Chopper Road 150 Manual de Serviços (Ingles) tz150

TZ150
99500H363ECH000
维修说明书
FOREWORD GROUP INDEX
This manual contains an introductory description on the
HAOJUE TZ150(CBS) and procedures for its inspection
service and overhaul of its main components. Other
information considered as generally known is not
GENERAL INFORMATION 1
included.
Read the GENERAL INFORMATION section to familia-
rize yourself with the motorcycle and its maintenance.
Use this section as well as other sections to use as a
guide for proper inspection and service.
PERIODIC MAINTENANCE 2
This manual will help you know the motorcycle better so
that you can assure your customers of fast and reliable
service.
This manual has been prepared on the basis of the 8

ENGINE
3
latest specifications at the time of publication. If
modifications have been made since then, differ-
ences may exist between the content of this manual
and the actual motorcycle.
FUEL AND LUBRICATION 4
Illustrations in this manual are used to show the
basic principles of operation and work procedures.
They may not represent the actual motorcycle
exactly in detail.
This manual is written for persons who have enough
CHASSIS 5
knowledge, skills and tools, including special tools,
for servicing HAOJUE motorcycles. If you do not
have the proper knowledge and tools, ask your
authorized HAOJUE motorcycle dealer to help you.
ELECTRICAL
6
WARNING
Improper repair may result in injury to the

mechanic and may render the motorcycle unsafe
SERVICING INFORMATION 7
for the rider and passenger.
CAUTION
Inexperienced mechanics or mechanics without

proper tools, not to able to properly perform the
services described in this manual.
HAOJUE HOLDING CO.,LTD.

DEC, 2017
(The 1st Edition)
©COPYRIGHT HAOJUE HOLDING CO.,LTD. 2017

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1.The text of this manual is divided into 7 sections.
2.The section titles are listed in the GROUP INDEX.
3.Holding the manual as shown as at the right will allow you to
find the first page of the section easily.
4.The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instruction and tightening torque,
lubricating points and locking points, are provided.
Example: Front wheel
1 Front axle
2 Spacer
3 Dust cover
4 Lock washer
5 Front brake disc
6 Oil seal
7 Bearing
8 Spacer
9 Front rim
10 Front tire
11 Speedometer driver
12 Oil seal
13 Speedometer gearbox
A Front brake disc bolt
B Front axle nut
ITEM N•m Kgf•m
A 18-28 1.8-2.8
B 36-52 3.6-5.2
SYMBOL
The following symbols are instructions and necessary information for maintenance.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply THREAD LOCK “1360"
Data beside it indicates specified
99000-32130
torque.
Apply oil. Use engine oil unless

OIL
Apply or use the absorber oil

otherwise specified.
Apply SUPER GREASE “A”

Apply or use the brake fluid
99000-25010
Apply MOLY PASTE

Measure in voltage
99000-25140
Apply sealant “1215”

Measure in resistance
99000-31110
Apply sealant “1207B”

Measure in continuity test range
99000-31140

Use special tool
99000-32050

The data of maintenance
99000-32030
WIRE COLOR
B ............. Black Gr ............. Grown R ............. Red
Bl ............. Blue Lbl............. Light blue V ............. Violet
Br ............. Brown Lg ............. Light green W ............. White
Dg ............. Deep green O ............. Orange Y ............. Yellow
G ............. Green P ............. Pink
B/Bl ............. Black with Blue tracer O/Bl ............. Orange with Blue tracer
B/Br ............. Black with Brown tracer O/W ............. Orange with White tracer
B/G ............. Black with Green tracer O/Y ............. Orange with Yellow tracer
B/R ............. Black with Red tracer R/B ............. Red with Black tracer
B/W ............. Black with White tracer R/Y ............. Red with Yellow tracer
B/Y ............. Black with Yellow tracer W/B ............. White with Black tracer
Bl/W ............. Blue with White tracer W/R ............. White with Red tracer
Bl/Y ............. Black with Yellow tracer Y/G ............. Yellow with Green tracer
Br/Y ............. Brown with Yellow tracer Y/R ............. Yellow with Red tracer
G/Y ............. Green with Yellow tracer Y/W ............. Yellow with White tracer
O/B ............. Orange with Black tracer
GENERAL INFORMATION
1
1
CONTENTS
WARNING/CAUTION/NOTE 1-1
GENERAL PRECAUTIONS 1-1
SERIAL NUMBER LOCATION 1-2
FUEL AND OIL RECOMMENDATION 1-2
BREAK-IN PROCEDURE 1-2
SPECIFICATIONS 1-3
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the
symbol and the words WARNING,CAUTION and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and the cautions contained in this manual cannot possibly cover
all potential hazards relating to the servicing, or lack of servicing of the motorcycle. In addition to the
WARNING and CAUTION stated, you must use good judgment and basic mechanical safety principles. If
you are unsure about how to perform a particular service operation, ask a more experienced technician for
advice.
GENERAL PRECAUTION
WARNING
Proper service and repair procedures are important for the safety of the service technician and the
safety and reliability of the motorcycle.
When 2 or more persons work together, pay attention to safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor.
When working with the toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer's instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
After servicing fuel, oil, exhaust or brake system, check all lines and fittings related to the system
for leakage.
1-1
GENERAL INFORMATION
SERIAL NUMBER LOCATIONS BREAK-IN PROCEDURE

The frame serial number or V.I.N. (Vehicle During the manufacture only the best p ossible
Identification Number) 1 is stamped on the right materials are used and all machined parts are
side of the steering head pipe. The engine serial finished to a very high standard, it is still necessary
number 2 is located on the left side of the to allow the moving part to “BREAK-IN” before
crankcase. These numbers are required especially subjecting the engine to maximum stresses. The
for registering the machine and ordering spare future performance and reliability of the engine
parts. depends on the care and restraint exercised during
its early life . The general rules are as follows:
The throttle must not be opened to the full during

the new motorcycle's break-in period. Throttle
opening should be limited to less than 3/4 of its
maximum, while violent acceleration should be
avoided.
Do not maintain constant engine gear and
FUEL AND OIL speed for an extended time period during any
portion of the break-in. Try to vary the throttle
RECOMMENDATIONS position. During the period of break-in, increase
the throttle opening properly to enable break-in
FUEL fully.
Use fuel with an octane number of 89-97 (Research
When engine is running at constant low speed
method), preferably unleaded.
(low load), parts will wear rapidly leads to bad
NOTE: brake-in.
Use non-unleaded gasoline and low quality engine
oil will shorten the spark plug and muffler accelerant
life. Dirty gasoline will clog the fuel hose. Do not
overfill the gasoline.
ENGINE OIL
Be sure that the motorcycle engine oil you use
comes under API classification of SF or SG and its
viscosity rating is SAE 10W-40. In winter of
northen cold area uses SAE 5W-30, If engine oil
mentioned above is not available, select the oil
viscosity according to the following chart:
SAE
40
30
20W/50
10W/50
10W/30
20W
10W
C -20 -10 0 10 20 30 40
Temp.
F -4 14 32 50 68 86 104
1-2
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
Overall length 1995 mm
Overall width 810 mm
Overall height 1115 mm
Wheelbase 1285 mm
Ground clearance 185 mm
Curb weight 130 kg
ENGINE
Type Single cylinder, vertical, air-cooled, four stroke
Number of cylinders 1
Bore 57.3 mm
Stroke 57.8 mm
Piston displacement 149 ml
Compression ratio 9.3 : 1
Carburetor VM
Air cleaner P olyurethane foam element
Starter system Electric
Lubrication system Wet sump
TRANSMISSION
Clutch Wet multi-plate type
Transmission 5-speed
Primary reduction ratio 3.333
Final reduction ratio 3.000
Gear ratios, Low 3.083
2nd 1.941
3rd 1.450
4th 1.173
Top 0.960
Drive chain KMC 428H 116 links
1-3
GENERAL INFORMATION
ELECTRIC
Ignition type Electronic ignition (CDI)

Ignition timing 10° B.T.D.C at 1 500 r/min
Spark plug D8RC/D8RTC
Battery 12V 7Ah
Fuse 15A
Headlamp 12V, 35W/35W
Tail light / brake light 12V, 5W/21W
Turn signal light 12V, 21W
Position light 12V, 5W
CHASSIS
Front absorber Telescopic, coil spring, oil damped

Rear absorber Swingarm type, 5 level adjustable coil spring oil damped
Steering angle 42°
Caster 29°
Trail 109mm
Turning diameter 4320 mm
Front brake Brake disc/Brake lever
Rear brake Brake disc /Brake pedal(CBS)
Front tire size 2.75-18
Rear tire size
3.5-16
Front absorber stroke
130 mm
CAPACITIES
Fuel tank 9L
Reserve 1.86 L
Engine oil, oil change 1 000 ml
Overhaul 1 200 ml
Front absorber oil (single) 168 ml
* The specifications subject to change without notice.
1-4
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE 2-1
MAINTENANCE PROCEDURES 2-3 2
BATTERY/FUSE 2-3
AIR FILTER 2-4
MUFFLER BOLTS 2-5
CYLINDER HEAD NUTS 2-5
VALVE CLEARANCE 2-6
SPARK PLUG 2-7
ENGINE OIL 2-8
OIL SUMP FILTER 2-8
ENGINE OIL FILTER 2-9
CLUTCH CABLE CLEARANCE 2-9
CARBURETOR(IDLING) 2-9
FUEL HOSE AND 2ND AIR HOSE 2-10
EVAPORATION EMISSION CONTROL SYSTEM 2-10
DRIVE CHAIN 2-11
BRAKES 2-12
TIRES 2-16
STEERING 2-16
FRONT AND REAR ABSORBERS 2-17
LIGHTING AND SIGNAL 2-17
2ND AIR VALVE 2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS 2-18
COMPRESSION PRESSURE INSPECTION 2-20
定期保养和调整
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

Interval Km Initial 1 000 Every 3 000 Every 6 000
Page
Item Month 3 6 12
Battery / Fuse Inspect Inspect 2-3
1
Air cleaner Clean 2-4
1
Clean every 18 months or every 12000 km 2-4
Exhaust pipe bolts and
Inspect Inspect 2-5
muffler bolts
Cylinder head, cylinder bolts Inspect Inspect 2-5
and nuts
Valve clearance(when cold) Inspect Inspect 2-6
Inspect Inspect
Spark plug 2-7
Replace every 10 000 km
Engine oil Replace Replace 1 2-8
Oil sump filter Clean every 18 months or 12 000 km 2-8
Engine oil filter Clean every 18 months or 12 000 km 2-9
Clutch cable play Inspect Inspect 2-9
Carburetor Inspect Inspect 2-9
Inspect Inspect
Fuel hose and 2nd air hose 2-10
Replace every 4 years
Evaporation emission
Inspect Inspect 2-10
control system
Drive chain Clean & lubricate for every 1,000 km 2-11
Brake Inspect Inspect
Inspect Inspect
Brakes Brake hose 2-12
Replace every 4 years
Brake fluid Inspect every 3 000 km, replace every 2 years
Tire Inspect Inspect 2-16
Steering Inspect Inspect 2-16
Front and rear absorbers Inspect 2-17
Lights and signals Inspect Inspect 2-17
2nd air valve Inspect every 3 years or every 18 000 km 2-17
Chassis bolts and nuts Inspect Inspect 2-18
Note 1: The interval for replacement or inspection, cleaning should be adjusted according the
driving condition.
2-1
定期保养和调整
LUBRICATION CHART
Interval Km Every 6 000km Every 12 000km

Item Month 6 12
Throttle cable Engine oil
Throttle grip Grease
Clutch cable Engine oil
Speedometer cable Grease
Speedometer gear box Grease
Drive chain Engine oil, every 1 000 km
Break lever pivot Engine oil
Break pedal pivot Grease or engine oil
Steering stem bearings
Grease every 2 years or 20 000 km.
Swing arm bearings
WARNING
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the
linings, break slippage will result.
CAUTION
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the
motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean
off any rusty spots and wipe off any grease, oil dirt or grime.
2-2
MAINTENANCE PROCEDURES
This section describes the service procedures for each
section of Periodic Maintenance.
BATTERY/FUSE
Inspect initial 1 000 km and every 3 000 km
BATTERY
Inspect the electrolyte's level and specific gravity, the
battery must be removed.
Remove the right side cover and battery band.
Dismount the negative pole of the battery.
Dismount the positive pole of the battery.
Take the battery down from the battery holder.
Inspect the electrolyte level. If necessary, repour some
distilled water to make the electrolyte level higher than the
“LOWER LEVEL” 2 and lower than the “UPPER LEVEL” 1
. Use a hydrometer to inspect the electrolyte's specific
gravity to see the charging situation of the battery. If the
data is below 1.28 (20 oC), it means that the battery should
be charged now. During charge, the battery should be
dismounted and charged with a charger. If not, the rectifier
Standard specific gravity: 1.28± 0.01 20 oC
09900-28403: Hydrometer
Assemble the battery in the reverse order of the

disassembly.
CAUTION
When installing the battery lead wires, fix the lead

first and lead last. Battery
Air vent hose

Make sure that breather pipe is tightly secured and
undamaged, and is routed as shown in the figure.
FUSE
The fuse locates on the band of the battery. In case of
engine stop suddenly or the opened circuit, the fuse must
be inspected.
WARNING
Do not use a fuse of a different specification , or it
will incur negative effect to electric, fire and power
loss of engine which is very dangerous.
Do not use aluminum, iron wire or any other
substitute for the fuse. If the fuse blows frequently,
it indicates the electric system may has problem.
Always investigate the cause, correct it and then
replace the fuse.
2-3
AIR FILTER
Clean initial 1 000 km and every 2 000 - 3 000 km
If the air filter is clogged with dust, intake resistance will be
increased with a resultant decrease in output and an increase
in fuel consumption.
CAUTION
If driving under dusty condition, clean the air filter

element more frequently.
Check and clean the filter in the following manner.

Remove the left frame cover bolt, take off the left side
cover 1 .
Remove the screws and take off the air filter cover 2 .
● Take out the air filter element assembly.

● Separate the polyurethane foam element from the
element frame.
Fill a washing pan of a proper size with nonflammable B

A
cleaning solvent. Immerse the element in the cleaning
solvent and wash it clean.
Squeeze the cleaning solvent out of the washed element by
pressing it between the palms of both hands.
Immerse the element in motor oil, and squeeze the oil out Non-flamable
of the element leaving it slightly wet with oil. solvent
D C
Do not twist or wring the filter because it will tear or the

individual cells of the filter will be damaged.
Inspect the filter carefully for rips, torn seams, etc. If any
damage is noted, replace the filter. Engine oil
Reinstall the air filter in the reverse order of removal.
2-4
AIR CLEANER DRAIN PLUG

Remove the plug and drain water and oil at the periodic
maintenance interval.
Make sure the drain plug if fitted correctly after cleaning.
MUFFLER BOLTS
Inspect initial 1 000km and every 3 000km
Tighten the muffler bolts 1 and 2 to the specified torque.
Muffler bolt 1 : 13-15 N•m

Muffler bolt 2 : 55-65 N•m
CYLINDER HEAD NUTS
Tighten the four cap nuts 3 to the specified torque with a

torque wrench under cool engine conditions.
Cylinder head nut: 25-35 N•m
2-5
VALVE CLEARANCE
Excessive valve clearance results in valve noise and

insufficient valve clearance results in valve damage and
reduced power. At the distances indicated above, check and
adjust the clearance to the following specification. The
procedure for adjusting the valve clearance is as follows:
● Remove the left and right side covers.

Remove the saddle lock, take off the saddle 1 .
Turn off the fuel cock, disconnect the fuel hose 2

Disconnect the tilt stop valve hose 3 .
Disconnect the fuel level sensor coupler 4 .

Remove the fuel tank mounting bolts, take off the fuel tank 5 .
Remove the valve inspection caps 6 .

Remove the valve timing inspection plug 7 and generator
cover cap 8 .
● Rotate the generator rotor counter clockwise to set the

piston at (TDC) of the compression stroke. (Rotate the
rotor until the “T”line on the rotor is aligned with center of
hole on the crankcase.
NOTE：
Valve clearance is to be checked when the engine is
cold. Both the intake and exhaust valves must be
checked and adjusted when the piston is at Top-Dead-
Center(TDC) of the compression stroke.
2-6
● Lift the rocker arm with special tool, check the intake and
exhaust valve clearance.
09900-20803: thickness gauge
11F14-017: Rocker arm hook
Valve clearance
Valve clearance(When cold)
Standard: IN: 0. 04-0.06mm
EX: 0.09-0.11mm
If the valve clearances is out of specification, bring it into

the specified range by using the special tool.

11F14-017: Rocker arm hook
11F14-017: T valve adjust wrench
Reassemble the removed parts in the reverse order of

removal.
SPARK PLUG
Inspect Initial 1 000 km and every 3 000 km.
Replace it every 10 000 km.
Remove the carbon deposits with a wire of pin and adjust

the spark plug gap to 0.7-0.8 mm, measuring with a A
thickness gauge.
When removing carbon deposits, be sure to observe the
appearance of the plug, noting the color of the carbon
deposits. The color observed indicates whether the standard
plug is suitable or not. if the standard plug is apt to get wet, a
hotter plug should be used. If the standard plug is apt to
overheat (porcelain is whitish in appearance), replace with a
cooler one.
Spark plug gap A : 0.7-0.8 mm
TYPE NHSP LD TORCH

A
Hot type D 7RTC DR7C
Standard D 8RTC DR8C
Cold type D 9RTC DR9C
2-7
ENGINE OIL
Change initial 1 000 km and every 3 000 km
The oil should be changed when the engine is warm. The
procedure is as follows:
Support the motorcycle by the center stand.
Drain the oil by removing the drain plug 1 and oil filler
cap/gauge 2 .
Tighten the drain plug 1 and pour new oil through the oil
filler. The engine will hold about 1 000 ml of oil. Use of
SF/SG in API with an oil viscosity of SAW 10W-40.
● Tighten the oil filler cap 2 .
Required amount of engine oil:

Oil change: 1 000 ml
Overhaul: 1 200 ml
Start up the engine and allow it to run for several

seconds at idling speed.
● Shut down the engine and wait about 1 minutes. Remove
the oil filler cap/oil level gauge, wipe the tip of the oil level
gauge with clean cloth.
Keep the motorcycle on level ground and hold it vertically.
● Close the oil filler cap/oil level gauge of the oil filler without
tightening the cap.
Lower line
Upper line
● Remove the oil filler cap/oil level gauge and inspect the oil
level. The oil level should be between the lower line and
upper line of the oil level gauge. If the oil level is below
lower line, fill with oil to the upper line. If oil level exceeds
upper line, drain some oil until below upper line.
OIL SUMP FILTER

Clean every 18 months and every 12 000 km
● Drain the engine oil.

Remove the filter cover 1 , take out the spring 3 and oil
sump filter 4 .
Clean the oil sump filter, replace the oil sump filter if it is
damaged.
Reinstall the oil sump filter 4 , spring 3 and oil sump filter
cover 1 .
CAUTION
Replace the O-ring 2 with a new one.
2-8
ENGINE OIL FILTER
Clean every 18 months and every 12 000 km
Remove the clutch cover. (Refer to page 3-1)

Remove the engine oil filter cover 1 .
Clean the engine oil filter.
Reinstall the engine oil filter cover 1 after cleaning.
CLUTCH
Inspect initial 1 000 km and every 3 000 km.
The clutch play should be 4 mm as measured at the clutch

lever holder before the clutch begins to disengage. If the play
in the clutch is incorrect, adjust it in the following way:
● Loosen the lock nut 1 and screw the adjuster 2 on the 4mm
clutch lever holder all the way in.
Loosen clutch cable adjuster lock nut 3 .
Turn the clutch cable adjuster 4 in or out to acquire the
specified play.
Use the adjuster 2 for minor adjustment.
Tighten lock nut 1 and 3 while holding the adjuster in
position.
CAUTION
Excessive clutch cable play makes clutch dragging

easily lead to the damage or wear of the clutch and gear
shifting mechanism.
CARBURETOR
Stable carburetor performance is the basis requirement for
engine. The carburetor is pre-set at the factory for the best
carbureting. Do not attempt to alter its setting. There are two
items of adjustment, engine idle speed and throttle cable play.
IDLING ADJUSTMENT
Start up the engine and keep at the low speed to preheat
the engine.
After preheating the engine, close the throttle, open the
seat, remove the plastic cover, set its speed at anywhere
between 1 400 and 1 600 r/min by turning adjusting screw.
Engine idle speed: 1500±100 r/min

CAUTION
Make this adjustment when the engine is hot.

2-9
THROTTLE CABLE PLAY

To adjust the throttle cable play:
● Loosen the lock nut 1 , turn the adjuster 2 so that the throttle
cable play has 0.5 -1.0 mm play.
● Tighten the lock nut 1 after adjustment.. 2 1
WARNING
0.5-1.0 mm
After adjustment is completed, checked that handlebar
movement does not raise engine idle speed and that the
throttle grip returns smoothly and automatically.
FUEL HOSE AND 2ND AIR HOSE

Inspect initial 1 000 km and every 3 000 km, replace
every 4 years.
Check the fuel hose 1 and secondary air hose 2 for

damage or leakage. If it is worn or damaged, replace the fuel
hose with a new one.
EVAPORATION EMISSION CONTROL SYSTEM

Inspect every 3 000 km
This motorcycle is equipped with fuel evaporation prevent

system. Inspect the following items periodically.
Inspect the connection of each hose.

Inspect each hose and EVAP canister 1 bodies for
damage, if any defects are found, replace the hose and
EVAP canister with a new one.
Check each hose, tilt stop valve 2 and EVAP canister 1 to
see whether they are clogged, clean or replace the clogged
part as necessary.
WARNING
If fuel evaporation emission control system is required

to be inspected and servicing, we strongly recommend
you do this job in a qualified service shop.
2- 1 0
DRIVE CHAIN
Clean & lubricate for every 1 000 km
DRIVE CHAIN/SPROCKET
When inspecting the drive chain, look for the following:
1. Loose pins 2. Damage rollers
3. Rusted links 4. Twisted or seized links
5. Excessive wear
If any defects are found, the drive chain must be placed.
Damage to the drive chain means that the sprockets may also
be damaged. Inspect the sprockets for the following:
1.Excessively worn teeth
2.Broken or damaged teeth
3.Loose sprocket mounting nuts
Cleaning and Lubrication
After throughly washing the drive chain with detergent liquid
and allowing it to dry, lubricate the drive chain with chain lube
or new engine oil.
Drive Chain Adjustment
Adjust the drive chain sag to the proper specification. The
drive chain may require more frequent adjustment than
periodic maintenance schedule depending upon your riding
conditions.
WARNING
Too much chain slack can cause the chain to come off the
sprockets, resulting in an accident or serious damage to the
motorcycle. Inspect and adjust the drive chain slack before
each use.
Place the motorcycle on center stand.
Loosen rear axle nut 4 .
Loosen the right and left lock nuts 2 .
Loosen or tighten both chain adjuster bolts 1 till there is 10-
20mm of slack at the middle of the chain between engine
and rear sprockets. The mark 3 on both chain adjusters 5
must be at the same position on the scale to ensure that
10-20mm
front and rear wheels are correctly aligned.
After adjusting the drive chain, tighten rear wheel axle nut
to the specified torque.
Check the rear brake pedal travel. (Refer to page 2-12)
Rear axle nut: 50-80 N•m
123 20 21 22
DRIVE CHAIN
Count out 21 pins of the chain and measure the distance 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
0 1 2 3 4 5 6 7 8
between. If the distance exceeds 259.4 mm, the chain must be

replaced.
Drive chain 20 pitch length:

Service limit: 259.4 mm
09900-20103 : Vernier caliper 2-11
BRAKES
BRAKE:
Inspect initially at 1 000 km and every 3 000 km
thereafter.
BRAKE HOSE AND BRAKE FLUID:
Replace hose every 4 years. Replace fluid every 2 years.
Brake fluid level

Support the motorcycle body on the center stand, and
place the handlebars straight. UPPER
Check the brake fluid level by observing the “Lower” line on
the brake fluid reservoir.
When the level is below the “Lower” line, replenish with
LOWER
brake fluid that meets the following specification.
Haojue Brake fluid
CAUTION
The brake system of this motorcycle is filled with a

glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based or pertroieum-
based. Do not use any brake fluid taken from old, used UPPER
or unsealed containers. Never re-use brake fluid left
over from the last servicing or stored for a long period.
LOWER
WARNING
Brake fluid is harmful or fatal if swallowed, and harmful
if it comes in contact with skin or eyes. If brake fluid is
swallowed, immediately contact a poison control
center or a physician. If brake fluid gets in eyes, flush
eyes with water and seek medical attention. Do not
wash the master cylinder with high pressure water.
2-12
BRAKE DISCS AND BRAKE PADS

FRONT BRAKE
Check the thickness 1 of front brake disc, replace the front
brake disc with new one if the thickness is less than 3.5mm.
The extent of brake pad wear can be checked by observing
the grooved limit line 2 on the pad. When the wear exceeds
the grooved limit line, replace the pads with new ones.
CAUTION
Replace the brake pad with a set, otherwise baking
performance will be adversely affected.
REAR BRAKE
Check the thickness 1 of rear brake disc, replace the rear
brake disc with new one if the thickness is less than 3.5mm.
The extent of brake pad wear can be checked by observing
the grooved limit line 2 on the pad. When the wear exceeds
the grooved limit line, replace the pads with new ones.
CAUTION
Replace the brake pad with a set, otherwise baking
WARNING
Do not drive the motorcycle immediately after the

replacement of the new brake disc or brake pads.
Squeeze and release the brake lever several times to
make the mating of brake disc and brake pads
completely and circulation of brake fluid stably. The
brake distance is longer than the original distance after
the replacement of new brake disc or brake pads. After
300 km of driving, the motorcycle will get the best
break performance. Before that , Keeping enough brake
distance is necessary during the driving.
2-13
REAR BRAKE PEDAL HEIGHT

Adjust the rear brake pedal retainer bolt to set the rear brake
pedal 10.5mm below the front footrest, then lock the nut.
Rear brake pedal height 1 : 10.5 mm
BRAKE LIGHT SWITCH

Step on the rear brake pedal to inspect the brake light switch.
If the brake light switch works inflexible, it may be adjusted by
turning the adjusting nut of the brake switch.
AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the fluid circuit acts like a cushion to absorb a
large proportion of the pressure developed by the master
cylinder and thus interferes with the full braking performance
of the caliper brake. The presence of air is indicated by
"sponginess" of the brake lever and also by lack of braking
force. Considering the danger to which such trapped air
exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the
normal condition, the brake fluid circuit be purged of air in the
following manner:
CAUTION
Spilled brake fluid can damage painted surfaces and
plastic parts.
Be careful not to spill any fluid when filling the brake
fluid reservoir. Wipe spilled fluid up immediately.
FRONT BRAKE
Fill up the master cylinder reservoir to the upper line.
Attach a hose to the air bleeder valve and insert the free end
of the hose into a receptacle.
Squeeze and release the brake lever several times in rapid
succession and squeeze the lever fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle. This will remove
the tension of the brake lever causing it to touch the handlebar
grip. Then, close the air bleeder valve, pump and squeeze
the lever, and open the valve. Repeat this process until fluid
flowing into the receptacle contains no air bubbles.
While bleeding the brake system, replenish the brake fluid in
thereservoir as necessary. Make sure that there is always some
fluid visible in the reservoir.
Close the bleeder valve, and disconnect the pipe. Fill the
reservoir to the "UPPER” level line, replace the reservoir cap.
2-14
REAR BRAKE AND CBS SYSTEM

Fill the rear master cylinder reservoir to the upper level.
Attach a hose to the front brake caliper rear air bleeder valve
and insert the free end of the hose into a receptacle.
Depress and release the brake pedal several times in rapid

succession and depress the pedal fully without releasing it.
Loosen the air bleeder valve by turning it a quarter of a turn so
that the brake fluid runs into the receptacle. Then, close the air
bleeder valve, release and depress the pedal, and open the
valve. Repeat this process until fluid flowing into the receptacle
contains no air bubbles.
Replenish the brake fluid reservoir as necessary while bleeding
the brake system. Make sure that there is always some fluid
visible in the reservoir.
Close the air bleeder valve, and disconnect the pipe. Fill the
reservoir to the "UPPER” level line, replace the reservoir cap.
Bleed air from the rear brake caliper in the same manner as
front brake.
2-15
TIRES
Check the tire pressure and surface during the maintenance.

There are serial marks 1 (tire wear indicator) in the edge of
the tire. Check the block 2 of T.W.I. in the tread near the
mark. If the tire wears off to reach the boss, the tire should be
replaced.
Check the damage 3 (punctures or fractures) on the tire
surface visually. As surface damage may impede driving
stability, such tires should be replaced.
SOLO RIDING DUAL RIDING

COLD INFLATON
TIRE PRESSURE Kpa kg/cm 2 kpa Kg/cm 2
FRONT 175 1.75 175 1.75
REAR 200 2.00 225 2.25
CAUTION
Proper tire pressure and condition affect vehicle

performance. Please check the tire pressure and
surface condition periodically.
STEERING
Inspect Initial 1 000 Km and every 3 000 Km
Steering stem bearings should be adjusted properly for

smooth turning of the handlebars and safe running.
Steering which is too stiff prevents smooth movement of
handlebars.
Steering which is too loose will cause vibration and damage to
the steering bearing. Check to see that there is no play in the
front fork attachment.
If the play is found, perform the steering bearing adjustment
as described in page 5-17 of this manual.
2- 1 6
FRONT AND REAR ABSORBERS

Inspect every 6 000 km.
FRONT ABSORBER
● Grasp the front brake, squeeze the front absorber to check
if it moves smoothly.
● Check for leaks or damage. Replace damaged parts and
tighten all bolts and nuts.
REAR ABSORBER
Depress the rear carrier, move the rear shock absorber up
and down four or five times to check for the noise or smooth
movement.
Inspect the rear absorber spring for damage, deformation
or oil leakage.
LIGHTING AND SIGNAL

Inspect the headlight, left and right turn signal light, tail
light/brake light and combination meter signal light, replace
the light with new one if there is something unusual. (Refer to
page 6-7)
2ND AIR VALVE

Inspect every 3 years or 18 000 km
● Remove the 2nd air valve mounting bolts, take off the 2nd
air valve 1 .
Remove the 2nd air valve one-way valve cover screw, take
off the one-way valve 2 .
Check the one-way valve 2 for dirt that affects the opening
and close of one-way valve. Clean the one-way valve and
2nd air valve assembly as necessary.
2-17
CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS

Inspect Initial 1 000 km and every 3 000 km
The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be
re-tightened, as necessary, to the specified torque with a torque wrench.
ITEM N•m Kg•m
1 Front axle nut 36-52 3.6-5.2
2 Front brake caliper mounting bolt 18-28 1.8-2.8
3 Brake hose mounting bolt 20-25 2.0-2.5
4 Brake disc mounting bolt 18-28 1.8-2.8
5 Upper bracket mounting bolt 35-55 3.5-5.5
6 Handlebar clamping bolt 12-20 1.2-2.0
7 Steering stem bolt 35-55 3.5-5.5
8 Lower bracket mounting bolt 25-35 2.5-3.5
9 Rear absorber fitting nut/bolt 22-35 2.2-3.5
10 Rear axle nut 50-80 5.0-8.0
11 Rear brake disc mounting bolt 20-25 2.0-2.5
12 Upper 33 - 39 3.3 - 3.9
13 Engine mounting bolts Front 33 - 39 3.3-3.9
14 Lower 50-60 5.0-6.0
15 Rear swing arm nut 50 - 80 5 .0 -8 .0
16 Exhaust pipe bolt 13 - 15 1 .3 -1 .5
17 Rear right footrest (muffler) mounting bolt 55 - 65 5 .5 -6 .5
2-18
2-19
COMPRESSION PRESSURE
The cylinder compression is an indicator of its inner state. The necessity of repair depends on the result of
the inspection. The record of your authorized dealer should include the compression pressure readings
obtained in every maintenance.
NOTE:
* Before testing the engine for compression pressure, make sure that the cylinder head nuts and bolts are
tightened to specified torque values and valves clearance are properly adjusted.
* Have the engine warmed up by idling before testing it.
* Ensure that the battery is fully charged.
Remove the related parts and inspect the compression pressure

in the following process:
Warm up the engine.
Remove the spark plug.(Refer to page 2-7) Fit the pressure
gauge and adapter to the spark plug hole, paying attention
to the connector tightening;
Turn the throttle to full opening;
Electrically start the motorcycle, take the maximum
reading in the recording as the cylinder compression
pressure.
09915-64512 : Compression gauge
Compression pressure
Standard Limit
1 000-1 400 kPa 800 kPa

10-14 kgf/cm 2 8 kgf/cm 2
When the compression pressure noted is down to or below

the limit indicated above, the engine must be disassembled,
inspected and repaired as required.
A low compression pressure may indicate any of the following
malfunctions:：
Excessively worn cylinder wall.
Worn piston or piston rings.
Piston rings stuck in the grooves.
Poor seating contact of the valves.
Defective the cylinder head gasket.
2-20
ENGINE
CONTENTS
REMOVABLE ENGINE PARTS WITH ENGINE IN PLACE 3-1
ENGINE REMOVAL AND REMOUNTING 3-2
CYLINDER HEAD AND VALVE 3-7
CYLINDER AND PISTON 3-17
CLUTCH 3-21
OIL PUMP 3-26
GEAR SHIFTING MECHANISM 3-27
GENERATOR AND STARTER CLUTCH 3-28 3

CRANKSHAFT AND TRANSMISSION 3-31
ENGINE
REMOVING ENGINE PARTS WITH ENGINE IN PLACE
UPPER SIDE OF ENGINE

Starter motor 3-7
Cam shaft tensioner 3-7
Cam sprocket 3-8
Cam shaft 3-8
Valve rocker arm 3-9
RIGHT SIDE OF ENGINE

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
Electric starter gear 3-28
Generator cover 3-28
Starter 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 AND REASSEMBLY

ENGINE REMOVAL
Before taking the engine out of the chassis, wash the engine
with a steam cleaner. The procedure of engine removal is
sequentially explained in the following steps:
Remove the left and right side cover 1 .
Unlock the saddle lock, take off the saddle 2 .
Disconnect the battery wire, loosen the battery band, take

off the battery 3 .
Turn the fuel switch to ”●” position .

Remove the fuel hose 4 .
Remove the tilt stop valve hose 5 .

Disconnect the fuel level gauge coupler 6 .
Remove the fuel tank bolts, take off the fuel tank 7 .
3-2
ENGINE
● Lossen the clutch cable lock nut and adjuster nut, remove
the clutch cable 8 from the clutch lever.
Loosen the generator wire clamp, remove the jacket 9 .

Disconnect the gear position switch coupler 10 and
generator coupler 11 .
Loosen the c hoke cable mounting screw, remove the choke cable 12 .
Disconnect the balancer hose 13 .
Remove the overflow hose 14 .
● Remove the vacuum hose 15 .

Remove the throttle cable and carburetor piston 16
Disconnect the air vent hose 17 .
Remove the carburetor intake hose nut 18 .
Loosen the carburetor clamp screws 19 , remove the

carburetor 20 and intake hose 21 .
3-3
ENGINE
● Loosen the rear axle nut 22 and chain adjuster bolt 23 .
Remove the gear shifting lever 24 .
Remove crankshaft air vent hose 25 , start motor wire

26 and engine ground wire 27 .
Remove the spark plug cap 28 .
● Remove the rear sprocket cover 29 .
● Remove the drive chain clip, disconnect the drive chain 30 .
3-4
ENGINE
● Disconnect the 2nd air intake hose 31 .

● Remove the exhaust pipe bolt.
Remove the muffler mounting bolt and nut, take off

the muffler 32 .
● Remove the engine rear mounting nuts 33 .
Remove the front footrest mounting bolt, take off the right
front footrest 34 .
Remove the engine upper mounting nut 35 .
Remove the engine front hanging mounting nuts 36 ,

engine front mounting nuts 37 .
Draw out the mounting bolts, remove the front hanging
bracket 38 and engine.
3-5
ENGINE
ENGINE REMOUNTING
The engine can be mounted in the reverse order of removal.
Temporarily fasten the engine mounting bracket before

inserting the engine mounting bolts.
NOTE:
The engine mounting nuts are self-lock 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 : 3 3-39 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
Right front foot rest mounting bolt E : 40-60 N•m
Muffler bolt F : 13-15 N•m
Rear footrest nut G : 55-60 N•m
G
D
F
E
● Install the drive chain clip, the clip opening faces to reverse
direction of traveling as shown.
After assembling the engine, add the engine. (Refer to

page 2-8)
Inspect the engine oil level. (Refer to page 2-8)
After remounting the engine, following adjustments are

necessary.
Throttle cable (page 2-9)
Clutch cable (page 2-10)
Idling speed (page 2-9)
Drive chain (page 2-11)
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 cam shaft chain 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 .
Bring the piston to the top dead center.
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 camshaft 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
DISASSEMBLY
Remove the camshaft chain tensioner 1 .
Remove the rocker 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 and installer
● Remove the valve spring retainer, inner spring and outer

spring.
Pull out the valve from the other side.
Remove the oil seal.
Removed oil seal should be replaced with a new one.
Remove the spring lower seat.
INSPECTION
ROCKER ARM SHAFT
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)
ROCKER ARM
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
VALVE SPRING
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
3-11
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 stem runout:

Limit: 0.03 mm
09900-20606: Dial gauge (1/100 mm)

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 进气门
angles to present three bevels. The valve seat contact
surface is 45°.
INTAKE EXHAUST
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
CYLINDER HEAD ASSEMBLY
● Clean the cylinder head with the detergent,clean all the oil
passages with compressed air.
Clean each valve with Moly paste.
Insert the valves into valve guide and Install the gasket,
spring, valve spring retainer.
99000-25140 : Moly paste
Install valve springs, making sure that the close-

pitch end of each spring goes in first to rest on the
head.
Turn the valve slowly while installing the valve oil seal
to prevent the valve oil seal from damage.
Install the valve cotters with the special tool.
11F14-018: Valve remover and installer tool
3-14
ENGINE
Oil the rocker arm shaft.

Mount 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 retainer 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
Install the 4 cap nuts and washers to secure the cylinder

head. Tighten each nut to the specified torque.
Cylinder head cover nut: 25-35 N•m
Install the camshaft, camshaft sprocket and cam chain.

B
Bring the piston to the top dead center when install the
A
camshaft and cam sprocket. Align the marks A on the
cam sprocket with the mark B on the cylinder head,
apply THREAD LOCK to the bolts.
99000-32030: Thread lock “1303"
Install the cylinder head left cover and gasket.
Replace the gasket with a new one.
Install the valve inspection covers and O-ring.
Replace the O-ring with a new one.
Install the cam chain tensioner.

Inspect the valve clearance.(Refer to page 2-5)
3-16
ENGINE
CYLINDER AND PISTON

CYLINDER REMOVAL
Remove the cylinder head. (Refer to page 3-7)
Remove the gasket, dowel pins and guide rod.
Remove the cylinder.
INSPECTION
Remove the remaining gasket on the cylinder surface.
Inspect the gasketed surface of cylinder head for distortion
with a straight edge and thickness.
Cylinder distortion:
Limit: 0.05 mm
09900-20803: Thickness gauge
Check the cylinder bore inner wall for scratches or wear.

Measure the cylinder bore diameter at six places. If any
one of measurements exceeds the limit, overhaul the
cylinder and replace the piston with an oversize, or replace
the cylinder.
Cylinder bore diameter: Limit: 57.43 mm
09900-20508: Cylinder gauge set
PISTON REMOVAL AND INSPECTION

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 remover
Hold the piston stably when taking out the piston pin to
prevent the damage to conrod big end bearing.
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.
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): 0.180 mm
(2nd):0.150 mm
Measure the piston outside diameter at the place 7mm
from the skirt end.
Piston outside diameter:
Limit: 7 mm from the skirt end, 57.145 mm 7mm
09900-20205: Micrometer (50-75 mm)
● Using a caliper gauge, measure the piston pin boreinside

diameter.
Piston pin bore inside diameter: Limit: 14.03 mm
09900-20605: Caliper gauge
● Using a micrometer measure the piston pin outside

diameter.
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 mmmm
09900-20605: Caliper gauge
Piston ring end gap: Limit(1st): 0.50 mm

(2nd):0.50 mm
NOTE:
Make sure fit the piston ring into the cylinder evenly
with the piston head.
REASSEMBLY
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.
12 0°
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 piston rings in the order of oil ring, 2nd ring
and 1st ring. Do not align the gap of oil ring with
expander ring.
Piston ring should turn smoothly in the piston groove after
assembly.
3-19
ENGINE
Apply engine oil to piston pin.
Place a clean rag over the cylinder base to prevent piston

pin circlip from dropping into crankcase, and then fit the
piston pin circlip with long-nose pliers.
Use a new piston pin circlip.

End gap of the circlip should not be aligned with the
cutaway in the piston pin bore.
When fitting the piston, turn the ”IN” on the piston head to
intake side.
● Apply engine oil to the conrod big end, small end, and piston sliding
part before reassembling cylinder.
● Apply bond to the contacting surface between crankcase and
cylinder, install the dowel pins 1 and gasket.
99000-31110: Bond “1215"
Always use new gasket to prevent leaking.
When mounting the cylinder, keep the cam chain 2

taut, or the chain 2 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 oil filer / gauge 2 .
Remove the clutch cover bolts diagonally and take off the
clutch cover 3 .
Remove the gasket and dowel pins.

● Remove the oil filter rotor cover 4 .
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 7 .
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 9 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.
Drive plate thickness: Checking thickness

Limit: 2.6 mm
Drive plate claw width:

Limit: 15.3 mm
Checking claw width
● Measure each driven plate for distortion with a thickness

gauge. Replace driven plates which exceed the limit.
Driven plate distortion: Limit: 0.1 mm
Replace the drive and drive plates as a whole set

Checking distortion
which exceed the limit.
Measure the clutch spring free length.
Clutch spring free length:

Limit: 36.2 mm
Replace all the springs if any spring is not within the

limit.
Inspect the clutch release bearing for any abnormality,

particularly cracks, to decide whether it can be reused or
should be replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
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.
REASSEMBLY
Apply engine oil to the clutch drive and driven plats,
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

11F14-011: 4 claws sleeve
Oil filter rotor lock nut: 40-45 N•m
3-24
ENGINE
99000-32050: Bond "1342"
● Install the dowel pin and new gasket.
Clutch cover bolt: 10-15 N•m
Re-adjust the clutch cable clearance. (Refer to page 2-9).
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"
3-26
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”
3-27
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 retainer bolt and retainer 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.
3-28
ENGINE
Hold the rotor with the special tool, remove the generator
rotor bolts.
11F14-001: Rotor holder
●
●
11F14-002: Generator rotor remover

09930-30102: Slide shaft
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.
3-29
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.
3-30
ENGINE
CRANKSHAFT, TRANSMISSION AND KICK STARTER

REMOVAL
●
● Remove the cam chain 1 .
● Remove the engine sprocket 2 .

● Remove the gear position mounting screws, take off the
gear position 3 and pin and spring.
● Remove the crankshaft retainer plate 4 , spring and pin.
11F14-036: Balancer shaft fixer
3-31
ENGINE
Remove the circlip, washer, balancer shaft driven gear

assembly 7 , and spacer.
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
forks.
Remove the gear shifting cam.
3-32
ENGINE
Remove the transmission assembly.
Remove the crankshaft with the special tool.
11F14-027: Crankcase separating tool
Remove the balancer shaft.
INSPECTION
Measure the big end of conrod side clearance with a
thickness gauge.
Conrod big end side clearance:

Limit: 0.5 mm
Support the crankshaft with “V” blocks as shown, with the

two end journals resting on the blocks. Measure the crank-
shaft runout with the dial gauge.
Crankshaft runout:
Limit: 0.05 mm
09900-20606:Dial gauge (1/100 mm)
09900-20701:Magnetic stand
09900-21304:V-block (100 mm)
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 extend 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 mm)

09900-20701:Magnetic stand
09900-21304:V-block (100 mm)
3-33
ENGINE
Shifting fork to groove clearance: 0.45 mm Checking clearance
Measure the thickness of gear shift fork.
Gear shift fork thickness: 4.93-5.0 mm
Checking thickness
Measure the gear shift fork groove width.
The gear shift fork groove width: 5.1-5.18 mm
Checking groove width
Inspect the gear shifting cam guide slot for damage.

Replace the gear shifting cam if the damage is found.
● Check if abnormal wear or poor lubrication exist on each

bush, inner race of gear and gear teeth surface.
3-34
ENGINE
●
●
BEARING REMOVAL
09921-20240 : Bearing removal tool
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”
3-35
ENGINE
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
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.
3-36
ENGINE
TRANSMISSION
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. BeforeA

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. A
Countershaft length(Low to 2nd) A ：

Standard: 96.2-96.5 mm
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 dowel pin and gasket.
Never reuse the gasket.
3-38
ENGINE
Install the right crankcase to the left crankcase, tighten the

mounting bolts.
Tighten the bolts in 2-3 steps diagonally.
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
A B
3-39
ENGINE
Install the engine sprocket, apply the Thread Lock

to the sprocket bolt 1 and tighten it.
99000-32050: Thread lock “1342"
3-40
FUEL AND LUBRICATION
CONTENTS
FUEL COCK 4-1
CARBURETOR 4-3
LUBRICATION SYSTEM 4-7
4
FUEL COCK AND FUEL FILTER

REMOVAL
Unlock the saddle lock, take off the saddle.
Turn the fuel cock to ” ” position and disconnect fuel hose
from the fuel cock.
Place a clean pan under the fuel cock assembly, turn fuel
cock to “ ” position and drain the gasoline.
Gasoline is very explosive. Extreme care must be

used.
Disconnect the tilt stop valve hose 1 .
Remove the fuel level sensor coupler 2 .

Remove the fuel tank mounting bolts, take off the fuel tank
3 .
Take off the fuel cock 4 .
CLEANING
Remove the fuel filter, blow it from inside to outside with the
compresses air. Rust from the fuel tank tends to build up in
the filter, which, when the filter has been neglected for a
long period, inhibits the flow of fuel. Remove the rust from
the filter using compressed air.
Replace the fuel mesh filter with a new one if it is damaged

or cracked.
4-1
REASSEMBLY
Reassemble the fuel cock in the reverse order of removal, pay
attention to the following points:
Install the fuel cock.
Seal
Gasket must be replaced with a new one to prevent
leakage.
FUEL LEVEL GAUGE

REMOVAL
Drain the gasoline in the fuel tank. (Refer to page 4-1)
Take off the fuel tank. (Refer to page 4-1)
Remove the fuel level gauge.
INSPECTION
(Refer to page 6-11)
REASSEMBLY
Reassemble the fuel level gauge in the reverse order or
removal.
4-2
CARBURETOR
CARBURETOR CONSTRUCTION
C
D
B
A
E
ITEM SPECIFICATION ITEM SPECIFICATION
Carburetor type PTG22 Main needle jet C
I.D. No. BROA Idle jet D
Main jet A #92 Idle air screw E 2,3/8 3/4 turn out
Bubbling pipe B Throttle cable play 0.5-1.0 mm
Main air jet #90 Idle 1500±100 r/min
4-3
REMOVAL AND DISASSEMBLY

Remove the choke cable 1 .
Disconnect the fuel hose 2 , balance hose 3 and overflow
hose 4 .
Remove the carburetor piston assembly 5 .

Remove the carburetor intake hose nut and bolt .
Disconnect the air vent hose 6 and vacuum hose 7 .
Loosen the carburetor clamp screws 8 .

Remove the carburetor and intake hose.
● Remove the throttle cable 9 , spring 10 and needle jet

11.
Remove the floater chamber cover by removing the

screws.
4-4
Take off the pin, float and needle valve.
Remove the main jet A .

Remove the bubble pipe B .
A
Remove the pilot jet C .
C B
● Clean the removed parts with carburetor cleaning solvent.
NEEDLE VALVE INSPECTION

If foreign matter is caught between the valve seat and the
needle, the gasoline will continue flowing and cause it to
overflow.
Clean the float chamber and float parts with gasoline, if the
needle is worn as shown in the illustration, replace it together
with a valve seat. Clean the fuel passage of the mixing
chamber with compressed air.
REASSEMBLY
Reassemble the carburetor by reversing the sequence of
disassembling steps. Pay attention to the follow points:
When installing the float chamber, make sure the O-ring is
fitted correctly.
Replace the O-ring with a new one.
4-5
REASSEMBLY
After the assembly of carburetor, perform the following
adjustments as necessary.
THROTTLE CABLE PLAY

Adjust the throttle cable play A to be 0.5-1.0 mm.
Adjust the throttle cable play as follows. A
Slide the boot, loosen the lock nut 1 of the throttle pulling
cable, turn the adjuster 2 clockwise or counterclockwise
until the throttle cable play (at the throttle grip) is between
0.5-1.0 mm.
Tighten the lock nut 1 after adjusting the play.
Recheck that handlebar movement does not raise the
engine idle speed and that the throttle grip returns
smoothly and automatically.
Throttle cable play: 0.5~1.0 mm
IDLING ADJUSTMENT
If engine running is necessary, be sure to keep the work

area well ventilated. Do not run engine in an closed space.
In engine exhaust gas, there is carbon monoxide that leads
to loss of consciousness or leads to death.
Engine running is allowable only at a well ventilated place
or in an enclosure with exhaust gas discharge system.
Pilot air screw is factory-installed and set. Adjustment is

not necessary unless carburetor needs to be dis-
assembled for inspection or screws need to be replaced.
For accurate adjustment, a ten-minute engine preheating is
necessary.
Screw the pilot air screw 1 clockwise by gently turning to

its home and turning it back to its Pre-set.
Pre-set: Turn out 2, 3/8 ± 3/4
● Start the engine, preheat it under idle running condition.

● Adjust the idle speed by means of the pilot screw 2 .
Idle speed: 1 500 ± 100 r/min
Slowly and repeatedly adjust the idle air screw 1 to obtain

maximum engine speed.
Adjust idle speed to specified value by means of pilot screw
2.
If the engine run unstable, repeat the 4, 5 step until the run
smoothly and stable.
Adjust the idling speed with pilot screw 2 .
4-6
FUEL AND LUBRICATION SYSTEM
LUBRICATION SYSTEM
Camshaft journal Conrod small

and cam face end bearing
Cam
Camchain
chain Cylinder wall
Rocker arm shaft
Conrod big
end bearing
Clutch release cam
Driven shaft bearing

Drive shaft bearing Oil filter
Side passage
Driven
Driven shaft and
shaft and gear
gear
Drive shaft and gear Oil pump
Primary driven
Primary driven gear bush
gear spacer
Oil strainer
Clutch plates
Oil pan
4-7
CHASSIS
CONTENTS
FRONT WHEEL 5-1

FRONT SHOCK ABSORBER 5-6
STEERING STEM 5-14
REAR WHEEL 5-18
REAR SHOCK ABSORBER AND SWING ARM 5-23
FRONT BRAKE 5-26
REAR BRAKE AND COMBINED LINKED VALVE 5-33 5
TIRE AND WHEEL 5-41
CHASSIS
FRONT WHEEL
CONSTRUCTION
Front axle Front rim

Spacer 10 Front tire Item N•m kgf•m
Dust seal 11 Speedometer driver A 18-28 1.8-2.8
Lock washer 12 Oil seal B 36-52 3.6-5.2
Front brake disc 13 Speedometer gear box
Oil seal A Brake disc bolt
Bearing B Front axle nut
Spacer
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 .
Remove the speedometer cable 2 .
Draw out the front axle shaft , take off the front wheel 3 .
Remove the speedometer gear box 4 .
Do not operate the front brake lever when removing the

front wheel.
Remove the front axle right spacer 5 and dust cover.
Flatten the lock washer, remove the brake disc bolts, take
off the brake disc 6 .
INSPECTION AND DISASSEMBLY

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
FRONT AXLE SHAFT

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)
09900-21304: V-block
Axle runout:
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:
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.
Remove the bearings on both side with the special tool,

take off the spacer.
09921-20240:Bearing remover tool
5-3
CHASSIS
REASSEMBLY
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"
Install left wheel bearing 1 first, then install the spacer 2

and right wheel bearing 3 using the special tool and
removed wheel bearings 4 .
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 wheel bearing B RH
OIL 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
Make sure that the brake disc is clean and free of any
greasy matter.
Install the brake disc, tighten the brake disc bolts to the
specified torque, then bend the lock washer to the bolt.
Front brake disc bolt: 18~28 N•m
SPEEDOMETER GEAR BOX

● Before installing the speedometer gear box grease it,
then install it on the wheel rim.
99000-25010: Super grease “A”
FRONT AXLE SHAFT

Install the front wheel and front axle, tighten the front
axle nut to the specified torque.
Install the speedometer cable.
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 SHOCK ABSORBER

CONSTRUCTION
1 Washer 5 Left front absorber

2 Dust cover A Cap bolt ITEM N•m kgf•m
A 35-55 3 . 5-5.5
3 Snap ring B Bolt
B 20-26 2.0-2.6
4 Oil seal
5-6
CHASSIS

Remove the front wheel. (Refer to page 5-2)
Remove the two bolts, take off the front brake caliper 1 .
Remove the front fender mounting bolts and brake hose

clamp 2 , take off the front fender.
Remove the left and right reflectors, take off the front
shock absorber protective cover 3 .
Remove the headlamp mounting bolts, disconnect the

headlamp coupler, take off the headlamp 4 .
Remove the clamp, disconnect the wire couplers.
5-7
CHASSIS
Remove the headlamp front cover 5 .
Remove the brake hose clamp 6 .
Disconnect the headlamp coupler.

Remove the master cylinder mounting bolts, take off the
master cylinder 7 .
Remove the right handlebar switch wire clamp.

Remove the right handlebar switch assembly 8 .
Disconnect the clutch switch coupler.

Remove the clutch lever mounting bolts, take off the
clutch lever 9 .
Remove the left handlebar switch wire clamp,
Remove the left handlebar switch assembly 10 .
5-8
CHASSIS
Remove the speedometer cable 11 .
Remove the handlebar clamp bolts, take off the handlebar
bracket and handlebar 12 .
Remove the front shock absorber upper cap and steering stem
lock bolt, take off the upper bracket and dashboard 13 .
Remove the left and right turn signal light bracket assembly 14
Loosen the lower bracket clamp bolts, take off the font
shock absorbers.
Remove the cap bolt and draw out the spacer and absorber
spring.
5-9
CHASSIS
Invert the absorber and stroke it several times to remove

the oil.
WARNING
The oil seal removed should be replaced with a new

one.
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.
5-10
CHASSIS
INSPECTION
DAMPER ROD RING
● Inspect the damper rod ring for wear and damage.
INNER TUBE AND OUTER TUBE

● 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: 392 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.
99000-32040: Thread lock “1303" Thread lock O-ring (copper)
11F14-010: Front fork installer and remover
Damper rod bolt: 20~26 N•m
Do not reuse the removed O-ring.
5-11
车体
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): 168±3 ml
Absorber oil type: MX34 #
REASSEMBLY
Reassemble the front absorber in the reverse order of removal,
pay attention to the following points:
Install the front shock absorbers, tighten the lower bracket
clamp bolts temporarily.
Install the left and right turn signal lights bracket assembly.
Install the upper bracket and dashboard, tighten the

front shock absorber cap bolt and steering stem lock bolt to
the specified torque.
Front shock absorber cap bolt: 35~55 N•m
Steering stem lock bolt: 35~55 N•m
Tighten the front shock absorber lower bracket clamping

bolt to the specified torque.
Lower bracket clamping bolt: 25~35 N•m
5-12
CHASSIS
Set the handlebars to match its punched mark to the

mating face of the holder.
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
Route the cable and wiring harness. (Refer to page 7-16)
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)
5-13
CHASSIS
STEERING STEM
CONSTRUCTION
1 Handlebar holder 11 Lower oil seal

2 Upper bracket 12 Cushion ITEM N•m kgf•m
3 Steering stem nut 13 Bracket A 35-55 3 . 5-5.5
4 Dust seal 14 Spacer B 12-20 1.2-2.0
5 Upper steering outer race 15 Lower bracket C 25-35 2.5-3.5
6 Balls (22pcs) 16 Haojue brand cover
7 Upper steering inner race A Steering stem bolt
8 Lower steering inner race B Handlebar clamp bolt
9 Balls (18pcs) C Lower bracket lock bolt
10 Lower steering outer race
5-14
CHASSIS
REMOVAL
Remove the front wheel. (Refer to page 5-2)
Remove the front shock absorbers. (Refer to page 5-6)
Remove the steering stem lock nut 1 and dust cover 2 .
09910-60611: Universal 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.
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
5-15
CHASSIS
INSPECTION
Inspect and check the removed parts for the following
abnormalities.
Race wear and brinelling.
Worn or damaged steel balls.
Distortion of steering stem.
Reassemble and remount the steering stem in the reverse

order of disassembly and removal, and also carry out the
following steps:
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.
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.
STEERING STEM NUT

● Tighten the steering stem nut with the special tool.
09940-14911: Steering nut socket wrench
5-16
CHASSIS
Turn the steering stem right and left , lock-to-lock, five or

six times to “seat” the steel ball bearings.
Turn back the stem nut by 1/4-1/2 turn.

Turn back 1/4 -1/2
09940-14911: Steering stem nut socket wrench
The adjustment will vary from motorcycle to motorcycle.
Install the front shock absorbers. (Refer to page 5-12)

Install the front wheel.(Refer to page 5-4)
5-17
CHASSIS
REAR WHEEL
CONSTRUCTION
1 Rear axle shaft 14 Rear tire

2 Chain adjuster assembly 15 Roller bearing
ITEM N•m kgf•m
3 Guide plate 16 Damper
A 50-80 5.0-8.0
4 Washer 17 Rear sprocket drum
B 18-28 1.8-2.8
5 Nut 18 Spacer
C 30-37 3.0-3.7
6 Rear brake disc 19 Roller bearing
7 Oil seal 20 Oil seal
8 Spacer 21 Spacer
9 Bolt 22 Rear sprocket
10 Dust seal plate A Nut
11 Roller bearing B Bolt
12 Spacer C Nut
13 Rear wheel rim
5-18
CHASSIS
Support the motoycycle with the main stand.

Remove the muffler. (Refer to page 3-5)
● Loosen the drive chain adjuster nut 1 and rear axle
nut 2 .
Rear the rear axle nut, draw out the rear axle, take off the
spacer, rear wheel and rear sprocket.
Remove the rear brake disc 3 .
Remove the rear sprocket 4 .
Remove the sprocket 4 mounting bolts.

Remove the rear sprocket drum and sprocket.
Remove the oil seal with the special tool.
5-19
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.
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
Axle shaft runout: Limit: 0.25 mm
09900-20606: Dial gauge (1/100)

09900-21304: V-block
5-20
CHASSIS
SPROCKET
Inspect the sprocket teeth for wear. If they are worn as
illustrated, replace the sprocket and drive chain.
Normal wear Excessive wear
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.
REAR SPROCKET MOUNTING DRUM

Insert the bearing by using the special tool.
5-21
CHASSIS
Install the sprocket mounting drum oil seal with the

special tool.
Apply grease to the mounting drum as shown.
99000-25010: Super grease ”A”
REAR SPROCKET
Tighten the four nuts to specified torque.
Sprocket lock nut: 18~28 N•m
Do not reuse the removed nuts, replace the nuts with

new ones for safe riding.
REAR WHEEL
Install the rear wheel and spacer, tighten the rear axle nut to the specified
torque.
Rear axle nut: 50~80 N•m
Adjust the drive chain. (Refer to page 2-11)
5-22
CHASSIS
REAR ABSORBER AND REAR SWING ARM

CONSTRUCTION
9
2
8
3
4
5
6
7 6
10
1 Rear swing arm shaft 7 Spacer

2 Spacer 8 Plain washer ITEM N•m kgf•m
3 Cover 9 U-nut A 50-80 5 . 0-8.0
4 Washer 10 Chain touch defense buffer B 1 0-16 1.0-1.6
5 Seal
6 Bush
5-23
CHASSIS

Remove the rear wheel. (Refer to page 5-18)
Remove the rear caliper 1 and take off the rear brake
hose from the rear swing arm.
Remove the rear brake absorber bolts and nuts, take off
the rear brake absorbers 2 .
Remove the rear swing arm shaft nut 3 , take off the rear
swing arm shaft.
Remove the chain case screws, take off the chain case 4 .
Remover the rear swing arm 5 and spacer 6 .
Remove the chain touch defense buffer 7 and dust cover

8.
5-24
CHASSIS
INSPECTION
SWING ARM PIVOT SHAFT
● Using a dial gauge, check the pivot shaft for runout and
Axle runout: Service limit: 0.6 mm
09900-20606: Dial gauge(1/100)

09900-21304: V-block
REASSEMBLY
Reassemble and remount the swing arm in the reverse order
of disassembly and removal, and also carry out the following
steps:
Insert the swing arm shaft from the left side, and tighten the
pivot nut to the specified torque.
Rear pivot shaft nut: 50~80 N•m
Tighten the rear shock absorber upper and lower bolts to

the specified torque.
Rear absorber upper bolt: 22~35 N•m
Rear absorber lower bolt: 35~55 N•m
Install the rear brake caliper.

Install the rear wheel. (Refer to page 5-21).
5-25
CHASSIS
FRONT BRAKE
CONSTRUCTION
B
A
B
1 Brake lever 8 Pad spring ITEM N•m kgf • m

2 Master cylinder 9 Brake pads A 8-12 0.8-1.2
3 Brake light switch 10 Air bleeder valve B 20-25 2.0-2.5
C 18-28 1.8-2.8
4 Piston 11 Front brake caliper
5 Brake hose I A Bolt
6 Brake hose II B Bolt
7 Brake caliper bracket C Bolt
5-26
CHASSIS
WARNING
The brake system of this motorcycle is filled with a Suzuki brake fluid. Do not use or mix
different types of fuid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will be caused.
Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the
brake fluid left over from the last servicing and stored for long periods.
When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
CAUTION
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

Loosen brake caliper mounting bolts 1 .
Loosen brake pads mounting bolts 2 .
Remove the brake pads 3 and replace theme with new

ones.
Replace the brake pads as a set, otherwise braking

Reassemble the new brake pads and brake caliper in the

reverse order of removal.
Tighten the brake caliper mounting bolts to the specified
torque.
Brake caliper mounting bolt: 18~28 N•m
CAUTION
Push the pistons all the way into brake caliper.
5-27
CHASSIS
BRAKE FLUID REPLACEMENT

Support the motorcycle with the main stand,
keep the steering straight.
Remove the master cylinder cover 1 and diaphragm.
Draw the brake fluid as mush as possible.
Add new brake fluid to the master cylinder.
● Attach the special tool hose to the brake caliper air

bleeder valve.
● Loosen the brake caliper bleed valve nut, starter the special
tool, draw out the brake fluid in the brake system, and add
new brake fluid in the master cylinder as necessary.
11F14-035: Pneumatic fluid drawer
Tighten the brake caliper bleed valve, take off the special
tool.
Add the new brake fluid in the master cylinder to the
upper level.
Add the new brake fluid in the master cylinder to the
upper level.
CALIPER REMOVAL AND DISASSEMBLY

Place a clean rag underneath the union bolt on the brake
caliper to catch any split brake fluid.
Remove the brake hose from the caliper by removing the
union bolt 1 and catch the brake fluid in a suitable
receptacle.
Remove the brake caliper mounting bolt 2 , take off the
brake caliper.
CAUTION
Never re-use the brake fluid left over from the last
servicing and stored for long periods.
BRAKE CALIPER DISASSEMBLY

Remove the brake caliper pads 1 and bracket 2 .
5-28
CHASSIS
Place a clean rag over the pistons to prevent it from

popping out and then force out the pistons using
compressed air.
Do not use high pressure air to prevent piston damage.
Remove the pad spring 3 .
Remove the piston, piston boot and piston seal.
INSPECTION
CALIPER CYLINDER
Inspect the brake caliper cylinder wall for nicks, scratches
and other damage. If any damage is found, replace the
caliper with a new one.
PISTON
Inspect the brake caliper piston surface for any scratches
piston with a new one.
BRAKE CALIPER SLIDING PIN
Inspect the brake caliper sliding pin for wear and other damage.
If any damage is found, replace it with a new one.
5-29
CHASSIS
RUBBER PARTS
Inspect the rubber parts for cracks and damage. If any
defects are found, replace the affected parts.
PAD SPRING
Inspect the pad spring for damage and excessive bend. If
any defects are found, replace it with a new one.
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:
Measure runout of the brake disc with a dial gauge.
09900-20606: Dial gauge (1/100 mm)

Brake disc runout:

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 master cylinder 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.
5-30
CHASSIS
Apply the super grease to slide pin.
99000-25010: Super grease ”A”
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 5-28)
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.
MASTER CYLINDER
R E M O VA L A N D D I S A S S E M B LY
caliper to catch any split brake fluid, Remove the brake
hose from the caliper by removing the union bolt.
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
will damage them severely.
Remove two clamp bolts and take off the master cylinder.
Remove two fitting screws, and remove the cap 1 and

diaphragm 2 .
Drain the brake fluid.
5-31
CHASSIS
Remove the dust seal boot.

Remove the circlip, piston and spring by using the special
tool.
09900-06108: Snap ring pliers
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.
REASSEMBLY
Reassemble and remount the master cylinder in the
reverse orders of disassembly and removal, and also carry
out the following steps:
Wash the master cylinder components with fresh brake
fluid before reassembly.
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
parts before inserting into the bore. Handlebar
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 5-28)
5-32
CHASSIS
REAR BRAKE AND COMBINED LINKAGE VALVE

CONSTRUCTION
1 Bundy tube No.3 8 Rear brake hose ITEM N•m kgf•m

2 Rear brake master cylinder 9 Brake pad A 18-28 1.8-2.8
3 Rear master cylinder 10 Rear brake caliper
B 20-25 2.0-2.5
4 Rear reservoir tank hose 11 Rear brake caliper bracket

5 Combined linkage valve A Master cylinder mounting bolt
6 Bundy tube No.1 and No.2 B Brake hose union bolt
7 Switch joint
5-33
CHASSIS
WARNING
The brake system of this motorcycle is filled with a Haojue brake fluid. Do not use or mix
different types of fuid such as silicone-based and petroleum-based fluid for refilling the
system, otherwise serious damage will be caused.
Do not use any brake fluid taken from old or used or unsealed containers. Never re-use the
brake fluid left over from the last servicing and stored for long periods.
When storing the brake fluid, seal the container completely and keep away from children.
When replenishing brake fluid, take care not to get dust into fluid.
When washing brake components, use new brake fluid. Never use cleaning solvent.
A contaminated brake disc or brake pad reduces braking performance. Discard contaminated
pads and clean the disc with high quality brake cleaner or neutral detergent.
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 pad pin plug 1 .
Remove the pad mounting pin 2 .
Remove the brake pad mounting bolt and brake pads 3

and replace brake pads with new ones.
Replace brake pads as a set; otherwise braking

Reinstall the new brake pads and caliper.

Tighten caliper mounting bolts to the specified torque.
Brake caliper mounting bolts: 18~28 N•m
While installing the brake caliper, push the pistons all

the way into the brake caliper.
5-34
CHASSIS
BRAKE FLUID REPLACEMENT

Support the motorcycle with the main stand and place the
handlebar straight.
Remove the rear brake fluid reservoir tank cap 1 and
diaphragm.
Drain the brake fluid as mush as possible.
Add new brake fluid to the rear brake fluid reservoir tank.
Attach the special tool hose to the front brake caliper

air bleeder valve.
Loosen the front brake caliper air bleeder valve, starter the
special tool to draw out the brake fluid in the brake system,
and add new brake fluid to the front brake fluid reservoir
tank as necessary.
● Tighten the rear brake caliper bleeder valve, take off the
special tool.
● Add the new brake fluid to the rear brake fluid reservoir
tank to the upper level.
Attach the special tool hose to the rear brake caliper air
bleeder valve.
Loosen the rear brake caliper air bleeder valve, starter the
special tool to draw out the brake fluid in the brake system,
and add new brake fluid to the rear brake fluid reservoir
tank as necessary.
Tighten the rear brake caliper air bleeder valve, take off the
special tool.
Fill the rear brake reservoir tank with brake fluid to the
upper line.
5-35
CHASSIS
REAR BRAKE CALIPER REMOVAL

Remove the rear wheel.(Refer to page 5-18)
caliper to catch any split brake fluid.
Remove the brake hose from the caliper by removing the
union bolt 1 and catch the brake fluid in a suitable
receptacle.
CAUTION
Never re-use the brake fluid left over from the last
servicing and stored for long periods.
Rear the rear brake pad slide shaft, take off the rear
brake caliper pads 1 and rear brake caliper bracket 2 .
● Remove the pad spring 3 .
Warning
Place a clean rag over the pistons to prevent it from

popping out, do not put the hand at the piston side.
Do not use high pressure air to prevent piston damage.
● Remove the piston 4 , piston boot 5 and piston seal 6 .
5-36
CHASSIS
INSPECTION
CALIPER CYLINDER
Inspect the brake caliper cylinder wall for nicks, scratches
caliper with a new one.
PISTON
Inspect the brake caliper piston surface for any scratches
piston with a new one.
BRAKE CALIPER SLIDING PIN

Inspect the brake caliper sliding pin for wear and other damage.
If any damage is found, replace it with a new one.
RUBBER PARTS
● Inspect the rubber parts for cracks and damage. If any
defects are found, replace the affected parts.
PAD SPRING
Inspect the pad spring for damage and excessive bend. If any
defects are found, replace it with a new one.
5-37
CHASSIS
REASSEMBLY
Reassemble and remount the master cylinder in the reverse
orders of disassembly and removal, and also carry out the
following steps:
Wash the caliper bore and piston with specified brake fluid.
Particularly wash the dust seal groove and piston seal
groove.
Brake fluid specification: DOT3 or DOT4
When washing the components, use the specified

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
components.
● Apply the brake fluid to new piston seal 1 and new dust
seal 2 .
Brake fluid specification: Dot 3 or Dot 4
Install the each seal as shown in the illustration.
1 Piston seal
2 Dust seal
3 Caliper body
Apply grease to the inside of boot.

Apply grease to the brake caliper sliding pin.
99000-25100: SILICONE GREASE or equivalent
CALIPER INSTALLATION
Install the caliper in the reverse order of removal. Pay
attention to the following points:
● Install the rear brake hose union bolt 1 , tighten it the
specified torque.
Brake hose union bolt: 20-25 N•m
Install the rear wheel and rear brake caliper. (Refer to page
5-22)
5-38
CHASSIS
BRAKE DISC INSPECTION

Inspect the rear brake disc in the same manner as the
inspection to front brake disc. (Refer to page 5-30)
Rear brake disc thickness: Service limit: 3.0 mm

Rear brake disc runout: Service limit: 0.30 mm
REMOVAL
Remove the frame rear right side cover 1 .
Remove the rear reservoir tank mounting bolt 2 , remove
the rear reservoir tank cap mounting screw 3 , take off the
cap and diaphragm.
Attach the special tool hose to the front brake caliper rear
bleeder valve 4 , loosen the lock nut, draw out the brake
fluid in front brake caliper CBS, and loosen the rear brake
caliper air bleeder valve lock nut, draw out the brake fluid
in the in rear brake system and CBS.
● Place a clean rag underneath the combined link valve to catch

any split brake fluid. Loosen the nut of each brake hose,
● Remove the brake hoses from the combined link valve.
Remove the combined link valve mounting bolts, take off
the combined link valve.
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
will damage them severely.
Remove the cotter pin, draw out the pin shaft, disconnect
the rear master cylinder 6 and rear brake pedal 7 .
Remove the rear master cylinder 6 mounting bolt 8 , take
off the rear master cylinder and rear reservoir tank
5-39
CHASSIS
REASSEMBLY
Reassemble the rear brake reservoir tank, rear master
cylinder and combined linkage valve, pay attention to the
following point:
Install the rear master cylinder, tighten the rear master
cylinder mounting bolts to the special torque.
Rear master cylinder mounting bolt: 18-28 N•m
Connect the brake hoses to the combined linkage valve,

tighten the brake hose mounting nut to the specified torque.
Brake hose mounting nut: 20-25 N•m
Install the rear brake reservoir tank, tighten the rear brake
reservoir tank mounting bolt to 8-12 N•m.
Rear brake reservoir tank mounting bolt: 8-12 N•m
Install the combined linkage valve, refill the brake fluid to

the brake system. (Refer to page 5-28)
5-40
CHASSIS
TIRE AND WHEEL

REMOVAL
The most critical factor of tubeless tire is the seal
between the wheel rim and the tire bead. For this reason,
it is recommended to use a tire changer that can satisfy
this sealing requirement and can make the operation
efficient as well as functional.
CAUTION
For operating procedures, refer to the instructions
supplied by the tire changer manufacturer.
NOTE:
When removing the tire in the case of repair or inspection,
mark the tire with a chalk to indicate the tire position relative to
the valve position.
Even though the tire is refitted to the original position after
repairing puncture, the tire may have to be balanced again
since such a repair can cause imbalance.
INSPECTION
WHEEL
Wipe the wheel clean and check for the following points:
Distortion and crack

Any flaws and scratches at the bead seating area.
Wheel runout ( Refer to page 5-4)
TIRE
Tire must be checked for the following points:
Nick and rupture on side wall

Tire tread depth
Tread separation
Abnormal, uneven wear on tread
Surface damage on bead
Localized tread wear due to skidding (Flat spot)
Abnormal condition of inner liner
5-41
CHASSIS
VALVE INSPECTION
Inspect the valve after the tire is removed from the rim.
Replace the valve with a new one if the seal A rubber is
peeling or has damage.
NOTE:
If the external appearance of the valve shows no
abnormal condition, removing of the valve is not
necessary. If the seal has abnormal deformation,
replace the valve with a new one.
Any dust o r r ust a round t he v alve h ole B must b e

c leaned o ff .
Then install the new valve C in the rim.
NOTE :
To properly i nstall t he v alve i nto t he v alve h ole , a pply a
s pecial tire lubricant o r n eutral s oapy l iquid t o t he v alve .
CAUTION
Be careful n ot t o d amage t he l ip C of v alve .
5-42
CHASSIS
TIRE INSTALLATION
Apply tire lubricant to the tire bead.
CAUTION
Never use oil, grease or gasoline on the tire bead in
place of tire lubricant.
When installing the tire onto the wheel, observe the following
points:
When installing the tire, the arrow A on the side wall
should point to the direction of wheel rotation.
Align the chalk mark put on the tire at the time of removal
with the valve position.
● For installation procedure of tire onto the wheel, follow the

● instructions given by the tire changer manufacturer.
Bounce the tire several times while rotating. This makes
●
the tire bead expand outward to contact the wheel, thereby
facilitating air inflation.
Inflate the tire.
Warning
● Do not inflate the tire to more than 400 kPa (4.0
kgf/cm2, 57 psi). If inflated beyond this limit, the tire
can burst and possibly cause injury. Do not stand
directly over the tire while inflating.
● In the case of preset pressure air inflator, pay special
care for the set pressure adjustment.
5-43
E L E C T R I C A L
CONTENTS
CAUTIONS IN SERVICING 6-1

STARTER SYSTEM 6-3
IGNITION SYSTEM 6-6
CHARGING SYSTEM 6-10
FUEL LEVEL GAUGE 6-13
DASHBOARD 6-14
LIGHTS 6-15
SWITCHES 6-16
BATTERY 6-18
6
ELECTRICAL
CAUTIONS IN SERVICING
CONNECTOR
“Click”
When connecting a connector, be sure to push it in until a click
is felt.
Inspect the connector for corrosion, contamination and
breakage in its cover.
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
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
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 Ignition switch on
Fuse
Starter motor
Clutch switch
* Inspection:
TROUBLESHOOTING
Battery is fully-charged.
Starter motor will not run Fuse is not blown before the diagnosis.
Check whether to run the starter
motor when connect the starter
Check whether to hear the click noise motor terminal to the battery
from the starter relay when the starter Clicks terminal directly. (Do not use thin
button is pushed. wire, because a large amount
of current flows.)
No click
Run Not run
● Faulty starter relay ● Faulty starter motor
Measure the starter relay voltage at the ● Loose or disconnected starter
starter relay connectors (between O motor lead wire
and Y/G ) when the starter button is Not voltage ● Faulty ignition switch
pushed. ● Faulty front brake light switch
● Faulty rear brake light switch
Voltage measured ● Faulty starter button

● Poor contact of connector
● Open circuit in wiring harness
Check the starter relay
Incorrect ● Faulty starter relay
(Refer to page 6-9)
Starter motor runs,

● Open circuit in wiring harness
but does not start engine.
● Poor contact of connector
● Faulty CDI unit
● Faulty ignition coil
● Faulty generator
● Faulty starter clutch
6-3
ELECTRICAL
STARTER MOTOR DISASSEMBLY

Remove the starter motor.
Disassemble the starter motor as shown.
1 O-ring 4 Starter motor case 7 Housing end(Outside)

2 Housing end(Inside) 5 Armature
3 Oil seal 6 Brush
STARTER MOTOR INSPECTION

CARBON BRUSH
Inspect carbon brush for cracks or abnormal wear. If any defects
are found, replace with a new carbon brush assembly.
COMMUTATOR
Inspect the commutator surface for abnormal wear or
undercut A .
If the commutator surface shows abnormal wear, replace with a
commutator.
If the commutator surface is worn unevenly, polish with no,.400
sand paper and wiped with a clean dry cloth.
If there is no undercut, scrape out insulator 1 with a saw blade.
6-4
ELECTRICAL
ARMATUR COIL
● Inspect for continuity between each segment and between
each segment and the armature shaft using the multi circuit
tester.
● If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
armature with a new one.
09900-25008: Pocket tester
Test range selection: Continuity
OIL SEAL AND BEARING

Inspect the oil seal lip for damage or leakage.
Inspect the bearing for abnormal noise and smooth movement.
If any defects are found, replace the housing end (inside).
BUSHING
Inspect the bushing for wear and damage.
If any defects are found, replace the housing end (outside).
STARTER MOTOR REASSEMBLY

Reassemble the starter motor in the reverse order of
disassembly. Pay attention to the following points:
Apply a small quanittty grease to the lip of the oil seal and
bearing.
99000-25010: SUPER GREASE ”A”
Apply a small quantity of moly paste to the armature shaft.
99000-25140: MOLY PASTE
6-5
ELECTRICAL
Install the gasket 1 to the housing end (outside) as shown.
Fit the depression B of the starter motor case to the

groove A of the housing end (outside).
Install the housing end (inside) to the starter motor case,

align the match mark on the starter motor body with the
match mark on the housing end (inside).
Apply a small quantity of super grease to the O-ring 2 .
99000-25010: SUPER GREASE “A”
● Tighten the starter motor mounting bolt 3 with the

battery - lead wire 4 .
● Tighten the starter motor lead wire bolt 5 .
6-6
ELECTRICAL
STARTER RELAY INSPECTION

● Remove the left side cover. 1
● Disconnect lead wire 1 of the starter motor at starter
relay.
Turn on the ignition switch, press the starter button, check
for continuity between the terminals.
If a ”click” is not heard, the starter relay is not working.
● Disconnect the starter relay coupler, measure the relay coil

resistance between the terminals using the multi circuit
tester. If the resistance is not within the specified value,
replace the starter relay with a new one.
09900-25008 : Pocket tester
Test range: Resistence
Starter relay resistence: 3-6 Ω
6-7
ELECTRICAL
IGNITION SYSTEM
DESCRIPTION
In the capacitor discharged ignition system, the electrical energy generated by the generator charges the
capacitor. The energy is released in a signal surge at the specified ignition timing, and current flows
through the primary side of the ignition coil. A high voltage current is induced in the secondary windings of
the ignition coil resulting in strong spark between the spark plug gap.
Ignition switch
O/Y
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

Looseness ● Poor contact of couplers
poor contact
Correct
Inspect the ignition circuit Incorrect ● Faulty ignition switch

● Broken wire harness or poor
Correct
contact of related circuit connectors.
Inspect the resistance of trigger coil

(G/W and Bl/W) Incorrect ● Faulty trigger coil
Correct
● Faulty CDI unit

● Faulty ignition coil
● Faulty high-tension cord
6-8
ELECTRICAL
IGNITION COIL
● Remove the spark plug cap 1 .
● Inspect the resistence of ignition coil with the pocket tester.

Tap

Tester knob indication: X1 Ω range Ω
kΩ
Primary: 0.19-0.23 Ω (tap-tap)
Secondary: 11.29-14.91 kΩ (tap - plug cap)
Tap
TRIGGER COIL
● Measure resistance between lead wires using multi-circuit
tester. If resistance is out of specified values, replace with
new trigger coil.

Tester knob indication: X1 Ω range
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.
6-9
ELECTRICAL
CHARGING SYSTEM
DESCRIPTION
The circuit of the charging system is indicated in the figure, which is composed of an AC generator,
regulator/rectifier unit and battery.
The AC current generated from AC generator is converted by rectifier and is turned into DC current, then is
charges the battery.
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 ● Faulty generator rotor.
Correct
(to next page )
6-10
ELECTRICAL
(Continue the last page)
Inspect regulator/rectifier. Incorrect ● Faulty regulator/rectifier
Correct
Inspect wirings Incorrect ● Short circuit of wiring harness.

● Poor contact of couplers
Correct
● Faulty battery
Others
Battery overcharge ● Faulty regulator/rectifier

● Faulty battery
● Poor contact of generator
wire coupler.
INSPECTION
BATTERY LEAK CURRENT INSPECTION
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.
Battery leakage: Less than 0.5mA
mA
Test scale: Current ( --- , 2mA)
CAUTION
* Because the leak current might be large, turn the
tester to high range first when connecting an
ammeter.
* Do not turn the ignition switch to the ON position
when measuring current.
GENERATOR COIL INSPECTION

Remove the right side cover.
Disconnect generator coupler 2 .
Measure the resistence between the lead wires, if the
resistence is incorrect, replace the generator coil.
Tester knob indication: Resistance
Generator coil resistance: 0.5-1.3 Ω (B-B)
6-11
ELECTRICAL
CHARGING OUTPUT INSPECTION

Remove the left side cover.
Start the engine, keep it running at 5 000 r/min, with
lighting switch turned ON and dimmer switch turned HI
position.
Measure the DC voltage between the battery terminal and
with a pocket tester. If the tester reads under the specified
value, inspect the generator coil and regulator/rectifier.
CAUTION
When making this test, be sure that the battery is Battery

fully-chaged condition.

Teat scale: Voltage (DC)
Pocket tester
Charging output
Standard: 14.0-15.0V at 5 000 r/min
GENERATOR NO-LOAD PERFORMANCE

INSPECTION
Disconnect the generator coupler. (Refer to page 6-4)
Start engine and keep it running at 5,000 rpm.
Measure voltage between generator terminal and ground
by using the pocket tester. If the reading is below standard
values, replace with a new generator coil.
(Refer to page 3-33)
CAUTION
It is not necessary to remove the engine from the chassis
during the removal the generator coil.

Teat scale: Voltage
Generator no-load performance:

More than 104-110V/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
FUEL LEVEL GAUGE

INSPECTION
FUEL LEVEL GAUGE
Remove the fuel lever gauge.
Check the resistance of each float position with a pocket
tester.
If the resistance measured is incorrect, replace the fuel gauge
assembly with a new one.
The relation between the position of the fuel gauge float and
resistance is shown in the following table. A
Float position Resistence B
A Full 4-10Ω
B Empty 90-100Ω
TOOL 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

Disconnect fuel level gauge coupler.
To test the fuel meter two different checks may be used.
The first, connect a jumper wire between B/W and Y/B wires
coming from the main wiring harness. With the ignition switch
turned ON, the fuel meter should indicted “F”.
The second test will check the accuracy of the meter in the full
and empty positions.
Fuel meter is normal if its pointer indicates the E (empty)
position when the specified resistance is applied to the circuit
and if its pointer indicates the F(full) position when the resistor
is changed to 4-10 ohms. If either one or both indications are 黑/白橙
黄/黑
abnormal, replace the fuel meter with a new one.
Resistance 4-10 Ω 90-100 Ω 黑/白
Float position Full Empty
6-13
ELECTRICAL
DASHBOARD
● Remove the dashboard. (Refer to page 5-15)
● Disassemble the dashboard as follows.
Upper case Dashboard unit Dashboard unit case

LED Bulb (4PCS) Bulb (12V 2W, 1PCS) Bulb (12V 3W, 1PCS)
Bulb (12V 3W, 2PCS) Bottom case Bracket
Dashboard wire Gear position display coupler Speedometer cable
INSPECTION
Using the pocket tester, check the continuity between lead Dashboard
wires.
If the continuity measured is incorrect, replace the respective
parts.
Tester knob indication: C ontinuity
B/W
R/W
G/Bl
Br/R
W/Y
Y/Bl
R/B
Y/B
CAUTION
Lg
Gr
Bl
Y
When making this test, it is not neceassary to remove

the dashboard.
6-14
ELECTRICAL
LIGHTS
HEADLAMP TURN SIGNAL LIGHT
TAIL LIGHT/BRAKE LIGHT
HEADLAMP AND POSITION LIGHT

REMOVAL
Remove the headlamp case left and right mounting
screws, take off the headlamp case.
Replace the headlamp bulb and position light bulb with a new
one.
TURN SIGNAL LIGHT

REMOVAL
Remove the turn signal light case screws.
Remove the turn signal light case, replace the turn signal light
bulb.
6-15
ELECTRICAL
TAIL LIGHT/BRAKE LIGHT

REMOVAL
Remove the taillight case screws, take off the tail light
case.
Replace the taillight/brake light bulb.
SWITCHES
● Inspect each switch for continuity with the pocket tester to the
chart. If it is found any abnormality, replace the respective
switch assembly with new one.

Confirm electrical conductance
IGNITION SWITCH 1
R O B/W Bl/W
OFF ○ ○
ON ○ ○
LOCK ○ ○
LIGHTNING SWITCH 2
Gr O Y/W
○ ○
○ ○ ○
STARTER SWITCH 3
B/W Y/G
○ ○
FRONT BRAKE LIGHT SWITCH 4

B B
OFF
ON ○ ○
6-16
ELECTRICAL
PASS SWITCH 5
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 ○ ○
GEAR POSITION INDICATION LIGHT SWITCH 10

Ground Bl W/Y R/B G/Bl Y/Bl Br/R
○ ○
Neutral
○ ○
1st
○ ○
2nd
○ ○
3rd
○ ○
4th
○ ○
5th
6-17
ELECTRICAL
BATTERY
SPECIFICATIONS
TYPE 12N7-4A
Capacity 7Ah
Standard electrolyte S.G. 1.28 ± 0.01 20OC
● In fitting the battery to the motorcycle, connect the breather

tube to the battery vent.
INITIAL CHARGING
Remove short sealed tube before filling electrolyte. Fill
battery with electrolyte (dilute sulfuric acid solution with acid
concentration of 35% by weight, having a specific gravity of
1.28 at 20 OC/86 OF) up to indicate UPPER LEVEL. Filling
electrolyte should be always cooled below 20 OC/86 OF before
filling into battery. Leave battery standing for half an hour
after filling. Add additional electrolyte if necessary.
Standard Charging current 0.7A
CHARGING TIME
The charging time for a new battery is determined by the
number of months that elapsed since the date of manufacture.
Near the end of the charging period, adjust the specific gravity
of electrolyte level to the UPPER LEVEL with DISTILLED
WATER.
Months after
6-12 Over 12
manufacturing
Necessary
5 8
charging hours
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.
6-18
ELECTRICAL
Check the electrolyte level and add distilled water, as

necessary, to raise the electrolyte to each cell’s upper level.
Check the battery for proper charge by taking an electrolyte
S.G. reading. If the reading is 1.22 or less, as corrected to
20 it means that the battery is still in a run-down condition
and needs recharging.
CAUTION
Disconnect the lead first.
BASED ON S.G. READING
Specific gravity
Normal
RECHARGING OPERATION Recharge
To read the S.G. on the hydrometer, bring the electrolyte in the

Recharge or Replace
hydrometer to eye level and read the graduations on the float
scale bordering on the meniscus (curved-up portion of
Temperature
electroylte) as shown in figure.
Check the reading (as corrected to 20 ) with chart to
determine the recharging time in hours by constant-current
charging at a charging rate of 0.7A,
Be careful not to permit the electrolyte temperature to exceed
45 , at any time during the recharging operation. Interrupt the
operation, as necessary, to let the electrolyte cool down.
Hydrometer
Recharge the battery to the specification.
09900-28403 : Hydrometer
Electrolyte specific gravity: 1.28 ± 0.01 20 c
CAUTION
Before charging a battery, remove the seal cap from each
Specific gravity
cell.
Keep fire and sparks away from a battery being charged.
When removing a battery from the motorcycle, be sure to
remove the terminal first.
CAUTION
Charging time (hour)
Constant-voltage charging, otherwise called “quick”
charging, is not recommendable for it could shorten the life
of the battery.
CAUTION
When a battery is left for a long term without using, it is apt

to be subject to sulfation. When the motorcycle is not used
for more than 1 month (especially during the winter season),
recharge the battery once a month at least.
6-19
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING 7-1
SPECIAL TOOLS 7-8
TIGHTENING TORQUE 7-10
SERVICE DATA 7-12
WIRING HARNESS ROUTING 7-17
CBS TUBE ROUTING 7-18
FRONT BRAKE HOSE ROUTING 7-19
EVAPORATIVE EMISSION CONTROL SYSTEM 7-20
2ND AIR SUPPLY SYSTEM HOSE ROUTING 7-21
WIRING DIAGRAM 7-22
7
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low

or is hard to start. Adjust.
1. Valve clearance out of adjustment
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 or rebore.
6. Poor seating of spark plug. Retighten.
7. Starter motor cranks but too slowly. Consult "electrical
complaints"
Plug not sparking
1. Fouled spark plug. Clean or replace.
2. Wet spark plug. Clean and dry.
3. Defective pick up coil. Replace.
4. Defective ignitor unit. Replace.
5. Defective ignition coil. Replace.
6. Open or short circuit in high-tension cord. Replace.
No fuel reaching the carburetor
1. Clogged hole in the fuel tank cap.
Clean.
2. Clogged or defective fuel cock.
Clean or replace.
3. Defective carburetor float valve.
Replace.
4. Clogged fule hose.
Clean or replace.
5. Clogged fuel filter.
Clean or replace.
Engine stalls easily 1. Fouled spark plug. Clean.

2. Defective pick up coil. Replace.
3. Defective ignitor unit. Replace.
4. Clogged fule hose. Clean.
5. Clogged jets in carburetor. Clean.
6. Valve clearance out of adjustment. Adjust.
7. Clogged fuel filter. 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 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.
Noise seems to come from clutch
1. Worn teeth of clutch plates. Replace.
2. Distorted clutch plates, driven and drive. Replace.
3. Clutch damper weakened. Replace.
7-1
Noisy engine. Noise seems to come from crankshaft

1. Worn of burnt bearings. Replace.
2. Big-end bearings worn and burnt. Replace.
3. Thrust clearance too large. Replace.
Noisy engine. Noise seems to come from transmission

1. Gears worn of rubbing. Replace.
2. Badly worn splines. Replace.
3. Primary gears worn or rubbing. Replace.
4. Badly worn bearings. Replace.
Slipping clutch. 1. Clutch control out of adjustment or loss of Adjust.

play.
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 Adjust.

play.
2.Some clutch springs weakened while others Replace.
are 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. Repair.
2.Shift shafts are rubbing or sticky. Replace.
3.Distrorted or worn gearshift forks.
Transmission jumps 1.Worn shifting gears on driveshaft or Replace.

out of gear. countershaft.
2.Distorted or worn gearshift forks. Replace.
Replace.
3.Weakened stopper pawl spring on gearshift
cam.
Replace.
4.Worn gearshift pawl.
Engine idles poorly. 1.Valve clearance out of adjustment. Adjust.
2.Poor seating of valves. Replace.
3.Defective valve guides. Replace.
4.Worn rocker arm or arm shaft. Replace
5.Defective pick up coil. Replace.
6.Defective ignitor uint. Replace.
7.Spark plug gap too wide. Adjust or replace.
8.Defective ignition coil resulting in weal replace.
sparking.
9.Clogged jets. Clean.
7-2
Engine runs poorly in 1.Valve springs weakened. Replace.

high speed range. 2.Valve timing out of adjustment. Adjust.
3.Worn cams or rocker arms. Replace.
4.Spark plug gap too narrow. Repair.
5.Defective ignition coil. Replace.
6.Clogged air cleaner element. Clean.
7.Clogged fule hose, resulting in inadequate Clean and prime.
fuel supply to carburetor,
8.Defective pick up coil or ignitor unit. Replace.
Dirty or heavy 1.Too much engine oil in the engine. Check and drain excess oil.
exhaust smoke. 2.Worn piston rings or cylinder. Replace.
3.Worn valve guides. Replace.
4.Cylinder wall scored or scuffed. Replace.
5.Worn valves stems. Replace.
6.Defective stem seals. Replace.
Engine lacks power. 1. Loss of valve clearance. Adjust.

2. Weakened valve springs. Replace.
3. Valve timing out of adjustment. Adjust.
4. Worn piston ring or cylinder. Replace.
5. Poor seating of valves. Repair.
6. Fouled spark plug. Clean or replace.
7. Worn rocker arms or its shafts. Replace.
8. Sprak plug gap incorrect. Adjust or replace.
9. Clogged jets in carburetor. Clean.
10. Clogged air cleaner element. Clean.
11. Too much engine oil. Drain out excess oil.
12. Suck air intake pipe. Retighten or replace.
Engine overheats. 1. Heavy carbon deposit on piston crown. Clean.

2. Not enough oil in the engine. Add oil.
3. Defective oil pump or clogged oil circuit. Repair or clean.
4. Air leak from intake pipe. Retighten or replace.
5. Use of incorrect engine oil. Change.
Trouble with starting. 1.Starter jet is clogged. Clean.

2.Starter pipe is clogged. Clean.
3. Air leaking from a joint between starter body Check starter body and
and carburetor. carburetor for tightness,
4.Starter plunger is not operating properly. adjust and replace gasket.
Check and adjust.
Idling or low-speed 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
trouble. 2. Pilot outlet or bypass is clogged. Check and clean.
3. Starter plunger is not fully closed. Check and adjust.
Medium or high-speed 1. Main jet or main air jet is clogged. Check and clean.
trouble. 2. Needle jet is clogged. Check and clean.
3. Throttle valve is not operating properly. Adjust
4. Filter is clogged. Check and clean.
7-3
Overflow and fuel 1. Needle valve is worn or damaged. Replace.

level fluctuations. 2. Spring in needle valve is broken. Replace.
3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle valve. Clean.
ELECTRICAL
No sparking or 1. Defective ignition coil. Replace.

poor sparking. 2. Defective spark plug. Replace.
3. Defective pick up coil or ignitor unit. Replace.
Premature carbon 1. Mixture too rich. Adjust carburetor.
buildup on spark plug 2. Idling speed set too high. Adjust carburetor.
3. Incorrect fuel. Change.
4. Dirty element in air cleaner. Clean.
5. Spark plug too cold. 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
Replace.
guides.
4.Worn stem oil seals. Replace.
Spark plug 1.Spark plug too hot. Replace by cold type plug.
electrodes 2.The engine overheats. Tune up.
overheat or burn.
3.Defective pick up coil or ignitor unit. Adjust.
4.Spark plug loose. Retighten.
5.Mixture too poor. Adjust carburetor.
Generator does 1.Open or short in lead wires, or loose lead Repair or replace or
not charge. connections. retighten.
2.Shorted, grounded or open generator coils. Replace.
3.Shorted or destroyed regulator/rectifler. Replace.
Generator charge, 1.Lead wires tend to get shorted or Repair or retighten.

but charging rate open-circuited or loosely connected at
is below the terminals.
2.Grounded or open-circuited generator stator. Replace.
specification. Replace.
3.Defective regulator/rectifier.
4.Not enough electrolyte in the battery. Add distilled water between
the level lines.
5.Defective cell plates in the battery. Replace the battery.
Generator 1.Internal short-circuit in the battery. Replace the battery.

overcharges. 2.Resistor element in the regulator/rectifier Replace.
damaged or defective. Clean and tighten ground
3.Regulator/rectifier poorly grounded. connection.
Repair or replace.
Unstable 1.Lead wire insulation frayed due to vibration,
charging. resulting in intermittent short circle.
2.Generator internally short circle. Replace.
3.Defective regulator/rectifier. Replace.
7-4
1.Batttery run down. Recharge or replace.

Starter button is not 2.Defective switch contacts. Replace.
effective. 3.Brusnes not seating properly on commutator Repair or replace.
in starter motor.
4.Defective start relay. Replace.
BATTERY
“Sulfation”, acidic 1. Not enough electrolyte. Add distilled water, if the

white powdery battery has not been
substanceor spots on damaged and "sulfation"
surfaceof cell plates. has not advanced too far,
and recharge.
2.Battery cases is cracked. Replace the battery.
3.Battery has been left in a run-down condition Replace the battery.
for a long time.
4.Contaminated electrolyte (Foreign matter If "sulfation" has not
advanced too far, try to
has enters the battery and become mixed with restore the battery by
the electrolyte.) replacing the electrolyte,
recharging it fully with the
battery detached from the
motorcycle and then
adjusting 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 Replace the battery, and
material as result of over-charging. correct the charging system.
3. A short-circuit condition exists within the Replace the battery.
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 the
adjust 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 sure to connect the battery
in the reverse direction. properly.
1. Changing rate too low or too high.
Battery “sulfation”. Replace the battery.
(When not in use, batteries should be
recharged at least once a month to avoid
sulfation.) Keep the electrolyte up to the
2. Battery electrolyte excessive or insufficient, prescribed level, or adjust the
S.G. by consulting the battery
or its specific gravity too high or too low. maker's directions.
3. The battery left unused for too long in cold Replace the battery, if badly
climate. sulfated.
7-5
Battery discharges 1. Dirty container tap and sides. Clean.

too rapidly. 2. Impurities in the electrolyte or electrolyte S.G. Change the electrolyte by
consulting the battery
Is too high. maker's directions.
CHASSIS
Steering feels too 1. Steering stem nut overtightened. 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 Replace.
suspensions.
2. Distorted front fork. Repair or replace.
3. Distorted front axle or crooked tire. Replace.
Wobbly 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 suspension 1. Weakened springs. Replace.

too soft. 2. Not enough fork oil. Refill.
Front suspension 1. Fork oil too viscous. Replace.

too stiff. 2. Too much fork oil. Remove excess oil.
Noisy front 1. Not enough fork oil. Refill.

suspension. 2. Loose nuts on suspension. 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 shock. Retighten.
Rear suspension 1. Weakened springs. Replace.

too soft. 2. Rear suspension adjuster improperly set. Adjust.
Rear suspension 1. Rear suspension adjuster improperly set. Adjust.

too stiff. 2. Warn swing arm bushings. Replace.
Noisy rear 1. Loose nuts on suspension. Retighten.

suspension 2. Worn swing arm bushings. Replace.
7-6
BRAKE
Poor braking. 1. Too much play on brake lever or pedal. Adjust

(front and rear) 2. Linings worn down. Replace
Insufficient 1.Worn pads. Replace.
brake power. 2.Oil adhesion on engaging surface of pads. Clean disc and park
Brake squeaking 1.Tilted pad. Modify pad fitting.
2.Damaged wheel bearing. Replace.
3.Loose front-wheel axle or rear-wheel axle. Tighten to specified torque.
4.Worn pads. Replace.
Excessive brake 1.Worn brake lever cam. Replace
lever stroke.
7-7
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
(1/100mm,0~25mm) (1/100mm,40~80mm) (1/100mm,10~34mm) (1/100mm,10mm) Magnetic bracket
09900-20803 09900-21304 09900-25008 09910-32812 09910-34510

Thickness gauge V-block (set) (100mm) Pocket tester Crankshaft installer Piston pin puller
09913-70210
09910-60611 09913-50121 Bearing installer set 09916-10911 09916-21110
Universal clamp wrench Oil seal remover (Φ10-75) Valve seat cutter set Valve cutter set
09921-20240
Crankcase separating 09921-20240 09924-84510 09930-30104 09930-40113
tool Bearing remover 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
11F14-010 11F14-011 11F14-018

11F14-001 11F14-004 Front absorber Double 4 claws nut Valve remover
Rotor holder Generator rotor remover remover and installer remover and installer
11F14-019 11F14-023 11F14-030 11F14-035

Tappet adjust driver Pressure gauge Gear stopper Pneumatic fluid drawer
7-9
TIGHTENING TORQUE
ENGINE
ITEM N•m Kg•m
Crankcase mounting bolt 10-15 1.0-1.5
Oil filter cover 20-28 2.0-2.8
Crankshaft bearing stopper bolt 8-12 0.8-1.2
Engine sprocket bolt 10-15 1.0-1.5
Cam stopper bolt 10-15 1.0-1.5
Fixing cam pin 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 bolt 8-12 0.8-1.2
Generator stator bolt 5-8 0.5-0.8
Trigger coil bolt 3-6 0.3-0.6
Cluch 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
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
Front 33-39 3.3-3.9
Engine mounting bolt
Rear upper 50-60 5.0-6.0
Rear lower 50-60 5.0-6.0
7-10
CHASSIS
ITEM Kg•m N•m
Front axle nut 3.6-5.2 36-52
Left 2.0-3.0 20-30
Upper bracket bolt Right 2.0-3.0 20-30
Middle 3.5-5.5 35-55
Lower bracket bolt(front fork clamp bolt) 2.5-3.5 25-35
Handlebar clamp bolt 1.2-2.0 12-20
Exhaust pipe bolt 1.3-1.5 13-15
Engine hanging bolt/nut(upper & front) 2.2-3.3 22-33
Front footrest mounting bolt 4.0-6.0 40-60
Rear shock absorber nut Upper 2.2-3.5 22-35

(upper & lower)
Lower 3.5-5.5 35-55
Rear axle nut 5.0-8.0 50-80
Rear b rake disc bolt 1.8-2.8 18-28
Rear sprocket nut 3.0-3.7 30-37
Rear swing arm shaft bolt/nut 5.0-8.0 50-80
Front brake disc bolt 1.8-2.8 18-28
Brake caliper air bleeder valve (Front and rear) 0.7-1.0 7-10
Brake caliper mounting bolt 1.8-2.8 18-28
Brake hose mounting bolt 2.0-2.5 20-25
Master cylinder mounting bolt (Front and rear) 0.8-1.2 8-12
TIGHTENING TORQUE CHART

Conventional or "4" marked bolt "7" marked bolt
Bolt Diameter(mm)
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
SERVICE DATA
CYLINDER HEAD + VALVE Unit: mm
ITEM STANDARD LIMIT

Valve diam. IN. 29
EX. 25
Valve clearance (when cold) IN. 0.04-0.06
EX. 0.09-0.11
Valve guide O.D. IN. 5.000-5.012
EX. 5.000-5.012
Valve stem I.D. IN. 4 .9 75- 4. 9 90
EX. 4 . 955-4.970
Valve 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
IN. 37.4
Valve spring free length (IN.& EX.)
EX. 40.1
Cylinder head distortion 0.05

Cylinder head cover distortion 0.05
CAM + ROCKER Unit: mm

ITEM STANDARD 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
CYLINDER + PISTON + PISTON RING Unit: mm

ITEM STANDARD LIMIT
Compression pressure 1 000-1 400kPa 800kPa
Piston to cylinder clearance 0.025-0.045 0.120
Cylinder bore 57.30-57.31 57.43
Piston diam. Measure at 7 mm from the skirt end 57.265-57.275 57.145
Cylinder distortion 0.05
Piston ring free end gap 1st Approx 5.3 4.24
2nd Approx 6.2 4.96
Piston ring end gap 1st 0.10-0.25 0.50
2nd 0.10-0.25 0.50
Piston ring to groove clearance 1st 0.180
2nd 0.150
1st 1.01-1.03
Piston ring groove width 2nd 1.01-1.03
Oil 1.505-1.525
Piston ring thickness 1st 0.97-0.99
2nd 0.97-0.99
Piston pin bore 14.002-14.008 14.030
Piston pin O.D. 13.996-14.000 13.980
CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 14.01-14.017 14.040
Conrod big end side clearance 0.1-0.3 1.0
Conrod big end width 15.95-16.00
Conrod deflection 3.0
Crankshaft web to web width 55.0-55.05
Crankshaft runout 0.05
7-13
CLUTCH Unit: mm
ITEM STANDARD 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 STANDARD LIMIT
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 126
20 pitch length 259.4 mm
Drive chain slack 10-20 mm
CARBURETOR
Carburetor type CPZ26 Needle jet (N.J.) Ø 2.6

I.D.No. PTG22 Pilot jet (P.J.) #35
Idle (r/min) Pilot screw ( P.S. ) PRE-SET (2,3/8±3/4 turn out)
Bubble pipe Ø 2.8 Jet needle (J.N.)

Main jet (M.J.) #92 Throttle cable play 0.5-1.0 mm
7-14
ELECTRICAL
ITEM SPECIFICATION NOTE
10°B.T. D. C. Below 1 500 r/min

Ignition timing
Type NHSP LD: D8R7C;TORCH:D8RC

Spark plug Gap 0.8-0.9 mm
Primary 0.19-0.23 Ω Terminal-Terminal
Ignition coil resistance
Secondary 11.29-14.91 K Ω Plug cap-Terminal
Trigger 115-155 Ω G/W-Bl/W
Generator coil resistance
Charging 0.5-1.3 Ω B-B
Generator no-load voltage 104V-110V at 5000r/min
Regulate voltage 14V-15V at 5000r/min
Model 12N7-4A
Battery
Capacity 12V 7Ah
Fuse 15 A
LIGHT
HI 35 W Neutral indicator light 3W

Headlight
LO 35 W Dashboard light LED
Tail/Brake light 5/21 W High beam indicator light 1.7 W
Turn signal light 10 W Turn signal indicator light 3W
Position light 5W Gear position indicator light LED
TIRE
ITEM SPECIFICATION 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 22.5 kPa(2.25 kgf/cm²)
Tire size FRONT 2.75-18 4PR
REAR 3.50-16 4PR
7-15
BRAKE + WHEEL Unit：mm

ITEM STANDARD LIMIT
Rear brake pedal height 10.5
Brake disc thickness Front 3.8-4.2 3.5
Brake disc runout 0.30
Brake fluid type Haojue brake fluid
Front 2.0
Wheel rim runout
Rear 2.0
Front 0.25
Wheel axle runout
Rear 0.25
SUSPENSION Unit：mm
ITEM STANDARD LIMIT
Front fork stroke 130
Front fork spring free length 400 392
Fork fork oil type 34#
Front fork oil capacity(each leg) 168
Rear suspension spring 0.adjustment 2nd
Rear swing arm runout 0.6
FUEL +OIL
ITEM STD/SPEC. NOTE
Fuel used should be graded 89-97 octane
Fuel type (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 Oil change 1 000 ml

capacity Overhaul 1 200 ml
7-16
WIRING HARNESS ROUTING

Clutch cable Left handlebar switch
Choke cable Throttle cable Ignition coil 09407-18402
Wiring harness
Ignition coil
Throttle cable
Choke cable
Right handlebar switch

Front brake hose Choke cable
Front brake hose
Gear position display
Tachometer cable
Throttle cable
Tachometer cable
Clutch cable
Dashboard Ignitor switch
Wiring harness 51455H3601X

Clamp opening faces forward
Tachometer cable
Clutch cable
36651-36H50
A Starter relay
09404-06431
Wiring harness
Wiring harness(Ignitor) A Starter relay
Fuel level sensor Wiring harness 09407-05403
09407-05403
Note: Depress A Starter relay Tail light
Note: Bend the clamp Left and right turn Rear license light
end to travel direction. the clamp signal lights Left and right turn Gear position display Ignitor switch
Rear license light signal lights
Do not clamp the naked wire.
Dashboard
Left and right
turn signal lights
36651-05310
Wiring harness 36651-05310
Note: After clamping, Right handle switch
do not contact the Gear position display
clamp to the headlamp Ignitor switch
case mounting bolt. Dashboard
Left and right
Left handlebar Headlamp turn signal lights
PVC jacket switch Note: After clamping,
do not contact the
Headlamp case clamp to the headlamp
internal wire routing case mounting bolt
PVC jacket
09407-14403 09407-14403 Fuel level sensor 09404-06431
Tail light, left and right rear turn signal light
Wiring harness Wiring harness Wiring harness Rear license light, alarm coupler.
09407-12402 09407-12402
Left handlebar switch Right handlebar
Welded clamp switch
Choke cable
Wiring harness
(Rubber grommet) Throttle cable
Throttle cable
Front brake hose
Choke cable
Wiring harness
Ignition coil Clutch cable
high-tension cord
Pass the wiring harness

between the bundy tube and frame
Keep wiring harness away
from ignition coil bracket PVC Jacket
Rear brake switch
Wiring harness - Wiring harness
Throttle cable
coupler.
09407-14403 2nd air filter hose
Choke cable Rear brake switch
Wiring harness (Generator,
A Battery + terminal gear position switch,Rectifier)
A Starter motor wire
Engine ground wire 09407-14403
Wiring harness
Front brake hose (Generator, gear position switch,Rectifier)
Rectifier
36618H7920X
Tachometer cable Generator, gear position switch, Rectifier
Starter motor wire couplers
Welded guide ring Rectifier

Engine ground wire.
A Fuse box 09407-14403
Engine ground wire. Generator
Rear brake switch Gear position switch
Locating wire clamp

Clutch cable (of Ignition coil)
7-17
Bundy tube clamp
Tightening torque
15N·m-19N·m
Wiring harness
Pass the wiring harness
between the bundy tube
and frame.
Pass the bundy tube
trough the guide ring
Install the bundy
tube clamp as shown.
Tightening torque Bundy tube
15N·m-19N·m
Transition joint
Hexagon head flange bolt

Frame
Bundy tube clamp
Bundy tube SECTION A-A
7-18
Pass the bundy tube Frame
trough the guide ring
Transition joint
Frame Hexagon head flange bolt
Combined link valve
Bundy tube
Bundy tube clamp
SECTION B-B
CBS TUBE ROUTING
Bundy tube clamp

SECTION C-C
Rear fender Install the bundy tube
clamp as shown.
Pass the bundy tube through rear fender
Combined link valve
Tightening torque
15N·m-19N·m
Hexagon head
flange bolt View Z
FRONT BRAKE HOSE ROUTING
Throttle cable Left handlebar

Right handlebar switch wire
switch wire
Choke cable
59200H36670H000
Front brake hose I Clutch cable
Tachometer cable
Tachometer cable
59240H36670H000
Front brake hose II 59246H36670H000
01570-0612B-000 Front brake hose clamp
Hexagon head bolt
59200H36670H000
Front brake hose I
Throttle cable
Choke cable
Front brake hose No.1
59240H36670H000 Clutch cable
Front brake hose II Right handlebar Left handlebar
switch wire switch wire
59268H36670H000
Brake hose clamp
09103H08007H000
Hexagon head flange bolts 533111H36300H000
Front fender
01550-0625B-000
Hexagon head flange bolt
59300H36670H000
Front brake caplier 09360-10039-000
Brake fluid bolt
09161-10009-000
Brake fluid washer
59240H36670H00
Front brake hose II
59200H36670H000
Front brake hose I
59246-05300-000
Front brake hose guide clamp 01570-0612B-000
Hexagon head bolt
59245H36670HN000
Front brake hose guide plate 59246H36670H00
Front brake hose guide clamp
59240H36670H000
Front brake hose II
After tightening the bolt, hose

end-fitting boss contacted
the caliper
Front brake hose clamp bracket
Tighten bolt with end-fitting
contacted with stopper
09360-10039-000
Brake fluid bolt
09161-10009-000
Brake fluid washer
7-19
EVAPORATIVE EMISSION CONTROL SYSTEM

DETAIL A
Assembly mark: Stopper
Faces clamp
opening downward
Face clamp
opening to right
DETAIL A
Must pass Item 13,Item 19 and

Item 7 (7') through item 18)
DETAIL B
VIEW Y
Clamp opening
faces right side
Clamp opening
faces right side
VIEW Z
White mark direction: Left side

Assembly white point
DETAIL B
Canister Wire clamp Bracket

Right lower bracket Wire clamp bolt Nut
Purge hose Clamp Clamp
Face the cut Air vent hose Clamp Gasket
rearward
Vacuum hose Clamp Vacuum hose
VIEW X
3 way joint Water drain hose Guide ring
Hose between tip over Hexagon head
valve and hose end-fittiing flange bolt 7’ Purge hose
7-20
2ND AIR SUPPLY SYSTEM HOSE ROUTING

DETAILⅠ
Vacuum hose
Connect the item 5

tube end with boss Clamp opening Clamp opening
to vacuum hose faces rearward faces downward
This end has

This end has a white
a white assembly point. Carburetor insulation
assembly point.
The point faces upward Opening faces
rearward
The point faces forward plate stopper faces
during assembly. to right
Fit the item 8
in this clamp
VIEW A
during assembly.
VIEW B
Fuel hose Carburetor air vent hose
Here has a white ring This end has

assembly mark. a white assembly point.
Pass carburetor air vent The mark faces forward The point faces rearward Clamp opening
Clamp opening Clamp opening Fit Item 21 hosebetween the Pass the fuel hose during assembly. during assembly. faces left side
faces left side faces left side in this clamp item 21 and fuel hose. below the item 21 .
Clamp Air vent hose

Direction
Upper Clamp Clamp

Front
Right 3 way joint Clamp
Vacuum hose Vacuum hose

Left Rear
Lower
Hexagon head flange bolt 2nd air hose
Guide clamp Hexagon head flange bolt

Technical requirement:
1. The routing drawing is only used as assembly guide to 2nd air supply
system and marked parts. The other parts (includes engine and Washer Hexagon head flange bolt
carburetor, etc) and routing is just for illustration. Please refer to
“wire rounting”, “”4 way joint installation” and “evaporative emission
control system” for assembly. Clamp 2nd air valve hose
2. After routing the hoses, keep the hoses smoothly, do not pinch, pull
and clogged the hoses.
3. Refers to “direction” illustration for the clamp direction . Unnoted 2nd air valve bracket Hexagon head flange bolt
clamp direction can be adjusted freely, but the clamp shouldn’t
contact with other parts.
4. The item No. in “ “ means the item is a standard part, and “ “ 2nd air valve Clamp
means a universal part or special part.
5. After each hose is connected properly clamp it firmly to make sure
good seal performance. 2nd air filter hose
7-21
Dashboard
Right handlebar switch Ignitor Ignition coil Rear brake switch
Rectifier
Lighting switch Starter Front brake O W/B
switch light switch Spark plug
O
W/B
B B
O
Lbl
W
B/W
Fuel level sensor
Bl/W
G/W
O/Y
R/W
O
W
B/W
Gr
Y/W
O
Y/G
O/W
Y
Lg
B
Gr
B/W
Y/B
O
W/B
R/W
O
Bl
Br/R
R/B
Y/Bl
W/Y
G/Bl
B
R
B
B/W
B/W
Y/B
Y
Lg
B
Gr
B/W
Y/B
O
R/W
Bl
Br/R
R/B
Y/Bl
W/Y
G/Bl
Gr
O
O
Y/W
Y/G
W/B
B/W
Y/B
Front right turn
signal light Rear right turn
Lg signal light
Lg
B/W B/W B/W
Lb Lb
Gr
Position light B/W
W W W/B W/B
Headlamp B/W B/W B/W B/W
Y Y B/W Gr Gr
Gr
B/W
Gr License light
Position light Gr
Front left turn B/W
Rear left turn
signal light
B/W signal light
7-22
B B
B B
B/W
R
R
O
B/Y
Y/G
O/Y
B/W
Lg
R
B
O
B/W
Bl/W
R
Bl/W
G/W
O
R
O/Y
B
O
Lb
Lg
Y
B/Bl
B/W
W
B/Y
Y/W
R Y O Y B Gr
B/W
Starter relay
B
B
Bl/W
G/W
Br/R
Y/Bl
R/B
Bl
W/Y
G/Bl
B/Bl
Ignition switch
Y
O
B
W
B/Y
Lg
Lb
B/W
B/Bl
Alarm Clutch Starter motor
Battery
Br/R
Y/Bl
R/B
Bl
W/Y
G/Bl
switch
Horn
Generator Engine ground
Y/W
Dimmer switch Pass switch Horn switch Turn signal
light switch
Left handlebar switch
Gear position switch

Chopper Road 150 Manual de Serviços (Ingles) tz150

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Chopper Road 150 Manual de Serviços (Ingles) tz150

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TZ150

This manual has been prepared on the basis of the 8

Improper repair may result in injury to the

Inexperienced mechanics or mechanics without

HAOJUE HOLDING CO.,LTD.

©COPYRIGHT HAOJUE HOLDING CO.,LTD. 2017

COMPONENT PARTS AND WORK TO BE DONE

Example: Front wheel

ITEM N•m Kgf•m

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply oil. Use engine oil unless

Apply or use the absorber oil

Apply SUPER GREASE “A”

Apply MOLY PASTE

Apply sealant “1215”

Apply sealant “1207B”

Apply THREAD LOCK “1342"

Apply THREAD LOCK “1303"

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.

SERIAL NUMBER LOCATIONS BREAK-IN PROCEDURE

The throttle must not be opened to the full during

Ignition type Electronic ignition (CDI)

Front absorber Telescopic, coil spring, oil damped

* The specifications subject to change without notice.

PERIODIC MAINTENANCE CHART

Interval Km Every 6 000km Every 12 000km

Standard specific gravity: 1.28± 0.01 20 oC

Assemble the battery in the reverse order of the

When installing the battery lead wires, fix the lead

Air vent hose

If driving under dusty condition, clean the air filter

Check and clean the filter in the following manner.

● Take out the air filter element assembly.

Fill a washing pan of a proper size with nonflammable B

Do not twist or wring the filter because it will tear or the

Reinstall the air filter in the reverse order of removal.

AIR CLEANER DRAIN PLUG

Make sure the drain plug if fitted correctly after cleaning.

Inspect initial 1 000km and every 3 000km

Tighten the muffler bolts 1 and 2 to the specified torque.

Muffler bolt 1 : 13-15 N•m

CYLINDER HEAD NUTS

Inspect initial 1 000km and every 3 000km

Tighten the four cap nuts 3 to the specified torque with a

Cylinder head nut: 25-35 N•m

Excessive valve clearance results in valve noise and

● Remove the left and right side covers.

Turn off the fuel cock, disconnect the fuel hose 2

Disconnect the fuel level sensor coupler 4 .

Remove the valve inspection caps 6 .

● Rotate the generator rotor counter clockwise to set the

If the valve clearances is out of specification, bring it into

09900-20803: thickness gauge

Reassemble the removed parts in the reverse order of

Remove the carbon deposits with a wire of pin and adjust

TYPE NHSP LD TORCH

Standard D 8RTC DR8C

Cold type D 9RTC DR9C

Required amount of engine oil:

Start up the engine and allow it to run for several

OIL SUMP FILTER