User manual DAELIM ROADWIN VJ125 - SERVICE MANUAL

HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997 HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the VJ125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 2). Sections 1 through 2 provide information on overall vehicle; and section 3 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 21: Troubleshooting. CONTENTS GENERAL INFORMATION INSPECTIONS / ADJUSTMENTS LUBRICATION FUEL SYSTEM COOLING SYSTEM ENGINE FRAME ELECTRICAL SYSTEM ENGINE REMOVAL CLUTCH / GEARSHIFT A.C.GENERATOR / STARTER CLUTCH CYLINDER HEAD / VALVES CYLINDER / PISTON CRANKCASE / TRANSMISSION / CRANKSHAFT Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co., Ltd., EXTERNAL PARTS FRONT WHEEL/FRONT FORK/STEERING REAR WHEEL /REAR SUSPENSION HYDRAULIC BRAKE BATTERY / CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES WIRING DIAGRAM TROUBLESHOOTING 1. GENERAL INFORMATION SERVICE INFORMATION SERVICE RULES CAUTION WHEN WIRING MODEL IDENTIFICATION SPECIFICATIONS 1-1 1-1 1-5 1-9 1-10 TORQUE VALUES SYMBOLS / ABBREVIATIONS TOOLS WIRING DIAGRAM 1-12 1-14 1-15 1-16 SERVICE INFORMATION 1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children) 3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops. 4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark. 5. When more than two person are working, always pay attention to other worker's action and always have safety in mind. 6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash carefully with soap and water after handling. 7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc. 8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or recommended parts. 2. Before maintenance, remove deposit or dust from the chasis. 1-1 GENERAL INFORMATION 3. Store the parts of each system discriminatively to install each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation. 5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation. 6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing. 7. Align the bolts to uniform the tightening points before tightening them when you don't know the bolt length. 8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque. 9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils. 10. Recommended grease must be applied to or filled in the specified place. 1-2 GENERAL INFORMATION 11. Maintenance needed to use the specialized tools must be performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually. Replace the ball bearing having excessive axial/ longitudinal hanging. Wipe the ball bearing likely to have hanging with cleaning oil.(except double-sided sealed type ball bearing) Replace the ball bearing of which press-fitted part is slacked at the case or shaft. 14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle. ' 15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing. 16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring. 17. Check each part for proper tightening and operation after installation. 18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact. 1-3 GENERAL INFORMATION 19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil) Pay attention not to bend or damage the lip. Apply the grease to the lip. 20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end. ' 21. Keep the pneumatic system interior or the engine interior from the infiltration of dust. 22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally. 23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage. 24. Install the boots with the installing groove by inserting the boots into the groove. 1-4 GENERAL INFORMATION CAUTION WHEN WIRING Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. Identify the two-colored cord by main color first and then spriped color . When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler. Recheck the condition of contact, securing and continuity of each part after maintenance. When connecting the battery, the plus terminal must be connected first. After connecting the terminal, apply the grease to the terminal. When disconnecting the battery, the minus terminal must be disconnected first. Make sure that the tool such as spanner do not contact with the frame. Connect covers to the terminal after maintenance. If the fuse is short-circuited, find out the cause and repair. Replace with the fuse having the specified capacity. If there is rust in the terminal, remove the rust with sand paper prior to connecting. VALIDATION OF CAPACITY! REMOVE THE RUST! 1-5 GENERAL INFORMATION Turn off the main switch before connecting/disconnecting. Release the lock to disconnect the lock of the coupler. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape. - Typical releasing method of the coupler is illustrated in the following. When disconnecting the coupler, disconnect it while holding the coupler body. Pull while holding the wire harness cord and do not remove the coupler connection. Insert the lock of the coupler until the lock is fully secured. Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler. Pay attention not to damage the vinyl cover of the coupler. Check to see if there is bended terminal and secure it to avoid disconnecting. If the wire harness coating is damaged, repair by winding vinyl tape or replace it. Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened. 1-6 GENERAL INFORMATION Insert the connector until the vinyl cover is fully inserted into the terminal. The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction. When removing T-start, broaden the groove of T-start using the wiring driver and release the torque. Connect the harness and the hose to T-start and then insert until the groove is locked. When removing T-start from the frame, replace it with the new one. Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part. Secure the wire harness firmly using the clamp. In case of the weld clamp, do not clamp in the welded part. When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part. When clamping the wire, pay attention not to contact with hot part. The wire harness must be routed without contacting with the end of the lamp or any sharp edge. The wire harness must be routed without contacting with the end of the bolt or the piece. 1-7 GENERAL INFORMATION In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. The wire must not hang down or be pulled excessively. NOT TO PULL! If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness is not pressed by the parts. Do not twist the wire harness. Wire the wire harness not to be pulled or expanded when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine. Prior to using the tester, please read the manual carefully and understand the contents. When testing the resistance of the tester, the zero adjustment must be performed before testing. Is this measurement range or configuration in accord with the manual? Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop. 1-8 GENERAL INFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The engine serial number is stamped on left crankcase. FRAME SERIAL NUMBER LOCATION The frame serial number is stamped on the left side of steering head. 1-9 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT CURB WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE (TYPE) REAR TIRE SIZE (TYPE) TIRE PRESSURE 1 PERSON FRONT REAR 2 PERSON FRONT REAR FRONT BRAKE REAR BRAKE FUEL CAPACITY FUEL RESERVE CAPACITY CASTER ANGLE TRAIL FRONT FORK OIL CAPACITY TYPE CYLINDER NUMBER, ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY 2,010mm 740mm 1,040mm 1,380mm 780mm 150mm 130kgf 147kgf Double Cradle Telescopic / 130mm Swingarm / 28mm 110/70-17 54P (Tubeless) 140/60-17 69P (Tubeless) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.25kgf/cm2(225kPa) Hydraulic Disk Hydraulic Disk 16 1.1 25.2 93.5mm 265 2.5cc Air Cooled 4-stroke SOHC 1 Cylinder, 15 Inclined from vertical 56.5 X 49.5mm 124.1cm3 10.7:1 SOHC Chain Drive 1.1 After Disassembly 1.05 After Draining and Oil Filter Change 1.0 After Draining Wet Pressing and Spray Paper Filter 13.0kgf/cm2 (600rpm) 6 BTDC 22 ABDC (1.12mm Lift) 24 BBDC -4 ATDC (1.12mm Lift) 0.12 0.02mm 0.12 0.02mm 32.3kgf FRAME ENGINE LUBRICATION SYSTEM AIR FILTRATION TYPE CYLINDER COMPRESSION INTAKE VALVE OPEN CLOSED EXHAUST VALVE OPEN CLOSED VALVE CLEARANCE INTAKE (A COOLING-OFF PERIOD) EXHAUST ENGINE DRY WEIGHT 1-10 GENERAL INFORMATION ITEM SPECIFICATIONS TYPE VENTURI BORE SETTING SERIES MARK MAIN JET CARBURETOR SLOW JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE TRANSMISSION TYPE GEAR RATIO 1st GEAR RATIO 2nd GEAR RATIO 3rd GEAR RATIO 4th GEAR RATIO 5th GEARSHIFT PATTERN PD 24 24mm VJ 125 C #100 #38 2 1/8 12.5mm 1,600 100(rpm) Multiplate Wet Clutch Constant Mesh Transmission 3.083(37/12 T) 1.882(32/17 T) 1.380(29/21 T) 1.095(23/21 T) 0.923(24/26 T) Left foot operated return system 1-N-2-3-4-5 DC-CDI Ignition 8 BTDC / 1,600(rpm) 28 BTDC / 4,000(rpm) 12V-11A/5,000(rpm) 12V 10AH CR8EH - 9 0.8 - 0.9mm 15A Starter Motor 35W/35W 3W 10W 4 21W/5W 3W 2W 3W 3W 3W 2 5W 2W DRIVE TRAIN ELECTRICAL IGNITION TYPE IGNITION TIMING "F" MARK FULL ADVANCE AC GENERATOR BATTERY CAPACITY SPARK PLUG SPARK PLUG GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT (HIGH/LOW BEAM) POSITION LAMP WINKER LAMP STOP/TAIL LIGHTS SPEEDOMETER LAMP FUEL RESERVE INDICATOR LAMP NEUTRAL INDICATOR LAMP HIGH BEAM INDICATOR LAMP WINKER INDICATOR LAMP LICENCE PLATE LAMP TACHOMETER LAMP 1-11 GENERAL INFORMATION TORQUE VALUES ENGINE ITEM Q'TY THREAD DIA (mm) TORQUE kgf.m,(N.m) REFERENCE CAM SHAFT HOLDER NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW TAPPET VALVE ADJUST HOLE CAP TAPPET ADJUST NUT PRIMARY DRIVE GEAR NUT CLUTCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARING SET PLATE BOLT OIL FILTER COVER SOCKET BOLT SHIFT DRUM STOPPER ARM BOLT DRIVE SPROCKET BOLT R. CRANKCASE COVER BOLT OIL FILTER COVER BOLT L. CRANKCASE COVER BOLT A.C GENERATOR CAP CRANKSHAFT HOLE CAP CRANKCASE BOLT SPARK PLUG OIL PUMP MOUNT BOLT START MOTOR NUT OIL THROUGH BOLT(CYLINDER) OIL THROUGH BOLT(RADIATOR) AIR CLEANER CASE COVER SCREW 4 2 1 2 1 1 4 1 1 1 3 2 1 1 2 11 3 7 1 1 10 1 2 1 2 2 4 M8 M6 M8 M6 M6 M36 M5 M16 M16 M10 M8 M6 M10 M6 M6 M6 M6 M6 M14 M30 M6 M10 M6 M6 M12 M12 M5 1.25 1.0 1.25 1.0 1.0 1.5 0.5 1.0 1.0 1.25 1.25 1.0 1.25 1.0 1.0 1.0 1.0 1.0 1.5 1.5 1.0 1.25 1.0 1.0 1.25 1.25 12 2.0 (20) 1.0 (10) 1.0 (10) 1.2 (12) 0.4 (4) 1.5 (15) 1.1 (11) 6.5 (65) 6.5 (65) 5.5 (55) 3.2 (32) 1.2 (12) 1.2 (12) 1.2 (12) 1.2 (12) 1.1 (11) 1.1 (11) 1.1 (11) 0.6 (6) 0.8 (8) 1.1 (11) 1.1 (11) 1.1 (11) 1.2 (12) 3.2(32) 3.2(32) 0.4(4) Apply Engine Oil Apply Engine Oil Apply Engine Oil Apply Engine Oil FRAME ITEM Q'TY THREAD DIA (mm) TORQUE kgf.m,(N.m) REFERENCE ENGINE HANGER BOLT (REAR) ENGINE HANGER BOLT (FRONT) STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROCKET NUT REAR BRAKE OIL BOLT 2 1 2 1 1 1 1 4 2 M10 M10 M8 M10 M10 M5 M14 M10 M10 1.25 1.25 1.25 1.25 1.25 0.8 1.5 1.25 1.25 4.9 (49) 4.9 (49) 2.6 (26) 1.5 (15) 4.5 (45) 0.42 (4.2) 8.8(88) 5.9(59) 3.4(34) HEX NUT U- NUT U- NUT 1-12 GENERAL INFORMATION FRAME ITEM Q'TY THREAD DIA (mm) TORQUE kgf.m,(N,m) REFERENCE REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER SOCKET BOLT FRONT AXLE NUT FRONT BRAKE DISK BOLT BRAKE OIL BOLT (FRONT/REAR) CALIPER BRACKET BOLT (FRONT/REAR) FRONT MASTER CYLINDER HOLDER BOLT STEERING STEM NUT STEERING TOP THREAD FORK TOP BRIDGE PINCH BOLT BOTTOM BRIDGE PINCH BOLT FORK HANDLE PIPE MOUNTING BOLT SWINGARM PIVOT NUT REAR CUSHION UPPER/UNDER BOLT CHAIN SLIDER SCREW L. DOWNTUBE COMP `B' HANDLE WEIGHT SOCKET BOLT REAR BRAKE DISK BOLT 2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 3 M8 1.25 M6 1.0 M14 1.5 M8 1.25 M10 1.25 M8 1.25 M6 1.0 M22 1.0 M22 1.0 M8 1.25 M8 1.25 M8 1.25 M14 1.25 M10 1.25 6mm Tapping M8 1.25 M8 1.25 M8 1.25 3.0(30) 1.2(12) 5.9(59) 4.2(42) 3.4(34) 3.0(30) 1.2(12) 7.4(74) 0.3(3) 2.6(26) 3.4(34) 2.6(26) 8.8(88) 3.4(34) 0.6(6) 4.2(42) 2.0(20) 4.2(42) U- NUT U- NUT SOCKET BOLT Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below. TYPE TORQUE kgf m N m TYPE TORQUE kgf m N m 15mm BOLT, NUT 16mm BOLT, NUT 18mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT 0.5 1.0 2.1 3.5 5.5 5 10 21 35 55 5mm SCREW 6mm SCREW, FLANGE BOLT 6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT 0.4 0.9 0.9 2.7 4.0 4 9 9 27 40 1-13 GENERAL INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious accident may result if instructions are not followed. vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures. The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance. SYMBOL CAUTION Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1) Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) Use silicone grease Apply a locking agent. Use the agent of the middle strength, unless otherwise specified Apply sealant Replace the parts with new ones before assembly Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified Use Fork or Suspension Fluid Use special tool Use option tool. These tools are obtained as you order parts. ( 3-1) Indicates reference page. (Example : Refer to page 3-1) Special grease, etc. that do not correspond to the above are indicated without using symbols. 1-14 GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION CLUTCH CENTER HOLDER ACG ROTOR PULLER VALVE GUIDE DRIVER VALVE GUIDE REAMER UNIVERSAL BEARING PULLER BEARING REMOVER SET THREAD ADAPTER ASSEMBLY SHAFT CRANK CASE ASSEMBLY COLOR BALL RACE DRIVER STEERING STEM DRIVER FORK SEAL DRIVER STEERING STEM SOCKET SNAP RING PLIERS COMMON REF. SEC. DESCRIPTION 7 WRENCH, 8 9mm 8 ADJUSTING WRENCH, B 9 FLOAT LEVEL GAUGE 9 LOCK NUT WRENCH, 20 24mm 11 EXTENSION BAR 11 FLY WHEEL HOLDER 11 VALVE SPRING COMPRESSOR 11 DRIVER 11 ATTACHMENT 13 PILOT 13 FORK SEAL DRIVER BODY 13 BEARING REMOVER HEAD 13 BEARING REMOVER SHAFT 15 REF. SEC. 2 2 4 7 7, 13 7, 8 9 11, 13, 14 11, 13, 14 11, 13, 14 13 14 14 TESTER, GAUGE DESCRIPTION COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER REFERENCE SECTION 2 16, 17 16, 17 17 REMARK VALVE SEAT CUTTER DESCRIPTION VALVE SEAT CUTTER 45 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 35 VALVE SEAT CUTTER 60 CUTTER HOLDER 5mm REFERENCE SECTION 9 9 9 9 9 REMARK 24.5mm IN, EX 23mm IN 20mm EX 22mm IN, EX Use with Valve Seat 1-15 GENERAL INFORMATION WIRING DIAGRAM BATTERY EARTH CABLE ST.-MOTOR CABLE SIDE STAND SW. CORD RR. STOP SW. CORD ST.-MAG SW. CORD ST.-MAG. BATTERY CABLE(+) BATTERY EARTH CABLE HARNESS COVER WIRE CLIP ST.-MAG. BATTERY CABLE(+) BATTERY EARTH CABLE ST.-MAG. SW. WIRE THROTTLE CABLE ST.-HAZ. SW. CORD FR. BRAKE HOSE HORN COMP. LH. RADIATOR HOSE RH. RADIATOR HOSE HIGH TENSION CORD NOISE SUPPRESSOR CAP CLUTCH CABLE FR. BRAKE HOSE SPDMT. CABLE CABLE GUIDE CLUTCH CABLE CHOKE CABLE C RR. BRAKE RESERVE TUBE RR. BRAKE HOSE RR. BRAKE HOSE CLAMP RR. BRAKE HOSE RR. CALIPER ASS'Y. CLUTCH CABLE WINKER SW. CORD CHOKE CABLE THROTTLE CABLE WIRE HARNESS REG. RECTIFIER WIRE WIRE CLIP G BREATHER TUBE CABLE GUIDE SPEEDOMETER CABLE FR.BRAKE HOSE A DRAIN TUBE WIRE CLAMP (WIRE PIVOT) WIRE CLIP FUEL UNIT CORD EARTH WIRE ST.-MAG. SW. WIRE FUSE WIRE FUEL UNIT WIRE ACG. WIRE WIRE CLIP CABLE CLAMP SEAT LOCK CABLE WIRE HARNESS HELMET HOLDER & SEAT LOCK ASS'Y. CABLE GUIDE LH. FR. WINKER HEAD LIGHT HORN COMP. E HORN CORD WIRE GROMMET HARNESS COVER(ACG. CORD SETT.) BRAKE HOSE CLAMPER SPDMT. CABLE CLAMP ACG. CORD ST.-MOTOR CABLE 1-16 GENERAL INFORMATION WIRE HARNESS IGN. COIL WIRE CLIP THROTTLE CABLE JUNCTION CLAMP CHOKE CABLE CLUTCH CABLE LH. RADIATOR HOSE RH. RADIATOR HOSE THROTTLE JUNCTION CABLE GUIDE IGN. COIL CORD CHOKE CABLE THROTTLE CABLE (TO. ACCELERATION PUMP) THROTTLE CABLE(TO. CARB.) FUEL COCK WIRE CLAMP(WIRE PIVOT) FUEL COCK(RES) FUEL COCK(ON) FUEL STRAINER COMP. WIRE HARNESS AIR VENT TUBE ST.-MAG. BATTERY CABLE(+) FUSE BOX BATTERY EARTH CABLE AIR VENT TUBE ST.-MAG. SW. WIRE FUSE CODE BATTERY BAND CDI COMP. HEAD LIGHT RELAY SEAT LOCK CABLE HEAD LIGHT RELAY WIRE CDI COMP. WIRE WINKER RELAY WIRE WINKER RELAY TAIL LIGHT WIRE LH. RR. WINKER CORD WIRE CLIP RH. RR. WINKER CORD TAIL LIGHT SOCKET COMP. TAIL LIGHT CORD TAIL LIGHT ASS'Y. 1-17 GENERAL INFORMATION ST.-MAG. BATTERY CABLE(+) ST.-MAG. SW. WIRE BATTERY EARTH CABLE WIRE CLIP HARNESS COVER ST.-MAG. BATTERY CABLE(+) ST.-MAG. SW. ASS'Y. ST.-MOTOR CABLE BATTERY EARTH CABLE SIDE STAND SW. CORD RR. STOP SW. CORD RESERVE TANK RR. BRAKE HOSE RR. BRAKE HOSE GUIDE RR. BRAKE RESERVE TUBE RR. BRAKE HOSE DETAIL OF VIEW C RR. CALIPER RR. BRAKE HOSE RESERVE TANK RR. BRAKE RESERVE TUBE RR. BRAKE HOSE CLAMP RR. BRAKE HOSE GUIDE TUBE CLIP RR. BRAKE HOSE GUIDE DETAIL OF VIEW B 1-18 GENERAL INFORMATION DRAIN TUBE FUEL DRAIN TUBE DRAIN TUBE TUBE GUIDE ENG. DREATHER TUBE CLUTCH CABLE BRAKE HOSE CLAMP BRAKE HOSE RH. RADIATOR HOSE BRAKE HOSE CLAMPER SPDMT. CABLE HORN COMP. SPDMT. CABLE GUIDE DETAIL OF VIEW A DETAIL OF VIEW D RH. CABLE GUIDE RH. WINKER CORD FR. BRAKE HOSE THROTTLE CABLE ST. HAZARD SW. CORD CHOKE CABLE CLUTCH CABLE WINKER SW. CORD COMBI. METER CORD WINKER SW. WIRE WINKER WIRE RH. WINKER CORD LH. WINKER CORD WIRE CLIP WIRE CLIP HEAD LIGHT CASE WIRE HARNESS THROTTLE CABLE HEAD LIGHT WIRE WINKER SW. CORD CHOKE CABLE CLUTCH CABLE LH. WINKER CORD LH. CABLE GUIDE DETAIL OF VIEW G WIRE HARNESS COMB. SW. CORD COMB. SW. WIRE HAZARD SW. CORD DETAIL OF HEAD LIGHT CASE PART 1-19 MEMO 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE (FUEL TUBE) THROTTLE GRIP OPERATION CARBURETOR CHOKE AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDER COMPRESSION PRESSURE CARBURETOR IDLE SPEED DRIVE CHAIN DRIVE CHAIN SLIDER 2-1 2-3 2-4 2-4 2-5 2-5 2-6 2-6 2-7 2-7 2-8 2-10 BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARINGS 2-10 2-10 2-11 2-12 2-12 2-12 2-13 2-14 2-14 2-15 2-15 SERVICE INFORMATION The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. For information on engine oil and oil filter, refer to sections 3-3 and 3-4. Stand the main stand prior to beginning work. SPECIFICATIONS THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE CARBURETOR IDLE SPEED CYLINDER COMPRESSION DRIVE CHAIN SLACK REAR BRAKE PEDAL FREE PLAY CLUTCH LEVER FREE PLAY IN. EX. 2~6mm CR8EH-9 0.8~0.9mm 0.12 0.02mm 0.12 0.02mm 1,600 100rpm 13.0kgf/ ( 600rpm ) 10~20mm 10~20mm 10~20mm TIRES COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT REAR FRONT REAR FRONT REAR FRONT REAR 200kPa (2.00kgf/ 200kPa (2.00kgf/ 200kPa (2.00kgf/ 225kPa (2.25kgf/ 110/70-17 54P 140/60-17 60P 5.5mm 7.0mm ) ) ) ) TIRE SIZE TIRE PART MINIMUM-DEPTH 2-1 INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG CYLINDER HEAD COVER BOLT VALVE ADJUSTING NUT AC GENERATOR CAP CRANKSHAFT HOLE CAP AIR CLEANER CASE COVER SCREW REAR AXLE NUT DRIVE SPROCKET BOLT DRIVEN SPROCKET NUT 1.1 kgf-m( 11N.m) 1.0 kgf-m( 10N.m) 1.1 kgf-m( 11N.m) 0.6 kgf-m( 6N.m) 0.8 kgf-m( 8N.m) 0.43kgf-m( 4.3N.m) 8.8kgf-m(88N.m) 1.2kgf-m(12N.m) 5.9kgf-m(59N.m) TOOLS WRENCH, 8 9 mm ADJUSTING WRENCH, B COMPRESSION GAUGE 2-2 INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Perform the Self Inspections Before Operation at each scheduled maintenance period. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart. FREQUENCY ITEM ODOMETER READING(NOTE 1) x 1000Km 1 4 6 8 12 12 18 MONTH I REFER TO PAGE REMARK FUEL LINE FUEL FILTER THROTTLE GRIP OPERATION CARBURETOR CHOKE AIR CLEANER ELEMENT SPARK PLUG VALVE CLEARANCE CARBURETOR IDLE ENGINE OIL ENGINE OIL FILTER DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE /PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HANDLE BEARING I R I I R I I R I I R R I I R I R I I R I I I R 2-4 2-4 2-4 2-5 2-5 2-6 2-6 2-7 3-3 3-4 2-8 2-10 2-10 2-10 2-11 2-12 2-12 2-12 2-13 2-14 2-14 2-15 2-15 NOTE (3) NOTE (2) I I R R I I R R Every 1,000 I I R R : I and L I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs. To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers. NOTES : (1) At higher odometer readings, repeat at the frequency interval established here. (2) Service more frequently when riding in unusually wet or dusty areas. (3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. 2-3 INSPECTIONS / ADJUSTMENTS FUEL TUBE FUEL TUBE FUEL TUBE FUEL LINE (FUEL TUBE) Check the fuel tube for deterioration, damage or leakage. Replace it if necessary. THROTTLE GRIP OPERATION 2~6mm 2~6mm 2~6mm 2~6mm Check if the throttle grip operates smoothly in all steering positions. If not operating smoothly, check the deterioration, damage and kink of the throttle cable. Measure the free play at the throttle grip. FREE PLAY : 2~6mm Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustment are made with the upper adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. LOCK NUT LOCK NUT LOCK NUT ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER ADJUSTER Major adjustments are made with the lower adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securely. Recheck the throttle operation. Replace any damaged parts, if necessary. LOCK NUT LOCK NUT LOCK NUT LOCK NUT 2-4 INSPECTIONS / ADJUSTMENTS CHOKE LEVER CHOKE LEVER CHOKE LEVER CARBURETOR CHOKE Check the deterioration, damage and kink of the choke cable. Check if the choke lever operates smoothly in any position. Pull the choke lever to the left, and close it perfectly. Check if the choke valve is closed perfectly by moving the carburetor choke arm. When adjustment is necessary, loosen the choke cable clamp in order that choke valve can be opened, and then adjust by moving the choke cable cover. CHOKE ARM CHOKE ARM CHOKE ARM SCREWS SCREWS SCREWS AIR CLEANER Remove the seat. ( 12-2) Loosen the 4 screws, remove the air cleaner housing cover. AIR CLEANER AIR CLEANER AIR CLEANER HOUSING COVER HOUSING COVER Remove and discard the air cleaner element in accordance with the maintenance schedule. ( 2-3) Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts in the reverse order of removal. AIR CLEANER AIR CLEANER AIR CLEANER ELEMENT ELEMENT ELEMENT The element is a viscous type which contains oil. Therefore do not use compressed air to clean the air cleaner element. 2-5 INSPECTIONS / ADJUSTMENTS SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits. If the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug. Always use a feeler gauge to check the gap. GENUINE PLUG : CR8EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf m (11N m) CHECK GAP, DEPOSITS 0.8~0.9mm CHECK WASHER FOR DAMAGE Make sure there is no dirt or debris on the seat of the spark plug hole before inserting the spark plug. To prevent damage to the cylinder head, handtighten the spark plug before using a wrench to tighten to the specified torque. Do not overtighten the spark plug. CHECK FOR CRACKS INDEX MARK INDEX MARK INDEX MARK VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold. (below 35° C/95°F) Remove the cylinder head cover. Remove the A.C generator cap and crankcase hole cap. Rotate the flywheel counterclockwise to align the "T" mark with the index mark on the left crankcase cover. Make sure the piston is at TDC(Top Dead Center) on the compression stroke. Measure the valve clearance with a feeler gauge. VALVE CLEARANCE : INTAKE : 0.12 0.02mm EXHAUST : 0.12 0.02mm "T" MARK "T" MARK "T" MARK Loosen the lock nut with a vlave wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut. FEELER GAUGE FEELER GAUGE FEELER GAUGE TORQUE : 1.1kgf m (11N m) TOOLS : WRENCH 8x9mm ADJUSTING WRENCH B FEELER GAUGE 2-6 INSPECTIONS / ADJUSTMENTS ADJUSTING WRENCH B ADJUSTING WRENCH B Measure the vlave clearance again. Install the cylinder head cover and tighten the bolts. TORQUE : 1.0kgf m (10N m) Install the A.C generator cap and crankcase hole cap. TORQUE : A.C GENERATOR CAP : 0.6kgf m(6N m) CRANK CASE HOLE CAP : 0.8kgf m(8N m) SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH SPARK PLUG WRENCH CYLINDER COMPRESSION PRESSURE Warm up the engine. Stop the engine, and remove the spark plug cap and spark plug. Install the compression gauge. Open the throttle completely and crank the engine with the starter motor until the gauge reading stops rising. TOOL : COMPRESSION GAUGE COMPRESSION GAUGE COMPRESSION GAUGE COMPRESSION GAUGE The maximum reading is usually reached within 4~7 seconds COMPRESSION PRESSURE : 13.0 f/ (600rpm) If compression is low, check the following: - Incorrect valve clearance adjustment - Valve leakage - Leakage from the cylinder head gasket. - Worn piston/cylinder If compression is high, check the following: - Carbon deposits on the piston head, and cylinder head. THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW CARBURETOR IDLE SPEED Inspect all other engine adjustments are within specifications and adjust idle speed. The engine must be warm for accurate adjustment. Support the motorcycle on a level surface and shift the transmission into neutral. Warm up the engine for about ten minutes. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED : 1,600 100rpm 2-7 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN Because there is a danger which fingers get jammed in the drive chain, never inspect or adjust it while the engine is running. DRIVE CHAIN SLACK ADJUSTMENT 10~20mm 10~20mm 10~20mm ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT LOCK NUT LOCK NUT LOCK NUT AXLE NUT AXLE NUT AXLE NUT Turn off the ignition switch, support the motorcycle on its main stand, and shift the transmission into neutral. Check slack in the lower chain with a hand midway between the sprockets. CHAIN SLACK : 10~20mm Adjust the slack of drive chain if necessary. Adjust it by loosening the axle nut, loosening both lock nuts of adjust, and turning the adjusting nut. Make sure that the chain adjuster scale are aligned with the correspondidng scale graduations on both sides of the swing arm. Tighten the axle nut with the specified torque. RETAINER CLIP RETAINER CLIP RETAINER CLIP TORQUE : 8.8kgf m(88N m) REMOVAL In case that the drive chain becomes extremely dirty, it should be cleaned before lubrication. Remove the drive sprocket cover. Remove the retainer clip. Remove the master link, drive chain. 130 LINKS Check the drive chain for adherence and damaging. Measure the length between the chain's pins and replace the chain if the prescribed limits are exceeded. Drive chain length (130 links). RETAINER CLIP ROTATING DIRECTION 2-8 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN INSPECTION WIPE AND DRY Lubricate with #80-90 gear oil after removing the contamination of chain with a cleaner, and drying fully. Because an extremely lubricated oil splash while the chain moves round, clean it with a piece of cloth. After checking a wear and damage of the drive chain, replace it if necessary. GEAR OIL(#80-90) WEAR After inspecting an excessive wear and damage of the drive sprocket, replace it if necessary. Always replace the chain and sprocket as a set. DAMAGE NORMAL BOLTS BOLTS BOLTS Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, torque them. TORQUE : DRIVE SPROCKET BOLT : 1.2kgf m(12N m) DRIVE SPROCKET NUT : 5.9kgf m(59N m) DRIVE SPROCKET DRIVE SPROCKET DRIVE SPROCKET DRIVE CHAIN INSTALLATION RETAINER CLIP MASTER LINK Install the drive chain. Install the master link and retainer clip. When installing the drive chain, it should be installed in order that the choked part of the clip can direct to a progressing derection of the chain. OUTSIDE RETAINER CLIP 2-9 INSPECTIONS / ADJUSTMENTS DRIVE CHAIN SLIDER WEAR INDICATOR Inspect the drive chain slider for excessive wear or damage. If it is worn to the wear indicator, replace the drive chain slider. BRAKE FLUID Do not mix a dust or different types of fluid when filling the brake fluid. Mind that the reservoir is level in checking and filling it. Avoid spilling the fluid on painted, plastic, or rubber parts. When the fluid level is low, check the brake pads for wear. If the brake pads are not worn and the fluid level is low, check entire system for leaks. ( 2-11) LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE FRONT BRAKE Turn the handlebar so that the reservoir is level and check the front brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear. REAR BRAKE Place the motorcycle on a level surface, and support it upright position. Check the rear brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear. LOWER LEVEL LINE LOWER LEVEL LINE LOWER LEVEL LINE BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 15-6 for brake pad replacement. WEAR INDICATOR 2-10 INSPECTIONS / ADJUSTMENTS REAR BRAKE PADS WEAR INDICATOR Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to page 15-6 for brake pad replacement. BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when operated, bleed the air from the system. Inspect the brake hose and fittings for deterioration, cracks and sighs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. BRAKE HOSE BRAKE HOSE BRAKE HOSE Refer to page 15-4 for brake bleeding procedures. FRONT BRAKE LEVER FREE PLAY Check the free play after pulling the lever. BRAKE LEVER FREE PLAY : 10~20mm 10~20mm 10~20mm 10~20mm REAR BRAKE PEDAL FREE PLAY Adjust the brake pedal free play at the end part of pedal. BRAKE PEDAL FREE PLAY : 10~20mm 10~20mm 10~20mm 10~20mm 2-11 INSPECTIONS / ADJUSTMENTS BRAKE PEDAL HEIGHT ADJUSTMENT STOPPER BOLT STOPPER BOLT STOPPER BOLT Loosen the lock nut and turn the stopper bolt until the correct pedal height is obtained. After adjustment, tighten the lock nut securely. The adjustment faulty of height may caused that the brake runs in state of operation. After adjusting the brake pedal height, inspect the operation of rear brake light switch and brake pedal, and adjust them if necessary. BRAKE STOP SWITCH BRAKE STOP SWITCH BRAKE STOP SWITCH Adjust the brake stop switch by turning the adjust nut, pressing the switch so that the brake light will come on just before the brake pedal is depressed and brake engagement begins. BOLT BOLT BOLT BOLT HEADLIGHT AIM Adjust the headlight beam vertically by turning the headlight case adjustment bolts. Adjust the headlight beam as specified by local laws and regulations. An improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance. CLUTCH SYSTEM Measure the clutch lever free play at the end of the clutch lever. FREE PLAY : 10~20mm 10~20mm 10~20mm 10~20mm 2-12 INSPECTIONS / ADJUSTMENTS ADJUSTER ADJUSTER ADJUSTER LOCK NUT LOCK NUT LOCK NUT Minor adjustments are made using the upper adjuster at the clutch lever. Loosen the lock nut and turn the adjuster. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustments as described as follow. LOCK NUT LOCK NUT LOCK NUT Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjuster nut to adjust free play. Hold the adjuster nut securely while tightening the lock nut. ADJUSTER ADJUSTER ADJUSTER If proper free play cannot be obtained, or the clutch slips during test ride, disassemble and inspect the clutch. (see section 7) SIDE STAND Support the motorcycle on a level surface. Pull the lower end of the side stand, and see if it moves freely. If the side stand does not move smoothly, apply grease to the pivot area. If the side stand moves too freely, check the side stand spring. Check the axial movement of the side stand. Check the side stand switch: - Sit astride the motorcycle and raise the side stand. - Start the engine with the transmission in neutral. - Lower the side stand. The engine should not accelerate as the throttle grip is operated. If there is a problem with the system, check the side stand switch. (section 17) SIDE STAND SWITCH 2-13 INSPECTIONS / ADJUSTMENTS SUSPENSION Do not ride motorcycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle's safety and operation efficiency. FRONT SUSPENSION INSPECTION Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions. Check the front fork for oil leakage, parts damage or looseness. REAR SUSPENSION INSPECTION Compress the near cushion up and down several times to check the operating conditions. Check the rear cushion for oil leakage, parts damage or looseness. Support the motorcycle with the main stand. Check a wear of the rear fork bush by moving the rear wheel aside. If there is a free play, replace the rear fork bush. Tighten all nuts and bolts of the rear suspension. BOLTS, NUTS, FASTENERS Check that all frame nuts and bolts are tightened to their correct torque values. ( 1-12) Check that all safety clips, hose clamps and cable stays are in place and properly secured. 2-14 INSPECTIONS / ADJUSTMENTS WHEELS/TIRES Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE f/ (kpa) ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 2.00(200) 2.00(200) DRIVER AND A PASSENGER 2.00(200) 2.25(225) Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tires. SERVICE LIMIT : FRONT : 5.5mm REAR : 7.0mm STEERING HEAD BEARINGS