ENGINE

CONTENTS

3-1

3-2

3-7

3-17

3-21

3-26

3-27 3
3-28

3-31
 ENGINE

REMOVING ENGINEPARTS WITH ENGINE IN PLACE

UPPER SIDE OF ENGINE

Starter motor 3-7
Cam chain tensioner 3-7
Cam sprocket 3-8
Cam shaft 3-8
Valve rocker arm 3-9

RIGHT SIDE OF ENGINE

Kick starter lever 3-21
Clutch cover 3-21
Oil filter rotor 3-21
Clutch 3-22
Oil pump 3-26
Gear shifting lever 3-27

LEFT SIDE OF ENGINE

Sprocket cover 3-28
Starter reduction gear 3-28
Generator cover 3-28
Starter motor idle gear 3-28
Generator rotor 3-29
Starter clutch 3-29
Generator stator 3-29
Trigger coil 3-29

3-1
 ENGINE

ENGINE REMOVAL

● Remove the left and right side covers 1 .

Open the saddle lock, take off the rear saddle 2 .

Remove the front saddle mounting bolt, take off the front
saddle 3 .

Remove the battery wire 4 .

Turn the fuel switch to the ” ” position.

Remove the fuel hose 5 .

Remove the overflow hose 6 and tip-over valve 7 .

Disconnect the fuel level gauge coupler 8 .
Remove the fuel tank bolts, remove the fuel tank 9 .

3-2
 ENGINE

Loosen the generator wire clamp, remove the wire jacket

11 .
Disconnect the generator coupler 12 , gear position switch
coupler 13 and speedometer sensor coupler 14 .

Disconnect the vacuum hose 17 .

Remove the throttle cable and carburetor piston 18 .
Remove the breather hose 19 .
Remove the carburetor intake hose nut.

3-3
 ENGINE

Loosen the rear axle nut 22 and chain adjuster bolt 23.

Remove the gear shifting lever 24.

Remove the crankshaft breather hose 25 , starer motor 26

, and engine ground wire 27 .

Remove the rear sprocket cover 28 .

Remove the chain clip, disconnect the drive chain 29.

3-4
 ENGINE

Disconnect the spark plug cap 30 .

Disconnect the 2nd air intake hose 31.
Remove the exhaust pipe bolts.

Remove the muffler mounting bolt and nut, take off the
muffler 32 .

Remove the engine rear mounting nut 33 .

Remove the front bumper 34 .

Remove the engine upper mounting nut 35 , engine
front hanging mounting nuts 36 , engine front mounting
nuts 37 .
Remove the right front footrest mounting bolts, remove the
right front footrest.
Draw out the mounting bolts, remove the front hanging
plate and engine.

3-5
 ENGINE

ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal.
Pay attention to the following points:
Temporarily fasten the engine, mounting bracket before
inserting the engine mounting bolts.

The engine mounting nuts are self-locking nuts. Once

the nut has been removed, it is no longer of any use. Be
sure to use new nuts and tighten them to the specified
torque.
Tightening torque for engine mounting bolts:
Engine front mounting nut A : 33-39 N•m
Engine front hanging nut B : 22-33 N•m
Engine upper mounting nut C : 33-39 N•m
Engine rear mounting nut D : 50-60 N•m E
Right footrest mounting bolt E : 40-60 N•m
Muffler bolt F : 11-15 N•m
Rear footrest nut G : 40-60 N•m

D
F

After installing the engine, add the engine oil. (Refer to

page 2-7).
Install the engine oil level. (Refer to page 2-7).

Inspect the following items.

* Clutch cable (Refer to page 2-8)
* Throttle cable (Refer to page 2-8)
* Idle speed (Refer to page 2-9)
* Drive chain (Refer to page 2-10)
3-6
 ENGINE

CYLINDER HEAD AND VALVE

REMOVAL
Drain the engine oil, remove the engine. (Refer to page 3-
2).

Remove the starter motor mounting bolts, take off the

starter motor 1 .

Remove the camshaft tensioner 2 .

Remove the generator cover cap 3 and inspection plug 4 .

Remove the valve inspection caps 5 .

3-7
 ENGINE

Remove the cylinder head left cover 6 .

When removing the cylinder head cover, piston must

be at top dead center on compression stroke.

Align the mark A on the cam shaft sprocket with the mark B
B
on the cylinder head.
Remove the cam shaft sprocket mounting bolt 7 , take off
the cam shaft sprocket.
A

Do not drop sprocket, drive chain and bolt into the

crankcase.

Remove the bolt 9 first.

If it is difficult to remove the cylinder head, gently

pry it off while tapping the finless portion of the cylinder
head with a plastic hammer. Be careful not to break the
fins.

Remove the cylinder head gasket 10 and dowel pin.

3-8
 ENGINE

Remove the cam chain tensioner 1 .

● Remove the rocker arm shaft retainer plate 2 .

● Remove the camshaft 3 .

● Draw out the rocker arm shaft 4 , remove the rocker arm 5
and spring 6 .

3-9
 ENGINE

Remove the valve cotters with the special tool.

11F14-018 : Valve remover

● Remove the oil seal.

Removed oil seal should be replaced with a new one.

● Remove the spring lower seat.

INSPECTION

Measure diameter of rocker arm shaft.

Rocker arm shaft O.D. (IN and EX.):

Standard: 11.986-11.994 mm

09900-20205 : Micrometer (0~25 mm)

When checking the valve rocker arm, the inside diameter of

the valve rocker arm and wear of the camshaft contacting
surface should be checked.

Rocker arm I.D (IN and EX.):

Standard: 12.0-12.018 mm
09900-20605 : Caliper gauge

3-10
 ENGINE

● Measure the valve spring free length.

Valve spring free length (IN and EX):

Limit (IN) : 37.44 mm
(EX): 40.13 mm

09900-20103: Vernier calipers

CAMSHAFT

CAM HEIGHT
CAM HEIGHT H ：
Service Limit: (IN.): 31.036 mm
(EX.): 30.941 mm

09900-20202: Micrometer (25~50 mm)

CYLINDER HEAD

Cylinder head distortion

Service limit : 0.05 mm

09900-20803 : Thickness gauge

 ENGINE

Measure the thickness 1 , and if the thickness is found to

have been reduced to the limit, replace the valve.
Valve face thickness: Limit: 0.5 mm

Visually inspect each valve for wear of its seating face.

Replace any valve with an abnormally worn face.

Support the valve with “V” blocks, as shown, and check its
runout with a dial gauge. The valve must be replaced if the
runout exceeds the limit.
Valve stem runout:
Limit: 0.05 mm

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand
09900-21304: V-block ( 100 mm)

Place the dial gauge at right angles to the valve head, and
measure the valve head radial runout. If measures more
than limit, replace the valve.

Valve head radial runout:

Limit: 0.03 mm

09900-20606:Dial gauge (1/100 mm)

09900-20701:Magnetic stand
09900-21304:V-block (100 mm)

Valve stem O.D.:

Standard (IN): 4.975-4.99 mm
(EX): 4.955-4.97 mm

09900-20205 : Micrometer (0~25 mm)

Oil each seal, and drive them into the position.

Always use new oil seal.

3-12
 ENGINE

09916-10911: Valve lapper set

Valve seat width: ：Standard：

Intake：1.0-1.2 mm
Exhaust: 1.1-1.3 mm
If either requirement is not met, correct the seat by servicing it
as follows.

● The valve seats 1 for both intake and exhaust valves are
angles to present three bevels. The valve seat contact 进气门

surface is 45°.

INTAKE EXHAUST
O O
Valve seat angle 30 , 45 30°,45°
Valve seat width 1.0-1.2 mm 1.1-1.3 mm
Valve diameter 29.0 mm 25.0 mm
Valve guide I.d. 5.000-5.012 mm

The valve seat contact area must be inspected after

each cut. Do not use lapping compound after the final
cut is made. The finished valve seat should have a
velvety smooth finish and not a highly polished or
shiny finish. The will provide a soft surface for the final
seating of the valve which will occur during the first
few seconds of engine operation.

Take extreme care when handling with gasoline.

3-13
 ENGINE

99000-25140: Moly paste

Install the valve springs, making sure that close-pitch

end of each spring faces to combusion room.
Turn the valve slowly while installing the valve oil seal to
prevent the valve oil seal from damage.

● Install the cotters with the special tool.

11F14-018: Valve remover and installer

3-14
 ENGINE

Oil the rocket arm shaft.

Install the rocker arm, rocker arm spring and rocker arm shaft to
the cylinder head.

Apply a small quantity moly paste to the camshaft journal

and place camshaft on the cylinder head.
Install the rocker arm stopper plate and tighten the bolts.
99000-25140: Moly paste

99000-31140: Bond “1207B”

Reassemble the cylinder head in the reverse order of removal.

Pay attention to the following points.
Remove the gasket material on the cylinder head
contacting surface.

Do not let the dirt and dust get into the engine.

Install the chain guide, dowel pin and cylinder head gasket
1 .

3-15
 ENGINE

Cylinder head cover nut: 25-35 N•m

Install the cam shaft, cam shaft sprocket and drive chain.
B

99000-32030: Thread lock “1303”

● Install the cylinder head left cover and gasket.

Always use a new gasket.

Install the valve inspection caps and O-ring.

Always use a new gasket.

3-16
 ENGINE

CYLINDER REMOVAL

CYLINDER INSPECTION
Remove the residual gasket of the cylinder surface.
Inspect the plainness of the cylinder with a ruler and a
thickness gauge.
Cylinder distortion:
Limit: 0.05 mm

09900-20803: Thickness gauge

Cylinder bore diameter: Limit: 57.43 mm

09900-20508: Cylinder gauge set

REMOVAL

Place a clean rag over the cylinder base to prevent

piston pin circlip from dropping into crankcase.

Remove the piston pin circlip.

Remove the piston pin and piston with the special tool.
09910-34510: Piston pin puller

In order not to damage conrod big end bearing, hold the

piston stable when take out the piston pin.
Removing the piston rings one by one by expanding the
gap symmetrically.

Do not expand the piston ring excessively since it is apt

to be broken down.
Do not damage piston while removing piston ring.
3-17
 ENGINE

Decarbonize the piston.

Using a soft-metal scrapper or discarded piston ring to

decarbon the ring grooves of the piston. Do not use the
steel brush or the piston will be scratched.

INSPECTION
Temporarily fit the piston ring on the suitable position with
the marked side to the top.
Measure the piston ring-groove clearance with thickness
gauge.
Piston ring-groove clearance:
Limit(1st):0.18 mm
(2nd):0.15 mm
09900-20803: Micrometer (50~75 mm)
Measure the piston outside diameter at the place 7 mm
from the skirt end.
Piston outside diameter:
Limit: 7 mm from the skirt end, 57.145 mm
7mm
09900-20803: Micrometer (50~75 mm)

Piston pin bore inside diameter: Limit: 14.03 mm

09900-20605: Caliper gauge

Piston pin O.D.: Limit: 13.98 mm

09900-20205: Micrometer (0-25)

3-18
 ENGINE

● Measure the conrod small end I.D.

Conrod small end I.D.: Limit: 14.04 mm

09900-20605: Caliper gauge

Piston ring end gap: Limit(1st): 0.50 mm

(2nd):0.50 mm
09900-20803: Thickness gauge

NOTE:
Make sure fit the piston ring into the cylinder evenly
with the piston head.

Reassemble the piston and cylinder in the reverse order of

removal, pay attention to the following points:
● Clean the piston top, skirt and groove.

Fit the piston rings in the groove correctly, rotate

the piston ring by hand to see if it turns smoothly.

● Install the piston ring carefully with marked side to the top.

120°

12
0° 0°
12
Be careful not to damage the piston ring and piston
during the installing the piston ring. Pay attention to the
angle between the 1st ring and 2nd ring.

● The gaps of two piston rings should be staggered at 120°.

Install the oil ring first, then expander ring,

Do not align the opening of oil ring with expander ring.

Inspect the piston rings for smooth rotation after assembly.

3-19
 ENGINE

Apply oil to the piston pin outer surface.

Place a clean rag over the cylinder base to prevent piston

pin circlip from dropping into crankcase and then, remove
the piston pin circlip with long-nose pliers.

Replace the circlip with new one.

End gap of the circlip should not be aligned with the
cutaway in the piston pin bore.

When fitting the piston, turn the ”IN” of the piston head to
intake side.

99000-31110: Bond “1215"

Always use new gasket to prevent leaking.

When mounting the cylinder, keep the cam chain taut,

or the chain will be caught between crankcase and cam
drive sprocket.
There are the guide holder for the bottom end of cam
chain guide cast in the crankcase. Be sure that the cam
chain guide are inserted properly.

Install the cylinder head. (Refer to page 3-15)

3-20
 ENGINE

CLUTCH
REMOVAL
● Drain the engine oil.
● Remove the clutch adjust bolt, disconnect the clutch cable
1.

Remove the kick starter lever 2 .

Remove the engine oil level gauge 3 .

Remove the clutch cover bolts diagonally and take off the
clutch cover 4 .

Remove the gasket and dowel pins.

Remove the oil filter rotor cover 5 .
Remove the clutch push rod 6 and bearing 7 .

Always use new gasket.

Hold the crankshaft with the special tool, remove the oil
filter rotor lock nut.

11F14-030: Gear stopper

11F14-011: Four claws sleeve

3-21
 ENGINE

Remove the washer and oil filter rotor 8 .

● Hold the clutch with the special tool, remove the clutch hub
lock nut.
09930-40113: Sprocket holder
11F14-011: 4 Claws sleeve

● Remove the washer and clutch driven hub assembly 9 .

● Remove the clutch washer and primary driven gear assembly

10 .

● Disassemble the clutch driven hub assembly, take off the

clutch push set, spring, drive and driven plates.

3-22
 ENGINE

INSPECTION
● Measure the thickness and claw width of each drive plate
with vernier calipers. Replace drive plates found to have
worn down to the limit.

09900-20103: Vernier calipers

Drive plate thickness: Checking thickness

Limit: 2.6 mm

Drive plate claw width:

Limit: 15 mm

Checking claw width

● Measure each driven plate for distortion with a thickness

gauge. Replace driven plates which exceed the limit.
09900-20803: Thickness gauge

Driven plate distortion: Limit: 0.1 mm

Replace the drive and drive plates as a whole set which Checking distortion
exceed the limit.

● Measure the clutch spring free length.

Clutch spring free length:
Limit: 36.2 mm

09900-20103: Vernier calipers

Replace all the springs if any spring is not within the

limit.

Rotate the inner race by hand to inspect for abnormal noise

and smooth rotation. Replace the bearing if there is
anything unusual.

3-23
 ENGINE

● Inspect clutch outer disk notch for flaws or dents caused by

drive and driven plate.

● Inspect the clutch driven hub for notches or abnormal wear

caused by drive hub.

● Apply engine oil to the clutch drive and driven plats,

reassemble the clutch sleeve hub, springs, push set and
bolts.

The top and bottom clutch drive plates have

different color with the 3 middle drive plates, install
them correctly. When install the clutch drive plates,
fit the top one to the shallow groove of clutch sleeve hub.

Reassemble the clutch in the reverse order of removal. Pay

attention to the follow points
● Hold the clutch sleeve hub with the special tool, tighten the
clutch lock nut to the specified torque.

11F14-030: Gear stopper

11F14-011: 4 claws sleeve
Clutch lock nut: 40-45 N•m

09930-40113: Sprocket holder

11F14-011: 4 claws sleeve

Oil filter rotor lock nut: 40-45 N•m

3-24
 ENGINE

99000-32050: Bond "1342"

Always use new gasket.

● Install the dowel pin and new gasket.

Always use new gasket.

Clutch cover bolt: 10-15 N•m

● Re-adjust the clutch cable clearance. (Refer to page 2-8).

3-25
 ENGINE

REMOVAL AND INSPECTION

Remove the oil pump 3 .

Check if the O-ring damage or missing. Replace it with a

new one if there is something unusual.

Check the oil pump if turns smoothly. Replace the oil pump
if there is something unusual.

Reassemble the oil pump in the reverser order of removal.

Pay attention to the following points:
Apply a small quantity of engin oil to the inside of oil pump
before installing the oil pump.
Apply thread lock "1342" to the oil pump mounting screws
and tighten.
99000-32050: Thread lock "1342"

3-25
 ENGINE

GEAR SHIFTING MECHANISM

REMOVAL
Remove gear shifting lever 1 .
Remove the clutch. (Refer to page 3-21).

Remove the gear shifting shaft assembly 2 .

Remove the fixing cam 3 and pin.

Remove the cam stopper assembly 4 .

INSPECTION
● Inspect the gear shifting shaft 5 for wear or bend.

Reassemble the gear shifting mechanism, pay attention to the

following points.
Apply the thread lock ”1342" to the threaded part of
stopper cam bolt and fixing cam pin, then install the
stopper cam and fixing cam pin.

99000-32050 : Thread lock”1342”

3-26
 ENGINE

REMOVAL
Disconnect the generator coupler 1 and gear position
switch coupler 2 .

Remove the gear shifting lever bolt and gear shifting lever
3 .
Remove the engine sprocket cover 4 .

Remove the idle gear cover 5 .

Remove the idle gear shaft 6 and starter idle gear 7 .
Remove the generator wire bolt and press plate.

Remove the bolts, take off the generator cover 8 .

Remove the gasket and dowel pin.

Loosen the generator cover bolts diagonally.

Be careful to the magnetic force between the generator
cover(stator) and rotor.

Remove the starter motor idle gear 9 and shaft.

3-27
 ENGINE

● Hold the rotor with the special tool, remove the generator
rotor bolts.
11F14-001: Rotor holder

11F14-002: Generator rotor remover

Do not damage the key slot and crankshaft when

removing the key.

INSPECTION

Inspect the starter driven gear spacer for damage, replace

the spacer if there is something unusual.

3-28
 ENGINE

Reassemble the generator cover in the reverse order of

removal. Pay attention to the following points:
●

99000-31140 : BOND“1207B”

99000-32050 : Thread lock“1342”

● Install the key to the crankshaft key slot.

● Degrease to the rotor cone surface and crankshaft cone
surface, make sure the surface is clean and dry without oil
or grease.

Do not damage the key slot and crankshaft when

installing the key.

99000-32050: Thread lock“1342”

Generator bolt: 45-50 N•m

11F14-001: Rotor holder

Replace the gasket with a new one to prevent leakage.

3-29
 ENGINE

CRANKSHAFT, TRANSMISSION AND KICK STARTER

REMOVAL
●

Remove the speedometer rotor 1 .

Remove the engine sprocket 2 .

Remove the cam chain 3 .
Remove the gear position mounting screws, take off the
gear position 4 and pin and spring.
Remove the crankshaft pressure plate bolt, pressure plate,
spring and pin.

11F14-036: Balancer shaft fixer

3-30
 ENGINE

09900-06107: Snap ring pliers (opening type)

● Remove the key and crankcase mounting bolts.

Remove the right crankcase with the special tool.

When installing the crankcase separating tool, the tool
plate should parallel with crankcase contacting surface.
11F14-027: Crankcase separating tool

The crankshaft and transmission components must

remain in the left crankcase half. This is necessary
because the gear shifting cam stopper is mounted on
the left crankcase half and will be damaged if the
transmission components remain in the right half.

Remove the gear shifting shaft, take off the gear shifting
fork.
Remove the gear shifting cam.

3-31
 ENGINE

Remove the transmission assembly.

Remove the crankshaft with the special tool.

11F14-027: Crankcase separating tool

Remove the balancer shaft.

Remove the kick starter assembly.

INSPECTION
Measure the big end of conrod side clearance with a
thickness gauge.
Conrod big end side clearance:
Limit: 0.5 mm
09900-20803 : Thickness gauge

Support the crankshaft with “V” blocks as shown, with the

two end journals resting on the blocks. Measure the
crankshaft runout with the dial gauge.

Crankshaft runout:
Limit: 0.05 mm
09900-20606: Dial gauge (1/100)
09900-20701: Magnetic stand
09900-21304: V-block
3-32
 ENGINE

Wear on the big end of the conrod can be estimated by

checking the movement of the small end of the rod. This
method can also check the extent of wear on the parts of
the conrod’s big end.
Conrod small end deflection:
Limit: 3.0 mm
09900-20606: Dial gauge(1/100)
09900-20701: Magnetic stand
09900-21304: V-block

Shifting fork to groove clearance: 0.45 mm

09900-20803 : Thickness gauge Checking clearance

Measure the thickness of gear shift fork.

Gear shift fork thickness: 4.93-5.0 mm

09900-20103: Vernier calipers

Checking thickness

Measure the gear shift fork groove width.

The gear shift fork groove width: 5.1-5.18 mm

09900-20103: Vernier calipers

Checking groove width

Inspect the gear shifting guide slot for damage.

Replace the gear shifting guide slot if the damage is found.

3-33
 ENGINE

Check if abnormal wear or poor lubrication exist on each

bush, inner race of gear and gear teeth surface.

BEARING REMOVAL

09921-20240 : Bearing removal tool

3-34
 ENGINE

Reassemble the bearing in the reverse of removal, pay

attention to the following points.

BEARING
Install the bearings on the left and right crankcases with
the special tool.

09913-70210: Bearing installer set

Apply the Thread Lock "1342" to threaded part of bearing

blocking plate bolt.

99000-32050 : Thread lock “1342”

CRANKSHAFT

● Decide the width between the webs referring to the right

figure when rebuilding the crankshaft.
Width between webs:
Standard: 55±0.1 mm

55±0.1 mm

3-35
 ENGINE

When mounting the crankshaft in the crankcase, it is

necessary to pull its left end into the crankcase.

09910-32812: Crankshaft installer

09910-20116: Conrod holder
09910-32812-02: Crankshaft installer attachment

Never fit the crankshaft into the crankcase by striking it

with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.

TRANSMISSION

3-36
 ENGINE

Never reuse a circlip. After a circlip has been removed

from a shaft, it should be discarded and a new circlip
must be installed. When installing a new circlip, care
must be taken not to expand the end gap larger than
required to slip the circlip over the shaft. After installing
a circlip, always insure that is is completely seated in its
groove and securely fitted.

● Press-fit 2nd drive gear onto the counter shaft. Before

reassembling, coat the internal face of the 2nd drive gear
with Thread Lock “1303" and install it so that the length A as
shown in Fig.

Countershaft length(Low to 2nd) A ：

Standard: 96.2-96.5 mm A
99000-32030: Thread lock " 1303"

This procedure may be performed only twice before

shaft replacement is required.

3-37
 ENGINE

● Install the gear shifting cam to the crankcase and install the
gear shifting fork in the order of “L, C, R”.

The forks resemble each other very closely in external

appearance and configuration, install the forks in the order
of mark”JBL, JBC, JBR”. Check if driven shaft and counter
shaft rotate smoothly after forks are installed.

Install the kick starter shaft, and tighten the stopper bolt to
the specified torque.

Stopper bolt: 25-30 N·m

Install the dowel pin and gasket.

Never reuse the gasket.

Install the right crankcase to the left crankcase, tighten the

mounting bolts.

Tighten the bolts in 2-3 steps diagonally.

3-38
 ENGINE

Install the dowel pin and gear shifting fixing pin, apply
thread lock to the threaded part of bolt.
Install the spring and gear stopper cam, apply the Thread
Lock to threaded part of bolt and tighten it.

99000-32050: Thread lock “1342"

● Install the balancer driven gear assembly, hold the

balancer shaft with special tool, apply the thread lock to
balancer shaft nut, tighten the nut to the specified torque.
11F14-036: Balancer shaft holder

99000-32050: Thread lock “1342"

Balancer bolt: 25-35 N•m

A B

99000-32050: Thread lock “1342"

09930-40113: Sprocket holder

3-39
CHASSIS

CONTENTS

5-1
5-6
5-12
5-20 5
5-24
5-30
 CHASSIS

FRONT WHEEL
Construction

Front axle Front wheel rim

Spacer Front tire ITEM N•m kgf•m
Dust cover Front brake disc A 18-28 1.8-2.8
Oil seal Spacer B 36-52 3.6-5.2
Wheel bearing A Brake disc bolt
Spacer B Front axle nut

5-1
 CHASSIS

Raise the front wheel off the ground and support the
motorcycle with a jack or a wooden block.
Remove the front axle nut 1 。

Draw out the front axle, remove the front wheel 2 .

Remove the front axle left spacer 3 and dust cover 4 .

CAUTION

Do not operate the front brake lever while dismounting

the front wheel.

● Remove the brake disc bolts, remove the brake disc 6 .

OIL SEAL
Inspect the oil seal for wear or damage. Replace the oil seal if
there is something unusual.

5-2
 CHASSIS

● Remove the oil seal with the special tool.

09913-50121: Oil seal remover

Using the special tools, check the axle shaft for runout and
replace it if the runout exceeds the limit.

09900-20606: Dial gauge (1/100)

09900-20701: Magnetic stand
09900-21304: V-block
Axle runout:
Limit: 0.25 mm

WHEEL RIM
Mark sure that the wheel rim runout does not exceed the
service limit when checked as shown. An excessive amount of
runout is usually due to loose spokes or a bent wheel rim. If
properly tightening the spokes will not correct the runout,
replace the wheel rim.

Wheel rim runout:

Service limit: 2.0 mm

WHEEL BEARING
Inspect the play of the wheel bearings inner race by hand
while fixing it in the wheel hub.
Rotate the inner race by hand to inspect whether abnormal
noise occurs or rotating smoothly.
Replace the bearing if there is something unusual.。

09921-20240: Bearing remover tool

5-3
 CHASSIS

Reassemble and remount the front wheel in reverse order of

removal. Pay special attention to the following points.
WHEEL BEARING
Apply super grease ”A” to bearings before reassembly.

99000-25010: Super grease ”A”

09924-84510: Bearing installer

The sealed cover of the bearing must face outside.

● Remove the removed bearing 4 .

1 Left bearing 3 Right bearing A LH a Clearance

2 Spacer 4 Removed bearing B RH

DUST SEAL
Apply the Super grease "A" to the dust seal lips.
Install the new dust seals using the special tool.

99000-25010 : Super grease ”A”

09913-70210 : Bearing installing set (10-75Φ)

5-4
 CHASSIS

BRAKE DISC

99000-32130: Thread lock “1360"

Front brake disc bolt: 18~28 N•m

Install the front wheel and front axle, tighten the front axle
nut to the specified torque.

Front axle nut: 36-52 N•m

WARNING

After installing the front wheel, pump the brake lever

until the pistons push the pads correctly.

5-5
 CHASSIS

FRONT BREAK
CONSTRUCTION

A
B

B
C

1 Brake lever 7 Bracket ITEM N•m kgf • m

2 Piston cup set 8 Pad set A 8-12 0.8-1.2
3 Master cylinder 9 Air bleeder valve
B 20-25 2.0-2.5
C 18-28 1.8-2.8
4 Brake hose A Master cylinder clamping bolt
5 Brake light switch B Brake hose union bolt
6 Brake caliper C Brake caliper mounting bolt

5-6
 CHASSIS

Immediately and completely wipe off any brake fluid contacting any part of the motorcycle. The
brake fluid reacts chemically with paint, plastics and rubber materials, etc., and will damage
them severely.

BRAKE PAD REPLACEMENT

● Remove the brake caliper mounting bolt 1 .

Remove the brake pad pin " B " clip 2 .

Remove the brake pads 3 and replace them with a new
set.

Replace brake pads as a set otherwise braking

performance will be adversely affected.

Brake caliper mounting bolts: 18~28 N•m

While installing the brake caliper, push the pistons all

the way into the brake caliper.

5-7
 CHASSIS

Disconnect the brake hose 1 from the caliper catch the

brake fluid in a suitable receptacle.
Remove the caliper mounting bolts 2 and then take off
the caliper.

Never reuse brake fluid left over from the last servicing
or stored for a long period of time.

Remove the “B” clip, take off the brake caliper pads.

Place a rag over the piston to prevent popping up. Force

out the piston by using air gun.

Do not use high pressure air to prevent piston damage.

Remove the piston, piston boot and piston seal.

INSPECTION
MASTER CYLINDER
● Inspect the master cylinder bore for any scraches or
other damage.

5-8
 CHASSIS

PISTON
● Inspect the piston surface for scratches or other damage.

RUBBER PARTS
Inspect the rubber parts for cracks and damage. If any
defects are found, replace the affected parts.

BRAKE DISC
● Visually inspect brake disc for cracks or damage, and
measure brake disc thickness with a micrometer.

09900-20205: Micrometer (0-25 mm)

Brake disc thickness:
Service limit: 3.5 mm

● Measure runout of the brake disc with a dial gauge.

09900-20606: Dial gauge (1/100 mm)

09900-20701: Magnetic stand

Brake disc runout ：

Service limit: 0.3 mm

B R A K E C A L I P E R R E A S S E M B LY
Reassemble and remount the brake caliper in the reverse orders
of disassembly and removal, and also carry out the following
steps.
WARNING

Wash the brake caliper components with fresh brake fluid

before reassembly.
Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all internal parts
before inserting into the bore.
5-9
 CHASSIS

Tighten the brake caliper mounting bolt 1 and brake hose

union bolt 2 to the specific torque.

Brake hose union bolt: 20~25 N•m

Brake caliper mounting bolt:18~28 N•m
Bleed air from the brake fluid circuit after reassembling
master cylinder. (Refer to page 2-12)

WARNING
Brake fluid, if it leaks, will interfere with safe running and
immediately discolor painted surfaces. Check the brake
hoses for cracks and hose joint for leakage before riding.

M A S T E R C Y L I N D E R R E M O VA L
Drain the brake filud.

Immediately and completely wipe off any brake fluid

contacting any part of the motorcycle. The fluid reacts
chemically with paint, plastics, rubber materials, etc and
damage them severely.

Remove the brake hose upper bolt.

Remove two fitting screws, and remove the cap 1 and

diaphragm 2 .

●
●

09900-06108: Snap ring pliers

5-10
 CHASSIS

INSPECTION
● Inspect the master cylinder bore for any scratches or
other damage.
Inspect the piston surface for scratches or other damage.
Inspect the primary cup, secondary cup and dust seal boot
for wear or damage.

Reassemble and remount the master cylinder in the reverse

orders of disassembly and removal, and also carry out the
following steps:
●

Brake fluid specification: Haojue brake fluid

When washing the components, use the specified Master cylinder

brake fluid. Never use different types of fluid or
cleaning solvents such as gasoline, kerosine, etc.
Do not wipe the brake fluid off after washing the Up
components.
Apply brake fluid to the cylinder bore and all internal Handlebar
parts before inserting into the bore.
Clearance
When remounting the master cylinder on the handlebars,
first tighten the clamp bolt for upside as shown.

Connect the brake hose, tighten the union bolt to the

specified torque.

Brake hose union bolt: 20~25 N•m

Bleed air from brake system after installing the master

cylinder. (Refer to page 2-12)
 CHASSIS

FRONT FORK
CONSTRUCTION

1 O-ring 5 Left front fork

2 Dust cover 6 ITEM N•m kgf•m
Reflector
A 35-55 3.5-5.5
3 Stopper ring A Cap bolt
B 20-26 2.0-2.6
4 Oil seal B Bolt

5-12
 CHASSIS

Remove the front wheel (Refer to page 5-2).

Remove the two bolts and dismount the front caliper 1 .

● Remove the cowling upper cover screws, take off the

cowling upper cover 3 .

● Remove the dashboard mounting bolts.

● Disconnect the dashboard wire couplers, take off the

dashboard 4 .

5-13
 CHASSIS

● Remove the brake fluid hose clamp 5 .

● Disconnect the left and right front turn signal lights and
position light couplers.
Remove the mounting bolts, push down the headlamp
assembly 6 .

● Disconnect the headlamp coupler 7 , take off the headlamp 6 .

Loosen the clamps, disconnect the couplers.

Remove the headlamp bracket 8 .

5-14
 CHASSIS

● Remove the left and right handlebar switches, choke cable

and throttle cable.

● Remove the front fork upper cap bolt.

● Loosen the lower bracket clamp bolts, take off the front forks.

Remove the front fork cap bolt, take off the round pipe, washer
and spring.

5-15
 CHASSIS

Invert the absorber and stroke it several times to remove

the oil.

● Remove the damper rod bolt by using the special tools and
hexagon wrench.

11F14-010: Front absorber remover and installer

Remove the oil lock piece and damper rod with rebound
spring.
Separate the inner tube from the outer tube.

● Remove the stopper ring.

● Remove the oil seal by using the special tool.

09913-50121: Oil seal remover

WARNING

The oil seal removed should be replaced with a new

one.

5-16
 CHASSIS

INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.

Inspect the inner tube and outer tube sliding surface for any
scuffing or flaws.

ABSORBER SPRING
Measure the fork spring free length. If it is shorter than the
service limit, replace it.

Fork spring free length:

Service limit: 421.4 mm

* Cleaning: clean the parts with solvent and blow dry.

REMOUNTING
Remounting the front fork in the reverse order of removal, pay
attention to the following points：

DAMPER ROD BOLT

Apply Bond No.4 and Thread Lock Cement to the damper
rod bolt and tighten the bolt by using the hexagon wrench
and special tools. Thread lock O-ring (copper)

99000-32040: Thread lock “1303"

11F14-010: Front absorber installer and remover

Damper rod bolt: 20~26 N•m

Do not reuse the removed O-ring.

5-17
 CHASSIS

OIL SEAL
Install the oil seal to the outer tube by using the special tool
as shown.
09940-50112: Absorber oil seal installer

Apply Super Grease lightly on the oil seal lip.

ABSORBER OIL
● Pour the specified fork oil into the inner tube.

Front absorber oil capacity (each leg): 160±2 ml

Absorber oil type: Mx34 #

Reassemble the front shock absorbers in the reverse order of

removal, pay attention to the following points:

Front shock absorber upper cap: 22-35 N•m

ABSORBER
● OIL
Tighten the front shock absorber lower bracket clamp bolt to
the specified torque.

Lower bracket clamp bolt: 25~35 N•m

● Secure the each handlebars clamp in such a way that the

clearance A ahead of and behind the handlebars should be
equalized.

Handlebar clamp bolt: 12~20 N•m

A A

5-18
 CHASSIS

● Install the front brake caliper 6 , tighten the mounting

bolt to the specified torque.

Front brake caliper mounting bolt: 18-28 N•m

● Install the front wheel. (Refer to page 5-4)

5-19
 CHASSIS

STEERING STEM
CONSTRUCTION
D

1 Handlebar holder 10 Oil seal

2 Upper bracket 11 Lower bracket ITEM N•m kgf•m
3 Dust seal 12 Bracket A 35-55 3.5-5.5
4 Upper steering outer race 13 Bracket B 22-35 2.2-3.5
5 Ball ring A Steering stem bolt C 12-20 1.2-2.0
6 Upper steering inner race B Cap D 25-35 2.5-3.5

7 Lower steering inner race C Bolt

8 Ball ring D Bolt
9 Lower steering outer race 14 Steering stem nut

5-20
 CHASSIS

REMOVAL
●
●
●

● Remove the steering stem lock nut 2 and dust seal 3 .

09910-60611 : U niversal clamp wrench

Hold the steering stem by hand to prevent from

falling.

● Remove the upper steering outer race 4 and steering

stem 5 .

● Remove the upper and lower steel balls.

Remove the outer race fitted on the steering stem. This

can be down with a chisel.

5-21
 CHASSIS

● Draw out the two inner races fitted to the top and bottom
ends of the head pipe with the special tool.
09941-54911: Bearing remover
09941-74910: Steering bearing installer

INSPECTION
● Inspect and check the removed parts for the following abnormalities.

Reassemble and remount the steering stem in the reverse

order of disassembly and removal, and also carry out the

INNER RACES
● Press in the upper and lower inner races using the
special tool.

09941-34513: Steering race installer

OUTER RACE
Apply grease on the new lower oil seal.
Press in the lower outer race by using the special tool.

99000-25010 : Super grease "A"

09941-74910: Steering bearing installer

Reassemble and remount the steering stem in the reverse

order of disassembly and removal. and also carry out the
following steps:
STEEL BALL
● Apply grease to the upper and lower inner races when
installing the steel balls .

99000-25010 : Super grease ”A”

5-22
 CHASSIS

STEERING STEM NUT

Turn the steering stem right and left , lock-to-lock, five or

six times to “seat” the steel ball bearings.
Tighten the steering stem nut.

09910-60611: Universal clamp wrench

Turn back the stem nut by 1/4-1/2 turn. Turn back 1/4 -1/2
09910-60611: Universal clamp wrench

The adjustment will vary from motorcycle to motorcycle.

Install the front shock absorbers. (Refer to page 5-18)

Install the front wheel.(Refer to page 5-4)

5-23
 CHASSIS

CONSTRUCTION

1 Rear axle shaft 14 Brake shoe

2 Chain adjuster assembly 15 Rear wheel rim
ITEM N•m kgf•m
3 16 Roller bearing
A 50-80 5.0-8.0
4 Sprocket 17 Rear brake cam
B 8-12 0.8-1.2
5 Spacer 18 Rear brake panel
C 30-37 3.0-3.7
6 Oil seal 19 Rear break cam lever
7 Roller bearing 20 Rear brake rod
8 Rear sprocket drum retainer 21 Spring
9 Rear sprocket drum 22 Spacer
10 Cushion A Nut
Roller bearing B Nut
12 Spacer C Nut
13 Tire

5-24
 CHASSIS

●
●

Separate the rear sprocket and mounting drum from the

wheel 6 .

Remove the rear sprocket 7 .

Remove the sprocket 4 mounting bolts.

Remove the rear sprocket drum and sprocket.

Remove the oil seal with the special tool.

09913-50121: Oil seal remover

5-25
 CHASSIS

Remove the bearing and retainer from the mounting drum.

Take off the cushions .

● Remove left and right side wheel bearing with the special
tool.
09921-20240: Bearing remover tool

It will be easier to remove the left side wheel bearing

first.

REAR BRAKE
Remove the rear brake shoe.

Remove the brake cam lever nut and bolt.

5-26
 CHASSIS

INSPECTION
WHEEL BEARING
Inspect the wheel bearings for play by hand. Rotate the inner
race by hand to inspect whether abnormal noise occurs and it
rotates smoothly. Replace the bearing if there are any defects.

AXLE SHAFT

Using the special tools, check the axle shaft for runout and
replace it if the runout exceeds the limit.

Axle shaft runout: Limit: 0.25 mm

09900-20606: Dial gauge (1/100)

09900-20701: Magnetic stand
09900-21304: V-block

SPROCKET

Normal wear Excessive wear

REAR BREAK DRUM

Measure the brake drum I.D to determine the extent of
wear and, if the limit is exceeded by the wear noted,
replace the drum. The value of this limit is indicated inside
the drum.

Break drum I.D. : Limit: 130.7 mm

09900-20103: Vernier calipers

5-27
 CHASSIS

BRAKE SHOE
● Check the brake shoes for wear and decide whether they
should be replaced or not from the thickness of the brake
shoe linings.
Brake shoe linings: Limit: 1.5 mm

09900-20101: Vernier caliper

CAUTION

Replace the brake shoes as a set, otherwise braking

performance will be adversely affected.

CUSHION
Inspect the cushion for wear and damage.

REASSEMBLY
Reassemble and remount the rear wheel and rear brake in
the reverse order of disassembly and removal, and also carry
out the following steps:
WHEEL BEARING
Apply grease to the bearings before installing.

99000-25010: Super Grease “a”

Install the wheel bearings by using the special tool.

First install the wheel bearing for right side.

.09913-70210: Bearing installer

MOUNTING DRUM
Insert the bearing by using the special tool.

09940-53311: Bearing installer

5-28
 CHASSIS

Apply grease to the mounting drum as shown.

99000-25010: Super Grease “A”

REAR SPROCKET
● Tighten the 4 nuts to the specified torque.

Sprocket lock nut: 18~28 N•m

Always use the new nuts for safe driving.

BRAKE CAM
● Apply grease to the break cam.

99000-25010: Super Grease “A”

WARNING
Be careful not to apply too much grease to the brake cam.
If grease gets on the lining, brake slippage will result.

BRAKE CAM LEVER

Install the brake cam lever and tighten the cam lever nut
with specified torque.

Tightening torque: 8~12 N•m

5-29
 CHASSIS

REAR ABSORBER AND REAR SWING ARM

CONSTRUCTION

A B

1 Rear swingarm pivot shaft 8 Chain buffer

2 Dust seal 9 Lock washer ITEM N•m kgf·m
3 Thrust washer 10 Rear swing arm A 50-80 5.0-8.0
4 Oil seal Rear torque link B 10-16 1.0-1.6
5 Spacer A Nut
6 Spacer B Rear torque link nut
7 Spacer

5-30
 CHASSIS

Remove the rear wheel. (Refer to page 5-30)

Remove the rear shock absorber lower bolt 1 .
Remove the rear brake rod spring.

Remove the swing arm pivot nut 2 and draw out the shaft.

Remove the rear swing arm shaft dust cover 5 and rear
swing arm pivot shaft spacer 6 .

5-31
 CHASSIS

Pull off the cotter pin and remove the nut and bolt.
Remove the torque link 9 .

INSPECTION
SWING ARM PIVOT SHAFT
● Using a dial gauge, check the pivot shaft for runout and
replace it if the runout exceeds the limit.
Pivot shaft runout: Service limit: 0.6 mm

09900-20606: Dial gauge(1/100)

09900-20701: Magnetic stand
09900-21304: V-block

Reassemble and remount the swing arm in the reverse order

of disassembly and removal, and also carry out the following
steps:
Tighten the torque link nut to the specified torque.

Torque link nut: 10-16 N•m

99000-25010: Super grease “A”

● Install the rear sprocket cover.

5-32
 CHASSIS

Pass the rear swing arm shaft from the left side, tighten the
rear swing arm shaft nut to the special torque.

Rear swing arm shaft nut: 50-80 N•m

● Install the rear shock absorber lower bolt, tighten it to the

specified torque.

Rear shock absorber lower bolt: 22-35 N•m

5-32
E L E C T R I C A L

CONTENTS

6-1

6-3

6-8

6-10

6-13

6-14

6-15

6-16

6-19
6
 ELECTRICAL

CAUTIONS IN SERVICING
CONNECTOR
“Click”

COUPLER “Click”
With a lock type coupler, be sure to release the lock when
disconnecting, and push in fully to engage the lock when
connecting.
When disconnecting the coupler, be sure to hold the coupler
itself and do not pull the lead wires.
Inspect each terminal on the coupler for being loose or bent.
Push in the coupler straightly. An angled or skewed insertion
may cause the terminal to be deformed, possibly resulting in
poor electrical contact.
Inspect each terminal for corrosion and contamination. The
terminals must be clean and free of any foreign material which Correct Incorrect
could impede proper terminal contact.

CLAMP
Clamp the wire harness at such positions as indicated in “
WIRING HARNESS ROUTING”.
Bend the clamp properly so that the wire harness is clamped
securely.
In clamping the wire harness, use care not to allow it to hang
down.
Do not use wire or any other substitute for the band type clamp.

FUSE
When a fuse blows, always investigate the cause to correct it
and then replace the fuse.
Do not use a fuse of a different capacity.
Do not use wire or any other substitute for the fuse.

SEMI-CONDUCTOR EQUIPPED PART

Incorrect
Be careful not to drop the part with a semi-conductor built in
such as a CDI unit and regulator/rectifier.
When inspecting this part, follow inspection instruction strictly.
Neglecting proper procedure may cause damage to this part.

6-1
 ELECTRICAL

BATTERY
The MF battery used in this motorcycle does not require
maintenance (e.g., electrolyte level inspection, distilled water
replenishment).
During normal charging, no hydrogen gas is produced.
However, if the battery is overcharged, hydrogen gas may be
produced. Therefore, be sure there are no fire or spark sources
(e.g., short circuit) nearby when charging the battery. Be sure
to recharge the battery in a well-ventilated and open area.
Note that the charging system for the MF battery is different
from that of a conventional battery. Do not replace the MF
battery with a conventional battery.

CONNECTING THE BATTERY

When disconnecting terminals from the battery for disassembly
or servicing, be sure to disconnect the battery lead wire
first.
When connecting the battery lead wires, be sure to connect the
battery lead wire first.
If the terminal is corroded, remove the battery, pour warm
water over it and clean it with a wire brush.
After connecting the battery, apply a light coat of grease to the
battery terminals.
Install the cover over the battery terminal.

USING THE MULTI CIRCUIT TESTER

Properly use the multi circuit tester and probes. Improper
use can cause damage to the motorcycle and tester.
If the voltage and current values are not known, begin
measuring in the highest range.
When measuring the resistance, make sure that no voltage is
applied. If voltage is applied, the tester will be damaged.
After using the tester, be sure to turn the switch OFF.

6-2
 ELECTRICAL

STARTER SYSTEM
DESCRIPTION
The starter system is shown in the diagram below: namely, the starter motor, starter relay, starter button, clutch
switch, ignition switch and battery.
Depressing the starter switch(on the right handlebar switch box) energizes the relay, causing the contact points
to close which connects the starter motor to the battery. The motor draws about 70 amperes to start the engine.

Starter relay

Starter button 点火开关

Fuse
Clutch switch
Battery
Starter motor

TROUBLESHOOTING * Check: One of the front and rear brake light switches is
ON position.
Ignition switch is ON position
Fuse is not blown before the diagnosis.
Starter motor will not run

Clicks

Not run
Run
No click
Faulty starter motor

(to next page )

6-3
 ELECTRICAL

●
●

1 O-ring 4 Starter motor body 7 Housing end(inside)

2 Housing end(outside) 5 Amature shaft
3 Oil seal 6 Carbon brush

STARTER MOTOR INSPECTION

CARBON BRUSH

6-4
 ELECTRICAL

09900-25008: Pocket tester

Test scale: Continuity

Inspect the oil seal lip for damage or distortion.

Inspect the bearing for abnormal noise or worn.
Replace the housing end if there is something unusual.

SPACER
Check the spacer for wear or damage.
Replace the housing end if there is something unusual.

Apply grease to the oil seal lip and bearing.

99000-25010: Super grease “A”

● Apply Moly paste to the amature shaft.

99000-25140: Moly paste

6-5
 ELECTRICAL

● Align the starter motor body boss A with housing end

groove B during the assembly.

● Install the front cover to the starter motor body, align the
mark on the body with the mark on the front cover

● Apply grease to the O-ring 2 .

99000-25010: Super grease “A”

● Tighten the starter motor mounting bolt 3 and battery -

lead wire 4 .
Tighten the starter motor wire mounting bolt 5 .

6-6
 ELECTRICAL

1
●

09900-25008: Pocket tester

Tester knob indication: Resistance (Ω)

Starter relay resistance: 3-6 Ω

6-7
 ELECTRICAL

IGNITION SYSTEM
DESCRIPTION

Ignition switch
O/W
R

W
Fuse
Tr i g g e r c o i l

G/W

Generator Ignitor Ignition coil

Bl/W Spark plug
Battery

B/W

TROUBLE SHOOTING
No spark at plug * Check the ignition switch is ” ” position. Inspect
that the fuse is not blown before the diagnosis.

Inspect the battery voltage Less than 12V Recharge the battery or replace
the battery
12V

Check the CDI unit couplers for poor Looseness ● Poor contact of couplers
contact

Correct

Inspect the ignition circuit

Incorrect

Correct

Inspect the resistance of trigger coil

Incorrect Faulty trigger coil
(G/W and Bl/W)

Correct

Faulty CDI unit

Faulty ignition coil
Faulty high-tension cord

6-8
 ELECTRICAL

IGNITION COIL
Remove the spark plug cap 1 .

Tap

09900-25008: Pocket tester

Tester knob indication: Resistance (Ω) Ω
kΩ
Primary: 0.19-0.23 Ω (tap-tap)
Secondary: 11.29-14.91 kΩ (tap - plug cap)

Tap

Trigger coil
●

09900-25008: Pocket tester

Tester knob indication: Resistance (Ω)

Trigger coil resistence: 115-155 Ω (G/W-Bl/W)

Spark plug
(Refer to page 2-7)

IGNITOR UNIT
If the ignition system doesn’t work properly and abnormality
is not detected in the inspections above, replace the ignitor
unit.
09900-25008: Pocket tester

6-9
 ELECTRICAL

CHARGING SYSTEM
DESCRIPTION

Ignition switch

Battery

Load
Regulator/rectifier

A.C generator

TROUBLESHOOTING

Battery runs down quickly

Check accessories which excessively

Installed Remove accessories
waste electric power

Not installed

Inspect battery leak current Leak Short circuit of wiring harness.

Loose or disconnected wires.
No leak Faulty battery.

Inspect charging voltage

Correct Faulty battery.
between battery terminals.
Abnormal driving condition.
Incorrect

Inspect continuity of generator coils No continuity Faulty generator coils or

disconnected lead wires.
Correct

Inspect generator no-load voltage Incorrect

Correct

(to next page ) 6-10

 ELECTRICAL

(Continue the last page)

Incorrect

Correct

Inspect wirings, Incorrect Short circuit of wiring harness.

Poor contact of couplers.
Correct

Others

Battery overcharge Faulty regulator/rectifier

Faulty battery
Poor contact of generator
INSPECTION lead wire coupler

Remove the left side cover 1 .

Turn the ignition switch to the OFF position.
Disconnect the battery lead wire.
Measure voltage between the battery - terminal and the
specified ground cable terminal. If the reading exceeds
the specified value, then leakage is present.
09900-25008: Pocket tester
Battery leakage: Less than 0.5mA

Test scale: Current ( --- , 2mA)

mA
CAUTION

09900-25008: Pocket tester

Tester knob indication: Resistance
Generator coil resistance: 0.5-1.3 Ω (B-B)
 ELECTRICAL

CHARGING OUTPUT INSPECTION

CAUTION
Battery
When making this test, be sure that the battery is
fully-chaged condition.

09900-25008: Pocket tester (DC)

Pocket tester
Teat scale: Voltage

Charging output
Standard: 14.0-15.0V at 5 000 r/min

CAUTION
It is not necessary to remove the engine from the
chassis during the removal the generator coil.

09900-25008: Pocket tester

Teat scale: Voltage

Generator no-load performance:

More than 123-129V/5000 r/min
(When engine is cold)

Regulator/rectifier inspection
If the resistance checked is incorrect, replace the
regulator/rectifier with a new one.

6-12
 ELECTRICAL

INSPECTION
FUEL LEVEL GAUGE

Float position Resistence B

A Full 4-10Ω
B Empty 90-100Ω

09900-25008: Pocket tester

Ω
Tester knob indication: x 1 Ω range

CAUTION

When inspecting the gauge resistance, be sure to

disconnect the battery lead wire, or a pocket
tester may be damaged.

FUEL LEVEL GAUGE

B/W O
Y/B

B/W

Resistance 4-10 Ω 90-100 Ω

Float position Full Empty

6-13
 ELECTRICAL

DASHBOARD
Remove the dashboard. (Refer to page 5-13)
Disassemble the dashboard as follows.

Upper case Cushion

Seal Lower case
Dashboard unit

INSPECTION
DASHBOARD

09900-25008: Multi circuit tester

Tester knob indication: C ontinuity

CAUTION
Br/R
G/Bl
B/W

W/Y

Y/Bl
B/R

R/B
Y/B
R/W
Gr

Lg

Bl
O
R
Y

When making this test, it is not neceassary to remove

the dashboard.
6-14
 ELECTRICAL

LIGHTS
HEADLIGHT

TAIL LIGHT/BRAKE LIGHT

HEADLIGHT AND POSITION LIGHT

REMOVAL
Remove the dashboard. (Refer to page 5-13).
Replace the headlamp bulb and position light bulb.

TURN SIGNAL LIGHT

REMOVAL

6-15
 ELECTRICAL

TAIL LIGHT/BRAKE LIGHT

REMOVAL
Remove the rear seat.
Replace the tail light/brake light bulb.

SWITCHES
● Inspect each switch for continuity with the pocket tester . If
any abnormality is found, replace the respective switch
assemblies with new ones.

09900-25008: Multi circuit tester

Tester knob indication: C ontinuity

IGNITION SWITCH 1
R O B/W Bl/W

OFF ○ ○

ON ○ ○

LOCK ○ ○

LIGHTING SWITCH 2
Gr O Y/W

○ ○
○ ○ ○

STARTING BUTTON 3
B/W Y/G

○ ○

FRONT BRAKE LIGHT SWITCH 4

B B
OFF
ON ○ ○

6-16
 ELECTRICAL

Y O

PUSH ○ ○

DIMMER SWITCH 6
Y/W W Y
○ ○
○ ○

TURN SIGNAL LIGHT SWITCH ⑦

B Lb Lg
○ ○

○ ○

HORN SWITCH 8
B/Bl B/W

○ ○

REAR BRAKE LIGHT SWITCH 9

O W/B
OFF
ON ○ ○

Ground Bl W/Y R/B G/Bl Y/Bl Br/R

○ ○
○ ○
○ ○
○ ○
○ ○
○ ○

6-17
 ELECTRICAL

BATTERY
SPECIFICATIONS
TYPE MTX7L-BS
Capacity 12V (6Ah)
Standard electrolyte S.G. 1.320 at 20OC

Filling electrolyte
Remove the aluminum tape 1 sealing the battery electrolyte
filler holes.

Filler holes

Remove the caps 2 .

CAUTION
After filling the electrolyte completely, use the removed
cap 2 as the sealed caps of battery-filler holes.

Insert the nozzles of the electrolyte container into the

battery’s electrolyte filler holes, holding the container firmly so
Electroyte
that it does not fall. containers

WARNING

Take precaution not to allow any of the fluid to spill.

Insert in
filler holes

Make sure air bubbles are coming up each electrolyte

container, and leave in this position for about more than 20
minutes.
Air
bubbles

6-19
 ELECTRICAL

CAUTION

If no air bubbles are coming up from a filler port, tap the

bottom of the two or three times. Never remove the
container from the battery.

After confirming that the electrolyte has entered that battery

completely, remove the electrolyte containers from the battery.
Wait for around 20 minutes.
Insert the caps into the filler holes, pressing in firmly so that the
top of the caps do not protrude above the upper surface of the
battery’s top cover.
CAUTION
Insert the caps firmly
Once install the caps to the battery; do not remove the
caps.

Using the pocket tester, measure the battery voltage. The

tester should indicate more than 12.5-12.6V (DC) as shown in
the Fig. If the battery voltage is lower than the specification,
charge the battery with a battery charger. (Refer to the
recharging operation.)

CAUTION
Initial charging for a new battery is recommended if two
years have elapsed since the date of manufacture.

SERVICING
Visually inspect the surface of the battery container. If any signs
of cracking or electrolyte leakage from the sides of the battery
have occurred, replace the battery with a new one. If the battery
terminals are found to be coated with rust or an acidic white
powdery substance, then this can be cleaned away with
sandpaper.

RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If the voltage
reading is less than the 12.0V(DC),recharge the battery with a
battery charger.

CAUTION
When recharging the battery, remove the battery from
the motorcycle.

Recharging time: 3A for 1 hour or 0.7A for 5 hours

CAUTION

Be careful not to permit the charging current to exceed 3A

at any time.

6-20
CONTENTS

7
 SERVICING INFORMATION

TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy

Engine will not start Compression too low

or is hard to start. 1. Valve clearance out of adjustment Adjust.
2. Worn valve guides or poor seating of valves. Repair or replace.
3. Valves mistiming. Adjust.
4. Piston rings excessively worn. Replace.
5. Worn-down cylinder bore. Replace.
6. Poor seating of spark plug. Retighten.
7. Starter motor cranks but too slowly. Refer to
"electrical complaints"
Plug not sparking
1. Fouled spark plug. Clean or replace.
2. Wet spark plug. Clean and dry.
3. Defective trigger coil. Replace.
4. Defective ignitor unit. Replace.
5. Defective ignition coil.
Replace.
6. Open or short circuit in high-tension cord.
Replace.

Clean.
Clean or replace.
Replace.
Clean or replace.
Clean or replace.
Engine stalls easily. Clean.
Replace.
Replace.
Clean.
Clean.
Adjust.
Clean or replace.
Noisy engine Excessive valve chatter
1. Valve clearance too large Adjust.
2. Weakened of broken valve springs. Replace.
3. Worn down rocker arm or rocker arm shaft
Replace.
Noise appears to come from the piston
1. Piston or cylinder worn down. Replace.
2. Combustion chamber fouled with carbon. Clean.
3. Piston pin or piston pin bore worn.
Replace.
4. Piston rings or ring groove worn.
Replace.
Nosie seems to come from clutch
1. Worn teeth of clutch plates Replace.
2. Distorted clutch plates, driven and drive. Replace.
3. Clutch dampers weakened. Replace.

7-1
 SERVICING INFORMATION

Complaint Symptom and possible causes Remedy

Engine stalls easily Clean.

Replace.
Replace.
Clean.
Clean.
Adjust.
Clean or replace.

Slipping clutch. 1. Clutch control out of adjustment or loss of play. Adjust.

2. Weakened clutch springs. Replace.
3. Worn or distorted pressure plate. Replace.
4. Distorted clutch plates, driven and drive. Replace.
Dragging clutch. 1.Clutch control out of adjustment or too much play. Adjust.
2.Some clutch springs weakened while others are Replace.
not.
3.Distorted pressure plate or clutch plates. Replace.
Transmission will 1.Broken gearshift cam. Replace.
not shift. 2.Distorted gearshift forks. Replace.
3.Worn gearshift pawl. Replace.
Transmission will 1.Broken return spring on shift shaft. Replace.
not shift back. 2.Shift shafts are rubbing or sticky. Repair.
3.Distrorted or worn gearshift forks. Replace.
Transmission jumps 1.Worn shifting gears on driveshaft or countershaft. Replace.
out of gear. 2.Distorted or worn gearshift forks. Replace.
3.Weakened stopper pawl spring on gearshift cam. Replace.
4.Worn gearshift pawl. Replace.
Engine idles poorly. Adjust.
Replace.
Replace.
Replace
Replace.
Replace.
Adjust or replace.
Replace.
Clean.
Engine runs poorly in Replace.
high speed range. Adjust.
Replace.
Repair.
Replace.
Clean.
Clean and prime.

Replace.

7-2
 SERVICE INFORMATION

CARBURETOR
Complaint Symptom and possible causes Remedy
Trouble with 1.Starting jet is clogged. Clean.
starting. 2.Starting pipe is clogged. Clean.
3.Air leakage from a joint between choke and carburetor. Check and retighten.
4.Air leakage at carburetor joint or vacuum tube joint. Check and retighten.
5.Starting plunger is not operated properly. Check and adjust.

Idle or low speed Check and clean.

trouble. Check and retighten.

Check and clean.

Check and adjust.

Medium or high- Check and clean.

speed trouble. Check and clean.
Check and adjust.
Check and clean.

Overflow and fuel 1. Needle valve is worn or damaged. Replace.

level fluctuations. 2. Needle valve spring is broken. Replace.
3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.

BRAKES
Complaint Symptom and possible causes Remedy

Poor braking. Check and refill to level mark.

Bleed air out.
Replace.
Replace.
Replace.
Replace.
Clean.
Adjust.

Brake squeaking. 1.Carbon adhesion on pad surface. Repair surface with sandpaper.
2.Tilted pad. Modify pad fitting.
3.Damaged wheel bearing. Replace.
4.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5.Pads or linings worn down. Replace.
6.Foreign material in brake fluid. Replace brake fluid.
7.Clogged return port of master cylinder Disassemble and clean master
cylinder.

Excessive brake Bleed air out.

lever free stroke. Replace brake lever.
Replenish .
Replace with correct fluid.
Replace.

Leakage of brake Tighten to specified torque.

fluid. Replace.
Replace piston and/or cup.

7-3
 SERVICE INFORMATION

ELECTRICAL
Complaint Symptom and possible causes Remedy

No spark or 1. Defective ignition coil. Replace.

poor spark. 2. Defective spark plug. Replace.
3. Defective trigger coil or ignitor unit. Replace.

Spark plug soon Adjust carburetor.

become fouled Adjust carburetor.
with carbon. Change.
Clean.
Replace by hot type plug.

Spark plug 1.Worn piston rings. Replace.

become fouled 2.Pistons or cylinder worn. Replace.
too soon. 3.Excessive clearance of valve stems in valve guides. Replace.
4.Worn stem oil seals. Replace.

Spark plug 1.Spark plug too hot. Replace by cold type plug.
electrodes 2.The engine overheats. Adjust.
overheat or burn. 3.Defective trigger coil or ignitor unit. Replace.
4.Spark plug loose. Tighten.
5.Mixture too poor. Adjust carburetor.

Generator does 1.Opened or shorted in lead wires, or loose lead Repair or replace or
not charge. connections. retighten.
2.Shorted, grounded or opened generator coils. Replace.
3.Shorted or destroyed regulator/rectifier. Replace.

Generator charge, 1.Lead wires tend to get shorted or opened circuit or Repair or tighten.
but charging rate loosely connected at terminals.
is below the 2.Grounded or opened circuit generator stator. Replace.
specification. 3.Defective regulator/rectifier. Replace.
4.Not enough electrolyte in the battery. Pour distilled water between
the level lines.
5.Defective cell plates in the battery. Replace the battery.

Generator 1.Internal shorted circuit in the battery. Replace the battery.

overcharges. 2.Resistor element in the regulator/rectifier damaged Replace.
or defective. Clean and tighten ground
3.Regulator/rectifier poorly grounded. connection.

Unstable 1.Lead wire insulation frayed due to vibration, resulting Repair or replace.
charging. in intermittent shorted circle.
2.Generator internally shorted circle. Replace.
3.Defective regulator/rectifier. Replace.
Starting button 1.Battery run down. Recharge or replace.
is not effective. 2.Defective switch contacts. Replace.
3.Brusnes not seated properly on commutator in Repair or replace.
starting motor.
4.Defective starting relay. Replace.

7-4
 SERVICING INFORMATION

BATTERY
Complaint Symptom and possible causes Remedy

“Sulfation”, acidic 1. Not enough electrolyte. Pour distilled water, if the battery
white powdery has not been damaged and
substance or spots "sulfation" has not advanced
on surface of cell too far, and recharge.
plates. 2.Battery case is cracked. Replace.
3.Charging rate is too low or too high. Replace.
4.Battery has been left in a run-down condition for Replace.
a long time.
5.Contaminated electrolyte (Foreign matter has If "sulfation" has not advanced
enters the battery and become mixed with the too far, try to restore the battery
electrolyte.) by replacing the electrolyte,
recharging it fully and then
adjust the electrolyte S.G.

Battery runs 1. The charging method is not correct. Check the generator,
down quickly. regulator/rectifier and circuit
connections, and make
necessary adjustments to
obtain specified charging
operation.
2. Cell plates have lost much of their active material Replace the battery, and
as result of over-charging. correct the charging system.
3. A shorted circuit condition exists within the battery Replace the battery.
due to excessive accumulation of sediments
caused by the high electrolyte S.G.
4. Electrolyte S.G. is too low. Recharge the battery fully
and adjust electrolyte S.G.
5. Contaminated electrolyte. Replace the electrolyte,
recharge the battery and
adjust the S.G.
6. Battery is too old. Replace the battery.

Reversed battery The battery has been connected the wrong way Replace the battery and be
polarity. round in the system, so that it is being charged in sure to connect the battery
the reverse direction. properly.

Battery discharges 1. Dirty container tap and sides. Clean.

too rapidly. 2. Impurities in the electrolyte or electrolyte S.G. is Change the electrolyte by
too high. consulting the battery
manufacturer’s directions.

7-5
 SERVICING INFORMATION

CHASSIS
Complaint Symptom and possible causes Remedy
Steering feels too 1. Steering stem nut over-tightened. Adjust.
heavy or stiff. 2. Worn bearing or race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.

Steering oscillation. 1. Loss of balance between right and left front absorbers. Replace.
2. Distorted front absorbers. Repair or replace.
3. Distorted front axle or crooked tire. Replace.

Wobby front wheel. 1.Distorted wheel rim. Replace.

2.Warn-down front wheel bearings. Replace.
3.Defective or incorrect tire. Replace.
4.Loose nut on axle. Retighten.

Front absorbers too 1. Weakened springs. Replace.

soft. 2. Not enough absorber oil. Refill.

Front absorbers too 1. Absorber oil too viscous. Replace.

stiff 2. Too much absorber oil. Remove excess oil.

Noisy front absorbers. 1. Not enough absorbers oil. Refill.

2. Loose nuts on absorbers . Retighten.

Wobbly rear wheel. 1. Distorted wheel rim. Remedy

2. Worn-down rear wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Worn swing arm bushings. Replace.
6. Loosen nuts on the rear absorbers. Retighten.

Rear absorbers too 1. Weakened springs. Replace.

soft. 2. Rear absorbers adjuster improperly set. Adjust.

Rear absorbers too 1. Rear suspension adjuster improperly set. Adjust.

stiff. 2. Warn swing arm bushings. Replace.

Noisy rear absorbers. 1. Loose nuts on the rear absorbers . Retighten.

2. Worn swing arm bushings. Replace.

7-6
 SERVICING INFORMATION

BRAKES
Complaint Symptom and possible causes Remedy

Poor braking. Check and refill to level mark.

Bleed air out.
Replace.
Replace.
Replace.
Replace.
Clean.
Adjust.

Brake squeaking. 1.Carbon adhesion on pad surface. Repair surface with sandpaper.
2.Tilted pad. Modify pad fitting.
3.Damaged wheel bearing. Replace.
4.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
5.Pads or linings worn down. Replace.
6.Foreign material in brake fluid. Replace brake fluid.
7.Clogged return port of master cylinder Disassemble and clean master
cylinder.

Excessive brake Bleed air out.

lever free stroke. Replace brake lever.
Replenish .
Replace with correct fluid.
Replace.

Leakage of brake Tighten to specified torque.

fluid. Replace.
Replace piston and/or cup.

7-7
 SERVICING INFORMATION

SPECIAL TOOLS

09900-06107 09900-06108 09900-20103 09900-20202 09900-20203

Snap ring pliers Snap ring pliers Vernier calipers Micrometer Micrometer
(open type) (closing type) (1/50mm, 300mm) (1/100mm, 25~50mm) (1/100mm, 50~75mm)

09900-20205 09900-20508 09900-20605 09900-20606

Micrometer Cylinder bore gauge kit Dial calipers Dial meter 09900-20701
(1/100 mm, 0-25 mm) (1/100mm,40~80mm) (1/100mm,10~34mm) (1/100mm,10mm) Magnetic bracket

09900-20803 09900-21304 09900-25008 09910-34510

09910-32812
Thickness gauge V-block (set) (100mm) Pocket tester Crankshaft installer Piston pin puller

09913-70210
09910-60611 09913-50121 Bearing installer set 09916-10911 09915-21110
Universal clamp wrench Oil seal remover (Φ10-75) Valve seat cutter set Valve cutter set

09920-13120
Crankcase separating 09921-20240 09924-84510 09930-30104 09930-40113
tool Bearing remover set Bearing installer set Slide shaft Sprocket holder

09941-54911
09940-50112 09940-53311 09941-34513 Bearing outer race 09941-74910
Fork oil seal installer Bearing installer Bearing installer remover Bearing installer

7-8
 SERVICING INFORMATION

11F14-010
11F14-001 11F14-004 Front absorber remover 11F14-011 11F14-018
Rotor holder Rotor remover and installer 4 claws nut remover Valve remover

11F14-049
11F14-019 11F14-023 11F14-030 Crankshaft installer
T type valve adjuster Pressure gauge set Gear stopper attachment 2

7-9
 SERVICING INFORMATION

ENGINE
ITEM N•m Kg•m
Crankcase bolt 10-15 1.0-1.5
Oil filter cover 20-28 2.0-2.8
Crankshaft bearing fixing plate bolt 8-12 0.8-1.2
Engine sprocket bolt 10-15 1.0-1.5
Gear fixing pin bolt 10-15 1.0-1.5
Gear shifting cam bolt 10-15 1.0-1.5
Balancer shaft nut 25-35 2.5-3.5
Oil pump mounting screw 8-12 0.8-1.2
Oil drain bolt 25-30 2.5-3.0
Rocker arm shaft retainer screw 8-12 0.8-1.2
Generator stator bolt 5-8 0.5-0.8
Trigger coil bolt 3-6 0.3-0.6
Clutch lock nut 40-45 4.0-4.5
Oil filter rotor lock nut 40-45 4.0-5.0
Rotor cover screw 3-6 0.3-0.6
Clutch cover bolt 10-15 1.0-1.5
Cylinder head nut 25-35 2.5-3.5
Camshaft sprocket bolt 10-15 1.0-1.5
Speedometer rotor bolt 18-28 1.8-2.8
Generator rotor bolt 45-50 4.5-5.0
Generator cover bolt 10-15 1.0-1.5
Spark plug 15-20 1.5-2.0
Upper 33-39 3.3-3.9
Engine mounting bolt Front 33-39 3.3-3.9
Rear upper 40-60 4.0-6.0
Rear lower 33-39 3.3-3.9
Engine hanging bolt Upper 22-35 2.2-3.5
Front 22-35 2.2-3.5

7-10
 SERVICING INFORMATION

CHASSIS
ITEM Kg•m N•m
Front axle nut 3.6-5.2 36-52
Left 2.2-3.5 22-35
Upper bracket bolt Right 2.2-3.5 22-35
Center 3.5-5.5 35-55
Lower bracket bolt (front shock absorber clamp bolt) 2.5-3.5 25-35
Handlebar clamp bolt 1.2-2.0 12-20
Exhaust pipe bolt 1.1-1.5 11-15
Engine hanging bolt /nut upper and front) 2.2-3.3 22-33
Front footrest mounting bolt 4.0-6.0 40-60
Rear shock absorber nut (Upper and lower) 2.2-3.5 22-35
Rear torque link bolt(front and rear) 1.0-1.5 10-15
Rear axle nut 5.0-8.0 50-80
Brake cam rocker bolt/nut (Front&rear) 1.0-1.6 10-16
Rear sprocket nut 3.0-3.7 30-37
Rear swing arm shaft bolt/nut 5.0-8.0 50-80
Brake disc bolt 1.8-2.8 18-28
Air bleeder valve 0.6-0.9 6-9
Brake caliper mounting bolt 1.8-2.8 18-28
Brake hose mounting bolt 2.0-2.5 20-25
Master cylinder mounting bolt 0.8-1.2 8-12

TIGHTENING TORQUE CHART

Bolt Diameter Conventional or "4" marked bolt "7" marked bolt

(mm) A
Kg • m N•m Kg • m N•m
4 0.1-0.2 1.0-2.0 0.15-0.3 1.5-3.0
5 0.2-0.4 2.0-4.0 0.3-0.6 3.0-6.0
6 0.4-0.7 4.0-7.0 0.8-1.2 8.0-12
8 1.0-1.6 10-16 1.8-2.8 18-28
10 2.2-3.5 22-35 4.0-6.0 40-60
12 3.5-5.5 35-55 7.0-10 70-100
14 5.0-8.0 50-80 11-16 110-160
16 8.0-13 80-130 17-25 170-250
18 13-19 130-190 20-28 200-280

7-11
 SERVICING INFORMATION

VALVE AND CYLINDER HEAD Unit: mm

ITEM LIMIT
Valve diam. IN. 29

EX. 25

Valve clearance (when cold) IN. 0.04-0.06

EX. 0.09-0.11

Valve guide I.D. IN. 5.000-5.012

EX. 5.000-5.012
Valve stem O.D. IN. 4.975-4.990

EX. 4.955-4.970

Valve stem deflection IN.& EX. 0.35

Valve stem runout IN.& EX. 0.05

Valve head thickness IN.& EX. 0.5

Valve seat width IN. 1.0-1.2

EX. 1.1-1.3

Valve head radial runout IN.& EX. 0.03

37.4
Valve spring IN.
free length (IN.& EX.) 40.1
EX.
Cylinder head distortion 0.05
Cylinder head cover distortion 0.05

CAM + ROCKER ARM Unit: mm

ITEM LIMIT
Cam height IN. 31.336 31.036
EX. 31.241 30.941
Rocker arm I.D 12.000-12.018
Rocker arm shaft O.D 11.986-11.994

7-12
 SERVICING INFORMATION

CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400 kPa 800 kPa
Piston to cylinder clearance 0.025-0.045 0.12
Cylinder bore 57.30-57.31 57.135
Piston diam. 57.265-57.275
56.81
Measure at 7 mm from the skirt end
Cylinder distortion 0.05
Piston ring free end gap 1st Approx.5.3 4.6
2nd Approx.6.2 4.6
Piston ring end gap 1st 0.10-0.25 0.7
2nd 0.10-0.25 0.7
Piston ring to groove 1st 0.18
clearance 2nd 0.15
Piston ring groove width 1st 1.01-1.03
2nd 1.01-1.03
Oil 1.505-1.52
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 14.002-14.008 15.03
Piston pin O.D. 13.996-14.0 14.98

CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 14.01-14.017 15.04
Conrod big end side clearance 0.1-0.3 1.0
Conrod big end width 15.95-16.0
Crankshaft web to web width 55.0-55.05
Crankshaft runout 0.05

7-13
 SERVICING INFORMATION

CLUTCH Unit: mm
ITEM LIMIT
Clutch cable play 4
Drive plate thickness 2.92-3.08 2.6
Drive plate claw width 15.75-15.85 15.0
Driven plate distortion 0.10
Clutch spring free length 38.1 36.2

TRANSMISSION + DRIVE CHAIN

ITEM
Primary reduction ratio 3.333(70/21)
Final reduction ratio 3.000(42/14)

Gear ratios Low 3.083(37/12)

2nd 1.941(33/17)
3rd 1.450(29/20)
4th 1.174(27/23)
Top 0.960(24/25)
Shift fork to groove clearance 0.10-0.25 mm 0.45 mm
Shift fork groove width 5.10-5.18 mm
Shift fork thickness 4.93-5.00 mm
Drive chain Type KMC 428H
Links 118
20 pitch length 259.4 mm
Drive chain slack 10-20 mm

CARBURETOR
ITEM ITEM

Carburetor type CPZ26 Needle jet (N.J.) Ф2.6

I.D.No. EA Pilot jet (P.J.) #35

Idle (r/min) 1600±100 Idle air screw(P.S.) 2±3/4 turn out

Bubble pipe Ф2.8 Jet needle (J.N.) C61W
Main jet (M.J.) #108 Throttle cable play 0.5-1.0 mm

7-14
 SERVICING INFORMATION

ELECTRICAL
ITEM NOTE

B.T.D.C 15°, when rpm is below 1 500 r/min

Ignition timing
B.T.D.C 35°, when rpm is below 4 000 r/min

Type BOSCH：D8RTC；NGK：DR8EA
Spark plug
BOSCH: 0.8-0.9 mm
Gap
NGK: 0.6-0.7 mm
Primary 0.19-0.23 Ω Tap-Tap
Ignition coil resistance
Secondary 11.29-14.91 KΩ Spark plug cap-tap
Trigger 115-155 Ω G/W-Bl/W
Generator coil resistance
Charging 0.5-1.3 Ω B-B
Generator no-load voltage 100V-115V at 5000r/min
Regulate voltage 14V-15V at 5000r/min
Type designation YTX7L-BS
Battery
Capacity 12V 6 Ah
Fuse 15 A

LIGHT
ITEM ITEM

HI 35 W Neutral indicator light LED

Headlight
LO 35 W Dashboard lighting LED
Tail/Brake light 5/21 W High beam indicator light LED
Turn signal light 10 W Turn signal indicator light LED
Position light 5W Gear indication light LED

TIRE
ITEM LIMIT
Cold inflation tire pressure FRONT 175 kPa(1.75 kgf/cm²)
(Solo riding) REAR 200 kPa(2.00 kgf/cm²)
Cold inflation tire pressure FRONT 175 kPa(1.75 kgf/cm²)
(Dual riding) REAR 225 kPa(2.25 kgf/cm²)
Tire size FRONT 2.75-18 4PR
REAR 90/90-18 51P

7-15
 SERVICING INFORMATION

BRAKE + WHEEL Unit：mm

ITEM STANDARD LIMIT
Rear brake pedal height 20-30
Rear brake pedal free travel 15-25
Brake disc thickness Front 3.8-4.2 3.5
Brake disc runout 0.30
Brake fluid type HAOJUE BRAKE FLUID
Brake drum I.D. 130.7
Brake lining thickness 1.5
Wheel rim runout Front 2.0
Rear 2.0
Wheel axle runout Front 0.25
Rear 0.25

SUSPENSION Unit：mm
ITEM STANDARD LIMIT
Front fork stroke 105
Front fork spring free length 430 421.4
Fork fork oil type 34#
Front fork oil capacity(each leg) 160
Rear suspension spring adjustment 2nd
Rear swing arm runout 0.6

FUEL +OIL
ITEM STD/SPEC. NOTE
Fuel type Fuel used should be graded 90-97 octane
(Research Method). An unleaded fuel is
recommended.
Fuel tank Including reserve 12 L
capacity Reserve 2.1 L
Engine oil type and grade SAE 10W-40, API Sg or higher
Engine oil Filter change 1 000 ml
capacity Overhaul 1 200 ml

7-16
WIRE AND CABLE ROUTING
Clamp
Position light wire Clamp (Clamp the tip
Clamp Wiring harness of clamping)
(Pass it through the frame) (White mark) Alarm (Optional) Alarm horn coupler Taillight coupler Wire jacket contains:
Fuel level sensor Wiring harness License light, rear left and right turn
Wiring harness (White mark)
wiring harness signal light coupler

Alarm hose (Optional)

Headlamp Detail Front right turn

signal light wire Clamp
Jacket (Fit it below Wiring harness jacket
the headlamp) Front right turn signal light wire
Main switch Position light (right) wire

Front left turn signal

Clamp
light wire
Right handlebar
switch jacket
Wiring harness Clamp
Main switch branch Left handlebar switch jacket
(Behind bracket)
Headlamp coupler Clamp (Clamp the tip
after clamping. 5-10mm
remaining )
Wiring harness
Clamp Clamp (Pass it through Alarm coupler Pass the alarm horn wire
left branch Fuel level sensor wire
Wiring harness Wiring harness Clamp the frame and prevent (Jacket) to the left side of alarm wire.
(Jacket) main switch branch Wiring harness the clamp end from
Note: Do not contact the wire to contacting to other wires.
headlamp adjust hole Wiring harness Wiring harness clamp Wiring harness clamp
during the routing. Detail C Wiring harness
Clamp Note: When tighten the Clamp
clamp, avoid tightening Battery
Right handlebar the wire between the Left handlebar
switch wire handlebar switch and switch wire
clamp.
Battery - wire A Battery + lead
(Connect to wiring harness) Rear fender
Guide ring A Starter relay Clamp
Battery - wire lead
(Connect to engine) Battery - wire
Clutch cable (To wiring harness)
Throttle cable
Battery - wire
(To engine)

Front brake hose Choke cable Rectifier

7-17
Welded ring
Starter motor wire A
Battery - wire Rear brake switch
(To the engine) Route the wire smoothly
and closely to inside of frame
pipe to avoid the wire bending
too much affect the looking.
SERVICING INFORMATION

Clamp
Clamp (Cut the tip after clamping) Clamp
Clamp
Wiring harness Wiring harness Gear position switch coupler Please see the Clamp
Generator coupler detail C for the Wiring harness
Clamp Clamp frame inside
Rectifier coupler Starter relay wire
Speed sensor coupler Rear brake switch Rear brake switch routing. A Starter motor wire
Wiring harness Battery - wire
(To wiring harness)
Clamp Battery - wire
Gear position switch (To engine)
Generator
Speed sensor coupler

A Routing location Control item Requirement

The clearance
Battery + lead between the
1 Starter relay terminal and Above 8mm
Starter motor lead other metal
parts.
View B
Battery + terminal Burr and sharp edge are not allowed.
2 to fuse
Taillight case Taillight case Do not route the wiring harness at the
wire clamp wire clamp movable position.
Battery + terminal Routing area
Tail light wire Tail light wire Alarm horn(Optional) Alarm (Optional) 3 to starter relay Clamp must be used for fixing the wire
(White mark) at the named position.
Starter relay to Do not contact the wire to other parts.
4 starter motor
 WIRING DIAGRAM

Speed sensor Dashboard Rear brake

Right handlebar switch Ignitor Ignition coil Rectifier
switch Turn relay
Lights switch Starter button

Front brake switch

Spark plug
W/B
O
Fuel level

O
Gr
Y/W
Y/G
B/R
B
B
sensor

B/W
B/P
B/W

R/W
W
B/W
B
R
O

O/Y
O
G/W
B
Lb

Bl/W
W
O

B/W
W/B
Diode

Y
B
B/W

Gr
R/W
R/B

Y/B
W/Y

R
Y/Bl

Lg
Bl

G/Bl

B/R
Br/R
B/W
Y/B

W/B

O
Bl/R
Y/G

Y/W
Gr
Front right

Y/B
B/W

Bl
Bl/R
Rear right
turn signal light
Lg Lg turn signal light
B/W B/W
Lg Lg
Gr
Position light B/W Tail light
W W/B W/B
Headlamp B/W B/W B/W
B/R B/W Gr Gr
Gr

Gr
Position light Rear left turn
B/W B/W
signal light

7-18
Front left
turn signal light B B
B/W B/W B/W
B B
License light
R

Gr Gr
B/W B/W
Fuse
SERVICING INFORMATION

Y/G
O

R
R
B/W

Lg

R
B
B/W
Bl/W

O
Bl/W
G/W

R
O
Lb
B

O
O/Y
Y
B/W
Lg

W
Bl/R
B/Bl

Y/W
R

Alarm socket
B/W

B
B

Starter relay
W/Y

B
Bl
G/W
Bl/W

R/B
G/Bl
Y/Bl
Br/R

B/Bl

B/R
Y
B/Bl
B/W
Lg
Lb
B

Y/W
B/R
Ignition switch Starter motor
Bl
W/Y
R/B

Battery
G/Bl
Br/R
Y/Bl

Horn
Clutch switch Engine ground wire
Generator

Dimmer switch Pass switch Horn button Turn signal

light switch
Left handlebar switch
Gear position switch