a reference when reinstalling the air screw Remove the air screw and spring AT CHAMBER FLOAT VALVE CAUTION NEEDLE JET Damage to the air screw seat will occur if the air screw is tightened against the seat Inspect each jet for wear or damage and replace if necessary Clean the jets with cleaning solvent and blow with compressed air FUEL SYSTEM CARBURETOR ASSEMBLY THROTTLE STOP SCREW AIR SCREW OO cana SPRING DRAIN SCREW O RING FLOAT CHAMBER THROTTLE Blow open each air and fuel passage in the carburetor body with compressed air Install the following Throttle stop screw and spring Needle jet Main jet CAUTION Handle all jets with care They can easily be scored or scratched Install the air screw with the spring and return it to its original position as noted during removal Perform the air screw adjustment procedure if a new air screw Is installed page5 10 FUEL SYSTEM Hang the float valve onto the float arm lip Install the float and float valve in the carburetor body then install the float pin through the body and float FLOAT LEVEL INSPECTION NOTE Set the float level gauge so that it is perpendicular to the float chamber face and in line with the main jet With the float valve seated and the float arm just touching the valve measure the float level with the special tool as shown FLOAT LEVEL 19mm 0 75in T
100. ssary Install the push rod spring washer and sealing bolt Tighten the sealing bolt to the specified torque TORQUE 23N m 2 3kef m 17Ibf ft ALTERNATOR CAM CHAIN TENSIONER Remove the crankcase sealing bolt and washer Fill the push rod with 1 2 cm of engine oil through the filler hole Check the sealing washer is in good condition and install the sealing washer and bolt Tighten the bolt securely STATOR FLY WHEEL INSTALLATION Check the stator base oil seal for damage replace if necessary Apply engine oil to the lip of the oil seal Apply engine oil to new O rings install them into the crankcase grooves and stator base groove Install the stator base and tighten the screws securely CAUTION Be careful not to damage the oil seal lips ALTERNATOR CAM CHAIN TENSIONER Install the stator and ignition pulse generator with the wire clamp and tighten the bolts securely Set the wire grommet into the crankcase groove Install the wire clamp and tighten the bolt Clean any oil from the tapered portion of the crankshaft and flywheel Install the woodruff key into crankshaft Install the flywheel by aligning the key way in the flywheel with woodruff key on the crankshaft Install the washer and flywheel nut ALTERNATOR CAM CHAIN TENSIONER I fee Hold the flywheel using the universal holder and tighten the nut to the specified torque TOOL Universal holder 07725 0030000 TORQUE 41N m 4 2kef
101. stall a new 14mm lock washer by aligning its short tabs with the grooves in the dive plate CLUTCH GEARSHIFT LINKAGE Install the lock washer B with its OUT SIDE mark facing out Install the lock nut Hold the clutch outer with the flywheel holder and tighten the lock nut to the specified torque using the special tools as shown TOOLS 07725 0040000 Flywheel holder Lock nut wrench 20x24mm 07716 0020100 Extension bar TORQUE 42N m 4 3kgf m 31 Ibf ft If the lock nut groove does not align with the lock washer tab further tighten the lock nut and align Bent up the tab of the 14mm lock washer into the groove of the lock nut Clean the inside of the clutch outer and outer cover page 3 10 Install the bearing and a new gasket onto the clutch outer cover CLUTCH GEARSHIFT LINKAGE Install the clutch outer cover and tighten the screws to the specified torque TORQUE 5N m 0 5kgf m 3 6lbf ft Install the clutch lifter cam plate Install the oil through spring and oil through Install the spring ball retainer and clutch lifter lever Install the right crankcase cover page9 1 7 GEARSHIFT LINKAGE REMOVAL Remove the clutch and primary driven gear page9 4 Remove the bolt and gearshift pedal Clean the gearshift spindle end to prevent dirt from entering the crankcase CLUTCH GEARSHIFT LINKAGE Remove the bolt stopper arm and return spring Pull down the gearshift arm them pull out the gearsh
102. t onto the crankshaft Install the primary drive gear Install the clutch assembly onto the crankshaft Install a new 14mm lock washer by aligning its short tabs with the grooves in the dive plate Install the lock washer B with its OUT SIDE mark facing out Install the lock nut Hold the clutch outer with the flywheel holder and tighten the lock nut to the specified torque using the special tools as shown TOOLS 07725 0040000 Flywheel holder Lock nut wrench 20x24mm 07716 0020100 Extension bar TORQUE 42N m 4 3kgf m 31 Ibf ft If the lock nut groove does not align with the lock washer tab further tighten the lock nut and align Bent up the tab of the 14mm lock washer into the groove of the lock nut Clean the inside of the clutch outer and outer cover page 3 10 Install the bearing and a new gasket onto the clutch outer cover Install the clutch outer cover and tighten the screws to the specified torque TORQUE 5N m 0 5kgf m 3 6lbf ft Install the clutch lifter cam plate Install the oil through spring and oil through Install the spring ball retainer and clutch lifter lever Install the right crankcase cover page9 1 7 GEARSHIFT LINKAGE REMOVAL Remove the clutch and primary driven gear page9 4 Remove the bolt and gearshift pedal Clean the gearshift spindle end to prevent dirt from entering the crankcase Remove the bolt stopper arm and return spring Pull down the gears
103. tall the fork assembly by aligning the locating pin with the groove in the outer tube Install the fork top bolt and washer and tighten it Wipe any excess grease of the outer tube 1 Steering Column Comp 2 Upper Panel 3 Lower Holder Handle Pipe 4 Upper Holder Handle Pipe 5 Front Cover 6 Nut 7 Adjusting Nut 8 Dust Cap 9 Upper Cone Race 10 Ball 11 Ball Race 12 Bottom Cone Race 13 Dust Seal 14 Flange Bolt M6x12 15 Flange Bolt M8x25 16 Flange Bolt M8x25 17 Bolt M8x30 FRONT WHEEL BRAKE SUSPENSION STEERING Install the stopper ring into the groove in the outer tube properly Install the dust seal over the outer tube Wipe any excess grease of the fork slider Install the brake cable onto the fork slider and secure it by tightening the cable nut Install the front wheel page 12 10 1 Steering Column Comp 12 Bottom Cone Race 2 Upper Panel 13 Dust Seal 3 Lower Holder Handle Pipe 14 Flange Bolt M6 12 4 Upper Holder Handle Pipe 15 Flange Bolt M8 25 5 Front Cover 16 Flange Bolt M8 25 6 Nut 17 Bolt M8 30 7 Adjusting Nut 8 Dust Cap 9 Upper Cone Race 10 Ball 11 Ball Race STEERING STEM REMOVAL Remove the following Number plate page2 3 handlebar page 12 3 Front wheel page 12 5 Front fender page 2 3 Steering stem nut and washer Fork top bolts and washers Top bridge Remove the steering stem top thread using the special tool TOOL Pin spanner 07702 0020001
104. the pedal with the joint pin and secure it with a new cotter pin Adjust the brake pedal free play page 3 15 14 IGNITION SYSTEM SERVICE INFORMATION GENERAL Me When the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause low of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area e When servicing the ignition system always follow the steps in the troubleshooting sequence on page 14 3 The CDI ignition system uses an electrically controlled ignition timing system No adjustments can be made to the ignition timing e The CDI may be damage if dropped Also if the connector is disconnected when current is flowing the excessive voltage may damage the module A faulty ignition system is often related to poor connections Check those connections before proceeding Use spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine For alternator and ignition pulse generator removal and installation see section 10 SPECIFICATIONS pM SPECIFICATIONS S Spark plug Standard S CR6HSA NGK U20FSR U DENSO _ Forcoldelimaterelow4 FS CRSHSA NGK UI6FSR U DENSO _ For extended high speed riding _____ SR7HSA NGK U22FSR U DENSO Spark plug gap o S OL60 0 70mm 0 024 0 028 in Ignition coil
105. ting links or otherwise appears unserviceable Measure the drive chain length between a span of 41 pins 40 links from pin center to pin center with the chain held taut and any kinked joint straightened SERVICE LIMIT 511mm 20 1in Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspect the teeth on both sprockets for wear or damage Replace if necessary Never use a new drive chain on worn sprockets Both chain and sprockets must be in good condition or the new replacement parts will wear rapidly Check the attaching bolts and nuts on both sprockets If any are loose torque them EEDE TIE KIC MESA a I E a Te T S d y ae ty ef a cols oa E a2 a per rE te retin A a NON FLAMMABLE OR HIGH FLASH POINT SOLVENT a E i amp a Meg lt r a The Te eerie LEAN Date Tee ne C 7 7 ny i WIPE AND DRY LUBRICATE CHAIN SPRAY 41 PINS 40 LINKS Pe a Pa gl acca gl Si Ni Install the drive chain onto the sprockets Install the master link and link plate Install the retaining clip so that its open end is opposite the normal rotation of the chain MASTER LINK LINK PLATE RETAINING CLIP MAINTENANCE DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage Replace the drive chain slider if the wear limit guide lug is worn out or it has been damaged BRAKE SYSTEM FRONT BRAKE
106. um reading to determine them SERVICE LIMIT Taper 0 10mm 0 004in Out of round 0 10mm 0 004in The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded The following oversize pistons are available 0 25mm 0 010in 0 50mm 0 020in The piston to cylinder clearance for the oversize piston must be 0 010 0 040mm 0 0004 0 0016in Inspect the top of the cylinder for warpage SERVICE LIMIT 0 05mm 0 002in Remove any carbon deposits from the piston ring grooves using an old piston ring as shown CYLINDER PISTON Temporarily install the piston to their proper position with the mark facing up Measure the piston ring to ring groove clearance with the rings pushed into the grooves SERVICE LIMITS Top 0 12mm 0 005in Second 0 12mm 0 005in inspect the piston for wear or damage Measure the diameter of the piston at 8mm 0 3in from the bottom and 90 degrees to the piston pin hole SERVICE LIMIT 38 90mm 1 531in Measure the piston pin bore SERVICE LIMIT 13 06mm 0 514in Measure the O D of the piston pin SERVICE LIMIT 12 98mm 0 51 1in Calculate the piston to piston pin clearance SERVICE LIMIT 0 08mm 0 003in CYLINDER PISTON Measure the connecting rod small end I D SERVICE LIMIT 13 08MM 0 515in Calculate the connecting rod to piston pin clearance SERVICE LIMIT 0 12mm 0 00
107. uster Tighten the lock nut and install the dust cover properly Recheck the throttle operation AIR FILTER MAINTENANCE SPARK PLUG REMOVAL Disconnect the spark plug cap Remove the spark plug using a spark plug wrench or an equivalent Inspect or replace as described in the maintenance schedule page3 3 Clean around the spark plug base with compressed air before removing and be sure that no debris is allowed to enter the combustion chamber INSPECTION Check the following and replace if necessary recommended spark plug page3 1 Insulator for damage Electrodes for wear Burning condition dark to light brown indicates good condition excessive lightness indicates malfunctioning ignition system or lean mixture wet or black sooty deposit indicates over rich mixture REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or special plug cleaner Check the gap between the center and side electrodes with a wire type feeler gauge If necessary adjust the gap by bending the side electrode carefully SPARK PLUG GAP 0 6 0 7mm 0 024 0 028 in ADJUSTER o DUST COVER LOCK NUT TUBE AIR FILTER CENTER ELECTRODE SIDE ELECTRODE MAINTENANCE CAUTION To prevent damage to the cylinder head hand tighten the spark plug before using a wrench to tighten to the specified torque Reinstall the spark plug in the cylinder head and hand tighten then torque it using a spa
108. wheel hub FRONT WHEEL BRAKE SUSPENSION STEERING INSPECTION Axle Set the axle in v blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20mm 0 0081n Wheel bearing Turn the inner race of each bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if they do not turn smoothly quietly or if they fit loosely in the hub Wheel rim runout Check the rim runout by placing the wheel in a turning stand Spin the wheel by hand and read the runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMITS Radial 2 0mm 0 081in Axial 2 0mm 0 08in DISASSEMBLY Remove the dust seal FRONT WHEEL BRAKE SUSPENSION STEERING Install the bearing remover head into the bearing From the opposite side install the bearing remove shaft and drive the bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing remover head 12mm 0 7746 0050300 equivalent commercially available in U S A Bearing remover shaft 07746 0050100 equivalent commercially available in U S A ASSEMBLY RIGHT WHEEL BEARING DISTANCE COLLAR DUST SEAL G gt GQ oN CAUTIONS LEFT WHEEL BEARING Never install the old bearing once the bearings have been removed the bearings must be replaced with new ones Pa
109. with 1 2cm page 10 6 Oil pump rotors Fill with 0 5 1cm Clutch centre guide whole surfaces Clutch discs Primary drive gear teeth and inner surface Primary driven gear teeth Mainshaft sliding surface Countershaft sliding surface Transmission gear sliding surface gear teeth and shifter groove Shift drum outer surface Kickstarter spindle sliding surface Other rotating and sliding area Each bearing rotating area Each oil seal lips Each O ring FRAME LOCATION MATERIAL REMARKS Air cleaner housing cover mating groove Multi purpose grease Throttle grip pipe flange Steering head bearing and race sliding surface Wheel hub dust seal lips Wheel bearing cavities Brake panel anchor pin sliding surface Brake cam spindle and sliding surfaces Brake pedal pivot Fork dust seal lips Fork slider outer surface slider guide sliding surface Apply5 6g Fork slider guide outer groove Apply5 6g Fork spring whole surface Swingarm pivot nut seating surface Side stand pivot and sliding surface Pack with 14g Brake cam dust seal Engine oil Throttle cable outer inside Brake cable outer inside Cable lubricant Handlebar grip rubber inside Air cleaner connecting tube housing mating areg MANUFACTURE bond A or equivalent CABLE amp HARNESS ROUTING ENGINE STOP SWITC WIRE FUEL TANK BREATHER TUBE FUEL TUBE THROTTLE CABLE BRAKRECABIE IGNITION COIL age F E o a j THROTTLE CABLE e A r z SP
110. y pee voltage adaptor 2 Faulty ignition pulse generator IGNITION SYSTEM INSPECTION NOTE e If there is no spark at plug check all connections for loose or poor contact before measuring each peak voltage DIGITAL e Use recommended digital multimeter or commercial available digital multimeter with an impedance of 10M DVC minimum e The display value differs depending upon the internal impedance of the multimeter PEAK E e If using peak voltage tester U S A only follow the ADADTAD manufacture s instructions Connect the peak voltage adaptor to the digital multimeter or use the peak voltage tester TOOLS peak voltage tester Peak voltage adaptor 07HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10M DCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE AWARNING GOOD KNOWN SPARK Avoid touching the spark plug and tester probes to and prevent electric shock NOTE e Check all system connections before inspection if the system is disconnected incorrect peak voltage might be measured e Check cylinder compression and check that the spark plug is installed correctly Disconnect the spark plug cap from the spark plug Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test with the ignition coil primary wire connected connect the peak voltage adaptor or peak voltage tester probes to t

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