Slide spacer bush onto crankshaft and 4

1
torque the bolt to specified value.
Bolt tightening torque:105N m
Rotate starter double gear counterclockwise to align
5
intermediate gear teeth with clutch sprag gear teeth.

NOTE:Breather shaft end with chamfer should 3

faces outside.
1.Double Gear 2.Breather Gear Shaft
3.Intermediate Gear 4.Sprag Clutch Gear
SPRAG CLUTCH 5.Spacer Bush 6.Bolt

NOTE:It is not necessary to remove if sprag clutch

has no problem.
2
3 4
Sprag Clutch Removal
1
Remove magneto cover (refer toMAGNETO
COVER above);

Remove rotor(refer to ROTOR above);

Remove sprag clutch gear;

1.Bolt
Remove sprag clutch housing screws and sprag
2.Rotor
clutch housing.
3.Sprag Clutch
Sprag Clutch Inspection 4.Sprag Clutch Housing

Perform a functional test of the sprag clutch.To do

so ,rotate driven gear in sprag clutch.

Inspect sprag clutch and sprag clutch housing for

wear and damage. 1

NOTE:
Sprag clutch must look in counterclockwise direction.
Sprag clutch,housing and gear must be replaced at
the same time ,if damaged.
Sprag Clutch Functional Test
1.Lock Direction

11-8
 11 MAGNETO SYSTEM

Sprag Clutch Installation

For installation,reverse the removal procedure .
3

Pay attention to the following details.

Apply threadlocker on threads of sprag clutch
housing screws.

Install rotor then torque sprag clutch housing screws

2 4
to 30 N m.
Apply engine oil on sprag clutch and inside sprag 1
clutch gear hole.

1.Sprag Clutch 2.Sprag Clutch Housing

3.Sprag Clutch Gear 4.Apply engine oil here

SPRAG CLUTCH GEAR

Removal

Remove rotor (refer toROTOR above);

Pull sprag clutch gear from the rotor.

11
1
2

1.Rotor
Inspection 2.Sprag Clutch Gear
Inspect gear,especially teeth and sprag clutch
collar,for wear and other damages.
3 2

Check needle bearing condition;

Replace Drive Gear if necessary.

Installation
Reverse the removal procedure for installation.

1
NOTE:
Apply engine oil on needle bearing and collar of drive INSPECT
gear. 1.Teeth
2.Collar
3.Needle Bearing

11-9
STARTER DRIVE GEARS
4
The starter gears are located on the engine MAG
side behind the magneto cover. 4

Removal 3

Remove magneto cover (refer toMAGNETO 2

COVER above);
1
Remove breather shafts,double gear,intermediate 1.Intermediate Gear
gear. 2.Starter Double Gear
3.Starter Gear
Inspection 4.Breather Shaft

Inspect gears and shafts for wear and damage.

Installation
Reverse the removal procedure for installation.

NOTE:
Apply engine oil on every gear shaft and teeth.

11-10
 12 FRONT WHEELS, BRAKE, SUSPENSION, STEERING

Check& repair information......................... 12-1 Brake system........................................ 12-4

Troubleshooting....................................... 12-2 Front suspension.................................. 12-7
Front Wheel............................................. 12-3 Steering system.................................... 12-12

MAINTENANCE INFORMATION
Operation Cautions:
CAUTIONS:

• Securely support the vehicle when performing, inspection and repair.

• The inspection and maintenance of light, instrument and switch, refer to Chapter 12.
• Do not overexert on the wheel. Be careful not to damage to the wheel.
• When removing tire, use the special tire lever and rim protector.

Maintenance Standard
Item Standards Service Limit
Radial 0.8 mm 2.0 mm
Wheel Run Out
Axial 0.8 mm 2.0 mm
Front Wheel
Tread Depth — 3.0 mm
Tire
Tire Pressure 70 kPa(0.70 kgf / cm2) —

Tightening Torque
Nut, steering tie-rod GB9457 M10x1.25 (30~40) N·m
Lock nut, steering stem GB9457 M10x1.25 (100~120)N·m
Bolt, front brake disc 901-08.00.03 (25~35) N·m
Bolt, front caliper GB5789 M8x20 (15~25) N·m
Axle nut 901-07.00.03 (15~25) N·m
Bolt, front shock absorber GB5789 M10x1.25x55 (15~25) N·m
Wheel nut 901-07.00.02A (70~80) N·m
Bolt, A-arm 9060-050103 (40~50) N·m

12-1
12 FRONT WHEELS, BRAKE, SUSPENSION, STEERING

SERVICE TOOLS
• Rod, bearing remover
• Head 10 mm, bearing remover
• Handle A, driving tool
• Sleeve 28 x 30, driving tool
• Guide tool 10 mm
• Locknut spanner
• Bearing remover set
• Rotor puller
• Remover shaft
• Remover hammer
• Assembling tool shaft

TROUBLESHOOTING
Heavy steering
• Upper thread is over tightened • Faulty wheel bearing
• Steering bearing is damaged or worn • Wheel installed improperly
• Inner&outer bearing races are damaged • Brake drag
• or not well tightened. Front suspension too soft
• Steering stem is distorted • Weakened front shock absorber
• Low tire pressure • Tire pressure is too low
• Tire worn Front suspension too hard
Excessive handlebar free play • Front shock absorber is damaged
• Steering bearing is damaged or not well tight- • Tire pressure is too high
ened. Noise from front shock absorber
• LH and RH shock absorber not matched • Faulty front shock absorber
• Deflected tires • Loosened tightening parts of front shock ab-
• Deformed frame sorber
• Worn tire Poor brake performance
• Shaking wheel bearing • Faulty brake adjustment
Severe front wheel run out • Stained brake disc
• Wheel rim distorted • Brake pads worn
• Faulty wheel bearing
• Faulty tires
• Improper balance of wheels
• Improper tightening of wheel shaft
Wheel cannot turn freely

12-2