HEAD OFFICE(FACTORY) #58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL: (82-55) 239-7000 / FAX: (82-55) 239-7520 OVERSEAS SALES OFFICE(FACTORY) 13-5,SEONGSU 1-GA,2DONG, SEONGDONG-GU, SEOUL, KOREA TEL: (82-2) 3408-2634 / FAX: (82-2) 467-9997 SERVICE MANUAL 2007. 01 PRINTED 2007. 01 PUBLICATION COPY PROHIBIT HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the VJF125 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 EMS (Engine Management 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. EXTERNAL PARTS FRONT WHEEL/FRONT FORK/STEERING REAR WHEEL /REAR SUSPENSION HYDRAULIC BRAKE BATTERY / CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES TROUBLESHOOTING WIRING DIAGRAM 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 ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER 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 2,025mm 764mm 1,180mm 1,380mm 780mm 139mm 162kgf 292kgf 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 14.85 4.0 25.2 93.5mm 265 2.5cc Liquid 4-stroke DOHC(4 Valve) 1 Cylinder, 20 Inclined from vertical 56.5 X 49.5mm 124.1cm3 11.8:1 DOHC Chain Drive 1.5 After Disassembly 1.35 After Draining and Oil Filter Change 1.3 After Draining Wet Pressing and Spray Paper Filter 13.0kgf/cm2 (600rpm) 23 BTDC 55 ABDC (1.12mm Lift) 66.3 BBDC 23.6 ATDC (1.12mm Lift) 0.15 0.02mm 0.20 0.02mm 32.0kgf 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 DRIVE TRAIN CLUTCH TYPE TRANSMISSION TYPE GEAR RATIO 1st GEAR RATIO 2nd GEAR RATIO 3rd GEAR RATIO 4th GEAR RATIO 5th GEARSHIFT PATTERN Multiplate Wet Clutch / 5 Constant Mesh 3.200(37/12 T) 2.143(32/17 T) 1.438(29/21 T) 1.095(23/21 T) 0.923(24/26 T) Left foot operated return system Down 1-N-2-3-4-5 Up Full Transisterized 18 BTDC / 1,600(rpm) 30 BTDC / 8,500(rpm) 12V-17A/5,000(rpm) 12V 10AH CR9EH - 9 0.8 - 0.9mm 30A Starter Motor 55W/55W 5W 10W 4 21W/5W 3W LED 1 LED LED 5W LED 1 LED 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 TURN SIGNAL LAMP STOP/TAIL LIGHTS SPEEDOMETER LAMP NEUTRAL INDICATOR LAMP HIGH BEAM INDICATOR LAMP WINKER INDICATOR LAMP LICENCE PLATE LAMP TACHOMETER LAMP MALFUNCTION INDICATOR LAMP 1-11 GENERAL INFORMATION TORQUE VALUES ENGINE ITEM Q'TY THREAD DIA (mm) TORQUE kgf.m,(N.m) 1.0~1.2 REFERENCE CAM HOLDER BOLT(SHBOLT) CYLINDER HEAD SPECIAL SOCKET NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH 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 START MOTOR NUT TAPPET ADJUST HOLE CAP ENGIN TEMPERATURE SENSOR 8 4 4 1 2 1 1 1 1 3 2 3 1 2 12 1 7 1 1 10 1 1 1 1 M6 M10 M6 M6 M6 M6 M16 M16 M12 M8 M6 M10 M6 M6 M6 M6 M6 M14 M30 M6 M10 M6 M36 M12 1.0 1.25 1.0 1.0 1.0 1.0 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 1.5 1.25 3.5~4.5 0.8~1.2 0.8~1.2 1.0~1.4 0.35~0.5 6.0~7.0 6.0~7.0 5.0~6.0 3.0~3.4 1.0~1.4 1.0~1.4 1.0~1.4 1.0~1.4 1.0~1.2 1.0~1.2 1.0~1.2 0.4~0.8 1.0~2.0 1.0~1.2 1.0~1.2 1.0~1.4 1.0~2.0 1.0~2.0 Apply Engine Oil Apply Engine Oil Apply Engine Oil Apply Engine Oil Apply Engine Oil Remove negative screw Remove negative screw FRAME ITEM Q'TY THREAD DIA (mm) TORQUE kgf.m,(N.m) REFERENCE REAR ENGIN HANGER BOLT(UPPER) REAR ENGIN HANGER BOLT(UNDER) FRONT ENGIN HANGER BOLT(UPPER/UNDER) FRONT ENGIN HANGER PLATE BOLT STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROKET NUT REAR BRAKE OIL BOLT 1 1 2 4 2 1 1 1 1 4 2 M10 1.25 M10 1.25 M10 1.25 M8 1.25 M8 1.25 M10 1.25 M10 1.25 M 5 0.8 M14 1.5 M10 1.25 M10 1.25 4.5~5.5 5.0~6.0 4.5~5.5 2.4~3.0 2.4~3.0 1.0~2.0 4.0~5.0 0.35~0.5 8.0~10.0 5.5~6.5 3.4~4.0 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 SOCKET BOLT 2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5 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 2.8~3.4 1.0~1.4 5.5~6.5 4.0~4.5 3.0~4.0 2.8~3.4 1.0~1.4 6.0~9.0 0.25~0.35 2.4~3.0 3.0~4.0 2.4~3.0 8.0~10.0 3.5~4.5 0.5~0.7 4.0~4.5 1.8~2.5 4.0~4.5 U- NUT U- NUT *Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below. TYPE TORQUE kgf m Nm TYPE TORQUE kgf m Nm 15mm BOLT, NUT 16mm BOLT, NUT 18mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT 4.0~6.0 8~12 18~25 29~39 49~59 0.45~0.6 0.8~1.2 1.8~2.5 3.0~4.0 5.0~6.0 5mm SCREW 6mm SCREW, FLANGE BOLT (Include SH type) 3.4~5.0 7~11 9.8~14 24~29 34~44 0.35~0.5 0.7~1.1 1.0~1.4 2.4~3.0 3.5~4.5 6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT *SH(Small Head) : It describe 6mm bolt of 8mm flange bolt. 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 8 WRENCH, 8 9mm 9 ADJUSTING WRENCH, B 10 LOCK NUT WRENCH, 20 24mm 10 EXTENSION BAR 12 FLY WHEEL HOLDER 12 VALVE SPRING COMPRESSOR 12 DRIVER 12 ATTACHMENT 12 PILOT 14 FORK SEAL DRIVER BODY 14 BEARING REMOVER HEAD 14 BEARING REMOVER SHAFT 14 LOCK NUT(M8) 16 REF. SEC. 2 2 6 8, 14 8, 9 10 12, 14, 15 12, 14, 15 12, 14, 15 14 15 15 10 TESTER, GAUGE DESCRIPTION COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER TESTER RECORDER REFERENCE SECTION 2 17, 18 17, 18 18 5 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 10 10 10 10 10 REMARK 24.5mm IN, EX 23mm IN 20mm EX 22mm IN, EX Use with Valve Seat 1-15 GENERAL INFORMATION WIRING DIAGRAM ST.-HAZ. SW. THROTTLE CABLE FR. BRAKE HOSE ST.-HAZ. SW. CORD CLUTCH CABLE POSITION LIGHT HEAD LIGHT C * "» »OE1.5 OE » BATTERY EARTH CABLE ST.-MAG SW.,RR. STOP SW., SIDE STAND SW. HARNESS COVER ST.-MAG. BATTERY CABLE(+) BATTERY EARTH CABLE ST.-MAG. SW. WIRE REG. RECTIFIER ST.-MAG. BATTERY CABLE(+) ST.-MOTOR CABLE RADIATOR RESERVE TANK ,fi D ST.-HAZ. SW. CORD CLUTCH CABLE WATER PASS TUBE ASS'Y D WATER PASS TUBE ASS'Y C FUEL DRAIN TUBE RADIATOR HOSE A DRAIN TUBE CLUTCH CABLE FR. BRAKE HOSE RH. FR. WINKER CORD RADIATOR HOSE B WATER PASS TUBE ASS'Y. THERMO SWITCH ASS'Y B REG. EARTH WIRE A RR. BRAKE HOSE CLAMP SPEEDOMETER CABLE RADIATOR HOSE C RR. BRAKE HOSE RR. CALIPER ASS'Y. RR. BRAKE HOSE RR. BRAKE RESERVE TUBE BY PASS TUBE TEMPERATURE SENSOR CLUTCH CABLE WINKER SW. CORD POSITION LIGHT THROTTLE CABLE BATT. + WIRE BATT. - WIRE ST.-MAG. SW.¯ WIRE WIRE CLIP CABLE CLAMP SEAT LOCK CABLE WIRE HARNESS HELMET HOLDER & SEAT LOCK ASS'Y. HEAD LIGHT COMBI.METER CORD O2 SENSOR WIRE WIRE HARNESS WATER TEMPERATURE SENSOR COMB. METER EARTH BREATHER TUBE HEAD LIGHT RELAY LH. FR. WINKER CORD ECU WIRE ACG., FUEL PUMP, GEAR POSITION, CPS CORD HARNESS COVER ST.-MOTOR CABLE ACG. CORD O2 SENSOR FR.BRAKE HOSE SPEEDOMETER CABLE SPDMT. CABLE CLAMP 1-16 GENERAL INFORMATION FUEL INJECTOR MAP & AT SENSOR (MAPAT) IDLE SPEED ACTUATOR (ISA) THROTTLE POSITION SENSOR (TPS) ST.-MAG. BATTERY CABLE(+) WIRE HARNESS O2 SENSOR COUPLER HIGH TENSION CORD NOISE SUPPRESSOR CAP IG. COIL EARTH ST.-HAZ. SW.,COMB.& LOCK SW., WINKER SW.. ·º ± WATER TEMPERATURE SENSOR CORD THROTTLE CABLE FAN MOTOR ASS'Y CONN-TUBE WIRE CLIP CLUTCH CABLE EMI. FILTER COUPLER BATTERY EARTH CABLE CLUTCH CABLE THROTTLE CABLE BY PASS TUBE MOTOR EMI. FILTER RADIATOR HOSE A WATER PASS TUBE ASS'Y C » "» ...... (D) DETAIL OF VIEW (D) ST.-HAZ. SW. WINKER SW. CORD CLUTCH CABLE THROTTLE CABLE ST.-HAZ. SW. CORD CABLE GUIDE WATER PASS TUBE ASS'Y. CABLE GUIDE WINKER SW. CORD THROTTLE CABLE COMB.& LOCK SW. CORD FR. BRAKE HOSE DETAIL OF VIEW(C) ,Ø" ...... (C) » POSITION LIGHT COUPLER HORN CORD LH. HEAD LIGHT HORN COMP RH. HEAD LIGHT COUPLER RH. HEAD LIGHT LH. FR. WINKER CORD HEAD LIGHT COUPLER RH. FR. WINKER CORD DETAIL OF HEADLIGHT CASE PART ¶ fi" ...... » 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 (B) 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 (A) 1-18 GENERAL INFORMATION ECU COMP. FUSE BOX SPARE FUSE(30A,15A) WINKER RELAY BATTERY EARTH CABLE ST.-MAG.BATTERY CORD(+) FUSE BATT. BAND WIRE CLIP WIRE HARNESS FUEL PUMP RELAY R/L.RR.WINKER CORD FAN MOTOR RELAY BATTERY(12V 10AH MF.) ST.-MAG.BATTERY CABLE(+) ECU COMP. COUPLER ECU COMP. EARTH CORD DETAIL OF FUSE BOX PART DETAIL OF BATTER PART REG. RECTIFIER REG. EARTH WIRE ST.-MAG. SW. WIRE O2 SENSOR WIRE REG. RECTIFIER COUPLER ST.-MAG. BATTERY CABLE(+) BATTERY EARTH CABLE DETAIL OF THROTTLE BODY PART DETAIL OF REGRECTIFIER PART 1-19 MEMO 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE (FUEL TUBE) THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDER COMPRESSION PRESSURE DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE PAD WEAR 2-1 2-3 2-4 2-4 2-5 2-6 2-6 2-7 2-8 2-10 2-10 2-10 BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEEL/TIRE STEERING STEM COOLANT LEVEL INSPECTION COOLANT REPLACEMENT 2-11 2-12 2-12 2-12 2-13 2-14 2-14 2-15 2-15 2-16 2-16 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 CYLINDER COMPRESSION DRIVE CHAIN SLACK REAR BRAKE PEDAL FREE PLAY CLUTCH LEVER FREE PLAY IN. EX. 2~6mm CR9EH-9 0.8~0.9mm 0.15mm 0.20mm 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 2.00kgf/ (200kPa, 29psi ) 2.00kgf/ (200kPa, 29psi ) 2.00kgf/ (200kPa, 29psi ) 2.25kgf/ (225kPa, 32psi ) 110/70-17 54P 140/60-17 60P 5.5mm 7.0mm 2-1 TIRE SIZE TIRE PART MINIMUM-DEPTH INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG CYLINDER HEAD COVER BOLT 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) 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 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 REFER TO PAGE REMARK MONTH I FUEL LINE FUEL FILTER THROTTLE GRIP OPERATION AIR CLEANER ELEMENT SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER ELEMENT DRIVE CHAIN 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 RADIATOR COOLANT RADIATOR CORE RADIATOR CAP I R I R I I I R I R R I R R : I and L I I I I I I I I I I R I R I I R R 2-4 2-4 2-4 2-5 2-6 2-6 3-3 3-4 2-8 NOTE (3) NOTE (2) R R R R Every 1,000 I I I I I I I I I I 2-10 2-10 2-11 2-12 2-12 2-12 2-12 2-14 2-14 I I I I I I I I I I I I I I I I I I I R I I I 2-15 2-15 I I 6-3 6-5 6-6 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 LINE (FUEL TUBE) Check the fuel tube for deterioration, damage or leakage. Replace it if necessary. FUEL TUBE FUEL TUBE FUEL TUBE THROTTLE GRIP OPERATION 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 2-4 INSPECTIONS / ADJUSTMENTS SCREWS SCREWS SCREWS AIR CLEANER Remove the seat. ( 13-2) Loosen the 4 screws, remove the air cleaner housing cover. AIR CLEANER AIR CLEANER AIR CLEANER COVER HOUSING COVER 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 in the reverse order of removal. AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER ELEMENT ELEMENT ELEMENT Do not reuse the air cleaner element to clean by compressed air. SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG SPARK PLUG Remove the spark plug cap. 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 : CR9EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf 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. Assemble the spark plug. CHECK FOR CRACKS 2-5 INSPECTIONS / ADJUSTMENTS 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 : 0.15mm EXHAUST : 0.20mm "T" MARK "T" MARK "T" MARK FEELER GAUGE FEELER GAUGE FEELER GAUGE SHIM ADJUSTMENT If the valve clearance is out of standard, adjust the shim as below. Remove the camshaft. Remove the valve lifter and seam. If the valve lifter is to be removed, use the special tool. VALVE RIFTER VALVE RIFTER VALVE RIFTER Be careful not to drop the shim into the cylinder when remove the shim with valve lifter. If it is too difficult to remove the shim, use a tweezer or magnet. SHIM SHIM SHIM Valve lifter, and shim should be preserved on the assembly position distinguishably. Remove the valve lifter and clean by compressed air. Mop the oil from the attahed area of shim, and measure and record the thinkness with a micrometer. 2-6 INSPECTIONS / ADJUSTMENTS The type of shim is 33 The clearance of shim is 1,500mm to 2,300mm with 0.025mm clearance. Demanded thickness of shim :A Recorded clearance of the valve lifter : B Specified clearance of the valve lifter : C (In :0.15mm / Ex : 0.20mm) Removed thickness of the shim : D how to calculate : A = (B-C)+D Example) B : 0.06mm D : 1.875mm C : 0.15mm(IN) A = (0.06-0.15)+1.875mm New thickness of the shim : 1.775mm Meaure the thickness of new shim and removed shim, using a micrometer accurately. If the demanded thickness of shim is over 2,300mm, to check the valve seat and remove the carbon deposit and modify the valve seat. Install the chosen shim into the valve spring retainer. Apply the molybdenum to wet side of valve lifter and install the lifter. Install the cam shaft and rotate the crank shaft for many timed and recheck the valve clearance after setting the shim. Apply the engine oil to O-ring of pulse generator cover cap and install the cap. TORQUE : 0.6kgf-m CYLINDER COMPRESSION PRESSURE Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps 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 PRESSURE GAUGE COMPRESSION PRESSURE GAUGE COMPRESSION PRESSURE GAUGE The maximum reading is usually reached within 4~7seconds compression 13.0kg f/ If compression is low, check the following Incorrect valve clearance adjustment. Valve leakage. Leak the gasket from the cylinder head. Worn piston/cylinder. If compression is high, check the following Carbon deposits on the piston head, cylinder head. 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 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. AXLE NUT AXLE NUT AXLE NUT AXLE NUT ADJUSTING NUT ADJUSTING NUT ADJUSTING NUT 10~20mm 10~20mm 10~20mm 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. LOCK NUT LOCK NUT LOCK NUT LOCK NUT Tighten the axle nut with the specified torque. 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. (chain color change : Black Gold) RETAINER CLIP RETAINER CLIP RETAINER CLIP 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 GEAR OIL(#80-90) 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. After inspecting an excessive wear and damage of the drive sprocket, replace it if necessary. WEAR DAMAGE NORMAL Always replace the chain and sprocket as a set. Because using the stretched chain and new sprocket or similar case, the parts will damage quickly cause by the pictch is not engage each other. Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, tighten them to the specified torque. 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. FR. BRAKE FLUID FR. BRAKE FLUID FR. BRAKE FLUID 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) RR. BRAKE FLUID RR. BRAKE FLUID RR.. BRAKE FLUID 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. UPPER LEVEL LINE UPPER LEVEL LINE UPPER LEVEL LINE UPPER LEVEL LINE UPPER LOWER 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 16-6 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 16-7 for brake pad replacement. BRAKE SYSTEM Check to see if there is a crack and damage in the front and rear brake hose. If leak, repluce it with new one. BRAKE HOSE BRAKE HOSE BRAKE HOSE 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 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. STOPPER BOLT STOPPER BOLT STOPPER BOLT STOPPER BOLT 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. BRAKE STOP SWITCH BRAKE STOP SWITCH BRAKE STOP SWITCH