1.

GENERAL INFORMATION

GENERAL INFORMATION
SERIAL NUMBER --------------------------------------------------------------1-1
PECIFICATIONS ----------------------------------------------------------------1-2
SERVICE PRECAUTIONS ----------------------------------------------------1-3
TORQUE VALUES--------------------------------------------------------------1-11
SPECIAL TOOLS----------------------------------------------------------------1-12
LUBRICATION POINTS-------------------------------------------------------1-13
CABLE ＆ HARNESS ROUTING ------------------------------------------1-17
WIRING DIAGRAM (ON ROAD)--------------------------------------------1-23
TROUBLESHOOTING ---------------------------------------------------------1-24

1-0
1.GENERAL INFORMATION

SERIAL NUMBER

(1) Location of Frame Serial Number

(Vehicle Identification Number)

(2) Location of Engine Serial Number

1-1
1.GENERAL INFORMATION

SPECIFICATIONS
Name & model No. SP450 Air cleaner type&No Dry type element

Fuel System
Motorcycle Name & Type SPEED Fuel capacity 14 L
Overall length 1825 mm (71.8 in) Type BDS42

tor
Carbure
Overall width (mm) 1205 mm (47.4in)
Main jet NO. 162.5
Overall height (mm) 1255 mm (49.4 in)
Venture dia. ψ42 mm (1.65 in)
Wheel base (mm) 1270 mm (50 in)
Full transistor digital

Electrical equipment

Ignition System
Type
Four-stroke, DOHC, ignition
Engine type Ignition timing 6˚BTDC/1500rpm
Liquid-cooled
Spark plug CR8E
Spark plug gap
Displacement 248.8 cm³
0.7~0.8mm (0.028~0.032in)
Fuel Used 95# nonleaded gasoline
Front wheel 109 kg (240 lbs) Battery Capacity 12V/10AH
Dry weight Rear wheel 110 kg (242 lbs) Clutch Type Wet multi-plate
Total 219 kg (482 lbs)

sion
Transmis-
Front wheel 111 kg (224 lbs)
5-forward and 1-reverse
Curb weight Rear wheel 118 kg (260 lbs) operation
Type
Total 229 kg (504 lbs)
Front wheel 21*7-10
Power Drive System

Tires
pattern
Gearshift

Rear wheel 20*11-9 Forward 1-down 4-up, foot operated

Ground clearance 260 mm (10.2 in)
Starting system Electric starter Reverse Foot / hand operated
Type 4-stroke, DOHC
Cylinder arrangement Single cylinder 1st 2.538
2st 1.684
Gear ratio

Valve arrangement O.H.C., 4 valve

96 × 62 mm 3st 1.261
Bore × stroke (mm) 4st 1.040
(3.78 × 2.44 in)
Compression ratio 11.8：1 5st 0.885
reverse 2.231
Compression pressure 16 kgf/cm²(at 500 rpm)
Final reduction 3.143
0.1~0.2 mm
Engine

Intake
Valve clearance (0.004~0.008 in) Drive chain 520 O-Ring Chain
(cold) 0.2~0.3 mm FR/RR tire rolling
Exhaust
Moving Device

(0.008 ~0.012 in) 1676/1596 mm(66/62.8 in)

circumference
Idle speed (rpm) 1800 rpm Front 0.32 kg/cm²
Tire pressure
Lubrication type Wet sump Rear (35 Kpa,5 psi)
system
Lubrication

Oil change 2.5 L Turning Left 40°

angle 40°
Oil and filter Right
2.6L
change Brake system Rear Disk brake
Engine overhaul 2.7L type Front Disk brake
Cooling Type Liquid cooled
Device
Damping

Front Independent, double A-arm

Suspension
type
Rear Linkage-type

1-2
1.GENERAL INFORMATION

SERVICE PRECAUTIONS

„ Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when
reassembling.

„ When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

„ Use genuine parts and lubricants.

„ When servicing the machine, be sure to

use special tools for removal and
installation.

„ After disassembly, clean removed parts.

Lubricate sliding surface with engine oil
before reassembly.

1-3
1.GENERAL INFORMATION

„ Apply or add designated greases and

Lubricants to the specified lubrication
points.

„ After reassembly, check all parts for

Proper tightening and operation.

„ When two persons work together, pay

Attention to the mutual working safety.

„ Disconnect the battery negative (-)

terminal before operation.
„ When using a spanner or other tools,
make sure not to damage the motorcycle
surface.

„ After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.
„ When connecting the battery, the positive
(+) terminal must be connected first.
„ After connecting, apply grease to the
battery terminals.
„ Terminal caps shall be installed securely.

1-4
1.GENERAL INFORMATION

„ If the fuse is burned out, find the cause

and repair it. Replace it with a new one
according to the specified capacity.

„ After operation, terminal caps shall be

Installed securely.

„ When taking out the connector, the lock

on the connector shall be released before
operation.

„ Hold the connector body when connecting

or disconnecting it.
„ Do not pull the connector wire.

„ Check if any connector terminal is

Bending, protruding or loose.

1-5
1.GENERAL INFORMATION

„ The connector shall be inserted

completely.
„ If the double connector has a lock, lock
it at the correct position.
„ Check if there is any loose wire.

„ Before connecting a terminal, check

for damaged terminal cover or loose
negative terminal.

„ Check the double connector cover for

proper coverage and installation.

„ Insert the terminal completely.

„ Check the terminal cover for proper
coverage.
„ Do not make the terminal cover opening
face up.

„ Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

1-6
1.GENERAL INFORMATION

„ After clamping, check each wire to make

sure it is secure.

„ Do not squeeze wires against the weld or

its clamp.

„ After clamping, check each harness to

make sure that it is not interfering with
any moving or sliding parts.

„ When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

„ Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of
bolts and screws.
„ Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.

1-7
1.GENERAL INFORMATION

„ Route harnesses so they are neither

pulled tight nor have excessive slack.

„ Protect wire and harnesses with

electrical tape or tube if they contact a
sharp edge or corner.

„ When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

„ Do not break the sheath of wire.

„ If a wire or harnesses is with a broken
Sheath, repair by wrapping it with
Protective tape or replace it.

„ When installing other parts, do not press

or squeeze the wires.

1-8
1.GENERAL INFORMATION

„ After routing check that the wire

harnesses are twisted or kinked.

„ Wire harnesses routed along with

handlebar should not to be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

„ When a testing device is used, make sure

to understand the operating methods
thoroughly and operate according to the
operating instructions.

„ Be careful not to drop any parts.

„ When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

1-9
1.GENERAL INFORMATION

„ Symbols：
the following symbols represent the
servicing methods and cautions included
in this service manual.

：Apply engine oil to the specified points。

(Use designated engine oil for lubrication。)

Engine oil

：Apply grease for lubrication。

Grease

：Transmission Gear Oil。

（SAE80W90）

Gear Oil

Special ：Use special tool。

：Caution

：Warning

1-10
1.GENERAL INFORMATION

TORQUE VALUES
STANDARD TORQUE VALUES
Torque
Torque
Item Item kgf-m (N-m,
kgf-m (N-m, lbf-ft)
lbf-ft)
5mm bolt and nut 0.5 (5, 3.6) 4mm screw 0.3 (3, 2.2)
6mm bolt and nut 1 (10, 7.2) 5mm screw 0.4 (4, 2.9)
8mm bolt and nut 2.2 (22, 16) 6mm screw, SH bolt 0.9 (9, 6.5)
10mm bolt and nut 3.5 (35, 25) 6mm flange bolt and nut 1.2 (12, 9)
12mm bolt and nut 5.5 (55, 40) 8mm flange bolt and nut 2.7 (27, 20)
14mm bolt and nut 7 (70, 50) 10mm flange bolt and nut 4 (40, 29)
Torque specifications listed below are for important fasteners.

ENGINE
Thread dia Torque
Item Q’ty Remarks
(mm) kgf-m (N-m, lbf ft)
Water temperature switch. 1 10 1.3 (13, 9.4)
Coolant drain bolt. 1 6 1.1~1.4 (11~14, 8~10)
Cooling fan thermo mounting bolt. 1 10 1.3 (13, 9.4)
Magneto rotor nut. 1 12 12 (120, 86.8)
Magneto cover bolt. 8 6 1.0 (10, 7.2)
Cylinder head bolt. 4 10 4.7 (47, 34)
Cylinder head cover bolt. 3 7 1.4 (14, 10)
Cylinder head base bolt. 1 6 1.0 (10, 7.2)
Cylinder base nut. 2 6 1.0 (10, 7.2)
Engine sprocket bolt. 2 6 1.1~1.3(11~13, 8~9.4)
Engine oil check plug. 1 12 1.8(18, 13)
Engine oil drain plug. 1 14 2.1(21, 15) Crankcase
Engine oil drain plug. 1 14 1.2(12, 8.7) Oil tank
Engine oil inlet hose union bolt. 1 12 2.3(23, 16.6)
Spark plug. 1 12 1.1 (11, 8)
Camshaft housing bolt. 8 6 1.0 (10, 7.2)
Cam chain tensioner mounting bolt. 1 6 1.0 (10, 7.2)
Cam chain tension adjuster mounting bolt. 2 6 1.0 (10, 7.2)
Cam chain tension adjuster bolt. 1 6 2.0(20, 14.5)
Crankcase bolt. 10 6&8 1.1 (11, 8)
Clutch sleeve hub nut. 1 20 9.0(90, 65)
Primary drive gear nut. 1 14 14(140, 101)
Gearshift cam stopper. 1 6 3.2(32, 23)
Gear position switch bolt. 1 5 0.65(6.5, 4.7)

1-11
1.GENERAL INFORMATION

FRAME
Thread dia Torque
Item Q｀ty Remarks
(mm) kgf-m (N-m, lbf ft)
Steering stem nut 1 14 7 (70, 50)
Front swing arm nut 8 10 4.5 (45, 32)
Front wheel nut 8 10 4.5 (45, 32)
Rear wheel nut 8 10 4.5 (45, 32)
Front wheel hub nut 2 14 7 (70, 50)
Rear wheel hub nut 2 18 10 (100, 72)
Front shock absorber upper mount bolt 2 10 4 (40, 29)
Front shock absorber lower mount bolt 2 10 4 (40, 29)
Rear shock absorber upper mount bolt 1 10 4 (40, 29)
Rear shock absorber lower mount bolt 1 10 4 (40, 29)
Rear swing arm axle 1 16 9 (90, 66)
Rear hub nut 4 12 6 (60, 43)
Rear wheel shaft nut 2 38 12 (120, 86)
Front engine bracket upper bolt 1 10 4.5 (45, 32)
Rear engine bracket lower bolt 1 10 4.5 (45, 32)
Engine hanger bracket bolt 1 10 4.5 (45, 32)
Engine hanger bracket bolt 1 14 7 (70, 50)
Exhaust muffler lock bolt (frame) 1 10 4.5 (45, 32)
Exhaust muffler lock nut (engine) 2 8 2 (20, 14.4)

SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Clutch sleeve hub holder 71600-E12-000 4-5,9-5
Valve spring compressor 71605-E12-000 7-12
Rotor remover 71604-E12-000 9-9
Conrod holder 71612-E12-000 9-9,9-30,9-31
Crankshaft installer 71613-E12-000 9-26
Crank case separator 71607-E03-000 9-11,9-13
Bearing puller 71606-E10-000
Ball join remover 71608-A03-000 12-9
Oil seal and bearing install 71620-E10-000 12-6

1-12
1.GENERAL INFORMATION

LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part z Engine Oil (SAE10W-40)
Cam lobes z API SL Engine Oil
Valve rocker arm friction surface
Cam chain -22 -4 14 32 50 68 86 104°F
Cylinder lock bolt and nut 20W50
Piston surroundings and piston ring grooves
15W40 15W50
Piston pin surroundings
Cylinder inside wall 10W40 10W50

Connecting rod/piston pin hole 10W30

Connecting rod big end 5W30
Crankshaft right side oil seal
Oil pump drive chain
Balance gear -30 -20 -10 0 10 20 30 40°C
A.C. generator
Starter one-way clutch
Bearing movable part
O-ring face
Oil seal lip

1-13
1.GENERAL INFORMATION

FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
Abnormal noise and rise the durability of the ATV.

Throttle Cable Steering Column Upper

Front Swing Arm Bush Front Swing Arm Bush

Steering Column Lower

1-14
1.GENERAL INFORMATION

Rear Swing Arm Axle

Driven Sprocket

Sprocket hub/Rear
Axle Hub Collar/Oil
Seal/Bearing

1-15
1.GENERAL INFORMATION

(1) Clutch lever holder

(2) Steering shaft holder

(3) Throttle lever (4) Front brake lever holder

(6) Drive shaft joint spline (5) Rear brake pedal and rod link

1-16
1.GENERAL INFORMATION

CABLE ＆ HARNESS ROUTING

Speedometer Cable

Blink Relay
Parking Cable
Throttle Cable

Hand Brake Hose Clutch Cable

Front Brake Cable

Reverse Cable
Handlebar，Switch Wire

Hose, Pressure Release Power Supplier Wire

Main Wire Ass’y

CDI Unit
Horn (ON ROAD)

Left Front Brake Fluid Hose

Right Front Brake Fluid Hose

Head Light Cable

Main Switch

Front Right Turn Signal Light

(ON ROAD)

1-17
1.GENERAL INFORMATION

Battery Cable
Main Wire Ass’y

Cable，Manual Choke

Gear Position Switch

Hose Comp, Oil

Outlet Water Hose

Rectifier & Regulator

Rear Left Turn Signal Light

(ON ROAD)

1-18
1.GENERAL INFORMATION

Rear Right Turn Signal Light

(ON ROAD)

Hose Comp, Oil

Start Motor Cable

Water Hose
Inlet Water Hose

1-19
1.GENERAL INFORMATION

Footbrake Switch Wire

Hose，Foot brake
Hydraulic Pump

1-20
1.GENERAL INFORMATION

Hose, Pressure Release

For Cylinder Head Cover
Hose, Pressure Release
For Air Cleaner
Oil Filter，Box

Cable，Rear Disk Brake

Hose，Rear brake

Speed Cable

1-21
1.GENERAL INFORMATION

Fuse Box
Starter Relay

Starter Motor
Battery
Cable

Ground Wire

1-22
 OPTION EQUIPMENT
RH. FR. LEDWINKER FAN MOTOR C.D.I UNIT BATTERY(MF)
(12V 0.82W) HAND BRAKE. FOOT BRAKE COMB. SW. FUSE DC POWER OUTLET ENG.STOP SWITCH THERMO.SW (CDI) THERMO.UNIT START MAG. SW. START MOTOR 12V 10AH
BAT

DG DG
B
15A

B
G/Y

G/Y
BR

POSITION BULB
BR

L/W
BR
B
R/W

Lb
Lb
(12V 5W)

G/Y
R
BR
BR
O/B

L
R

O/W
B

B
R

L/Y

R
B/Y
BR

Lb
B
M

O
BR
W/L
G/Y

BR

BR

B
BR

L/W
L
G/Y
BR

G/Y
O/W

HEAD LIGHT BULB

(HS1 12V 35/35W)

R
G
Y
B
RH. RR. LED WINKER
(12V 0.82W)
B
DG
Dg Dg
R-WINKER
PILOT G/Y
L-WINKER DBr DBr Br
PILOT B
HIGH Y Y
BEAM LED TAIL/STOP LIGHT
1.GENERAL INFORMATION

(12V 2.2W/4.2W)
CLOCK R
RPM L B/Y
SWITCH KEY BR Br B
DBr
LH. RR. LED WINKER
(12V 0.82W)
SENSOR G
SENSOR Br
+5V Pr
SPEEDOMETER MAGNET

B/Y
FUEL

BR
Y/W Y/W

Y/W
METER SENSOR

B
Lb L/Y
WIRING DIAGRAM (ON ROAD)

TEMPERATURE
PILOT

Lb
B
NEUTRAL GY

Y/W
PILOT

G
O
REVERSE
PILOT
W/L
D

G
L
Y
Y

Y
GND
W N

BR/W
DBR
L/W

DG
O R

G
Br

P
B
Y
L
B
P
COMB. METER ASS'Y

R/W
B

Y
Y
Y
BR/W
FUEL UNIT IG. COIL CHANGE SW.

Br
B
ACG.

BR/W
L/W
B/L
Max.=30A

P
Br

DG

Y
Max.=280W

G
L
LED
FLUSHER HORN EARTH REG./REC.
ST SG HO ACC R WR L ACC Hi LO RELAY
COMB. SW.
START HORN WINKER DIMMER
SW. SW. SW. SW.
LEFT SWITCH
HORN WINKER DIMMER
(12V 0.82W) Br P Br/W DBR DG L G Y
LH. FR. LED WINKER PUSH
FREE
DBr
B
START WARNING
B/L L/W Br/W DBR DG
PUSH
FREE

1-23
1.GENERAL INFORMATION

TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Compression too low
1. Valve clearance out of adjustment. Adjust
2. Worn valve guides or poor seating Repair or replace
of valve.
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
Plug not sparking complaints”

Engine will not start, 1. Fouled spark plug. Clean or replace

or is hard to start. 2. Wet spark plug. Clean and dry
3. Defective ignition coil. Replace
4. Open or short circuit in high tension Replace
cord.
5. Defective magneto. Replace
6. Defective igniter. 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 fuel pipe. Clean or replace.
1. Fouled spark plug. Clean
2. Clogged fuel hose. Clean
Engine stalls easily 3. Clogged jets in carburetor. Clean
4. Valve clearance out of adjustment. Adjust
5. Defective CDI unit. Replace

Excessive valve chatter

1. Valve clearance too large. Adjust
Noisy engine 2. Weakened or broken valve springs. Replace
3. Worn down camshaft. Replace

1-24
1.GENERAL INFORMATION

Complaint Symptom and possible causes Remedy

Noise appears to come from piston
1. Piston cylinder worn down. Replace
2. Weakened or broken valve springs. Replace
3. Worn down piston pin or piston pin Replace
bore.
4. Piston rings or ring groove worn. Replace
Noise seems to come from camshaft
drive chain
1. Stretched camshaft drive chain. Replace
2. Worn camshaft sprockets. Replace
3. Cam chain tensioner adjuster not Repair or replace
Noisy engine working.
Noise seems to come from clutch
1. Worn splines of countershaft or hub. Replace
2. Worn teeth of clutch plates. Replace
3. Distorted clutch plates, driven and Replace
drive.
Noise seems to come from
crankshaft
1. Worn or broken bearings. Replace
2. Big-end bearings worn and broken. Replace
3. Thrust clearance too large. Replace
Noise seems to come from
transmission
1. Gears worn or rubbing. Replace
2. Badly worn splines. Replace
3. Primary gears worn or rubbing. Replace
4. Badly worn bearings. Replace
Noise seems to come from water
pump
1. Too much play on pump shaft Replace
bearing.
2. Worn or damaged impeller shaft. Replace
3. Contact between pump case and Replace
impeller.

1. Clutch control out of adjustment or Adjust

Slipping clutch too much play.
2. Weakened clutch springs. Replace
3. Worn or distorted pressure plate. Replace
4. Distorted clutch plates, driven and Replace
drive.

1-25
1.GENERAL INFORMATION

Complaint Symptom and possible causes Remedy

1. Clutch control out of adjustment or Adjust
too much play.
Dragging clutch 2. Weakened clutch springs. Replace
3. Distorted clutch plates, driven and Replace
drive.
1. Broken gearshift cam. Replace
Transmission will not 2. Distorted gearshift forks. Replace
shift 3. Worn gearshift pawl. Replace
1. Broken return spring on shift shaft. Replace
Transmission will not 2. Shift shaft are rubbing or sticky. Repair
shift back 3. Distorted or worn gearshift forks. Replace
1. Worn shifting gears on driveshaft or Replace
countershaft.
Transmission jumps 2. Distorted or worn gearshift forks. Replace
out of gear 3. Weakened stopper pawl spring on Replace
gearshift cam.
4. Worn gearshift pawl. Replace
1. Valve clearance out of adjustment. Adjust
2. Poor seating of valves. Replace
3. Defective valve guides. Replace
Engine idles poorly 4. Defective pick-up coil. Replace
5. Spark plug gap too wide. Adjust or replace
6. Defective ignition coil resulting in Replace
weak sparking.
7. Float-chamber fuel level out of Adjust
adjustment in carburetor.
8. Clogged jets. clean
1. Valve spring weakened. Replace
2. Valve timing out of adjustment. Adjust
Engine runs poorly in 3. Worn cams. Replace
high speed range 4. Spark plug gap too narrow. Repair
5. Defective ignition coil. Replace
6. Float-chamber fuel level too low. Adjust
7. Clogged air cleaner element. Clean
8. Clogged fuel hose, resulting in Clean or replace
inadequate fuel supply to carburetor
1. Too much engine oil in the engine. Check with inspection
window, drain out excess oil.
2. Worn piston rings or cylinder. Replace
Dirty or heavy exhaust 3. Worn valve guides. Replace
smoke 4. Cylinder wall scored or scuffed. Replace
5. Worn valve stems. Replace
6. Defective stem seals. Replace
7. Worn side rails. Replace

1-26
1.GENERAL INFORMATION

Complaint Symptom and possible causes Remedy

1. Loosen of valve clearance. Adjust
2. Weakened valve springs. Replace
3. Valve timing out of adjustment. Adjust
4. Worn piston rings or cylinder. Replace
5. Poor seating of valve. Repair or replace
6. Fouled spark plug. Clean or replace
Engine lacks power 7. Worn camshaft. Replace
8. Spark plug gap incorrect. Adjust or replace
9. Clogged jets in carburetor. Clean
10. Float-chamber fuel level out of Adjust
adjustment.
11. Clogged air cleaner element. Clean
12. Too much engine oil. Drain out excess oil
13. Defective air intake pipe. Retighten or replace
1. Heavy carbon deposit on piston head. Clean
2. Not enough oil in the engine. Add oil
3. Defective oil pump or clogged oil Repair or replace
Engine overheats circuit.
4. Fuel level too low in float chamber. Adjust
5. Air leak from intake pipe. Retighten or replace
6. Use of incorrect engine oil. Change
7. Defective cooling system. See “cooling system”
section.
No sparking or poor 1. Defective ignition coil. Replace
sparking. 2. Defective spark plug. Replace
3. Defective igniter. Replace
1. Mixture too rich. Adjust carburetor
Spark plug soon 2. Idling speed set too high. Adjust carburetor
becomes fouled with 3. Incorrect gasoline. Change
carbon. 4. Dirty element in air cleaner. Clean or replace
5. Spark plug too cold. Replace by hot type plug
1. Worn piston rings. Replace
Spark plug become 2. Pistons or cylinder worn. Replace
fouled too soon. 3. Excessive clearance of valve stems in Replace
valve guides.
4. Worn stem oil seal. Replace
1. Spark plug too hot. Replace by cold type plug.
Spark plug electrodes 2. The engine overheats. Tune up.
overheat or bum. 3. Spark plug loose. Retighten
4. Mixture too lean. Adjust carburetor.

1-27