Pantera 50cc Yellow Scooter Manual

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL
Introduction
PanTerra 49cc & 90cc Dirt Bikes

by Nikota USA
INTRODUCTION
Introduction
Important Safety Notice
WARNING! WARNINGS INDICATE A STRONG POSSIBILITY OF SEVERE PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED CAUTION: CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED.
Note: Notes give helpful information. This manual does not contain detailed descriptions of standard workshop procedures, safety principles, and service operations. It is important to note that this manual contains some warnings and cautions against some specific service methods that could cause PERSONAL INJURY to service personnel or that could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service (whether or not recommended by PanTerra Motorworks) might be done or of the possibly hazardous consequences of each conceivable way, nor could PanTerra Motorworks investigate all such ways. It is the responsibility of the individual performing the work to ensure her or his own safety when servicing the vehicle and following any of the recommendations in this manual. Furthermore, when servicing the vehicle, the individual performing the work must use appropriate discretion when deciding which tools and procedures to use.
II
INTRODUCTION
Introduction
Introduction
This service manual describes the service procedures for the PanTerra 50/90cc dirt bike. This Model Specific Manual includes every service procedure that is of a specific nature to this particular model. Basic service procedures that are common to other PanTerra Motorcycle/ Motor Scooter/ATVs can be found in the Common Service Manual. This Model Specific Service Manual should be used together with the Common Service Manual in order to provide complete service information on all aspects of this motorcycle. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole ATV. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 4 through 13 describe parts of the motorcycle, grouped according to locations. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections describe the service procedure through system illustration. Refer to the next page for details on how to use this manual. If you dont know the source of the trouble, go to section 16 Troubleshooting. All information, illustration, direction and specifications included in this publication
INTRODUCTION
are based on the latest product information available at the time of approval for printing. PanTerra Motorworks and Nikota USA reserve the right to make changes at any time without incurring any obligation whatsoever. No part of this publication may be reproduced without written permission. This manual is written for persons who have acquired basic knowledge of maintenance on PanTerra motorcycles, motor Scooters or ATVs. PanTerra Motorworks Nikota USA Technical Communications office July, 2004
III
Introduction
Table of Contents
Chapter CHAPTER 1: CHAPTER 2: CHAPTER 3: CHAPTER 4: CHAPTER 5: CHAPTER 6: CHAPTER 7: CHAPTER 8: CHAPTER 9: CHAPTER 10: CHAPTER 11: CHAPTER 12: CHAPTER 13: CHAPTER 14: CHAPTER 15: CHAPTER 16: APPENDIX: INDEX: Topic General Information Frame/ Body Panels/ Exhaust System Maintenance Lubrication System Fuel System Engine Remove/Install Cylinder Head/Valves Cylinder/Piston Clutch/Gearshift Linkage Alternator/Cam Chain Tensioner Crankshaft/Transmission/Kick Starter Front Wheel/Brake/Suspension Rear Wheel/Brake/Suspension Ignition System Wiring Diagram Troubleshooting 50cc & 90cc Diagrams Index
Page
7 39 55 83 91 103 109 129 141 153 161 173 193 215 223 225 235 241
IV
INTRODUCTION
Introduction
How To Use This Manual
Finding Information You Need
This manual is divided into sections that cover each of the major components of the vehicle. To quickly find the section you are interested in, use the manual page numbers and chapter page number for quick access and reference. The first page of each section lists the table of contents within the section. Read the service information and troubleshooting related to the section before you begin working. The last chapter contains an index of the entire book so you can directly locate the information you need. The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken. Refer to the next page for the meaning of each symbol mark. Illustration also contain charts that list information such as the order in which the part is removed/ installed, the name of the part, and some extra notes that may be needed. Step by step instructions are provided to supplement the illustrations when a detailed explanation of the procedure is necessary or illustrations alone would not suffice. Service procedures required before or after the procedure described on that particular page, or inspection/adjustment procedures required following the installation of parts, are described under the heading Requisite Service within each chapter. Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual as follows: Symbol mark System illustration Detailed description of the procedure Step sequence (numerals or alphabets) Part name Number of parts
About the Illustrations

Part removal and installation is usually illustrated by large and clear illustrations that should provide the reader with visual aid in understanding the major point for servicing. The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should be removed or installed. The sequences of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately. For example, if the steps prior to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders.
INTRODUCTION
Introduction
How To Use This Manual (contd)
Extra notes or precautions related to the service procedure
-
Symbols
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly.
Molykote BR-2 Plus manufactured by Dow Corning, U.S.A.
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). For example:
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Molykote G-n Paste manufactured by Dow Corning, U.S.A.
Use silicone grease. Use recommended engine oil, unless otherwise specified. Apply a locking agent. Use the agent of the middle strength, unless otherwise specified. Apply sealant.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1). Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). For example:
Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified. Use Fork or Suspension Fluid.
VI
INTRODUCTION
Introduction
INTRODUCTION
Introduction
INTRODUCTION
Section 1
General Information
SECTION 1: GENERAL INFORMATION
1-1
Section 1: General Information

Table of Contents
Topic General Safety Service rules Model identification Specifications Torque values Page 1-2 1-4 1-5 1-6 1-17 Topic Tools Lubrication & seal points Cable & harness routing Emission control system Page 1-23 1-25 1-27 1-30
General Safety
Carbon Monoxide
If the engine must be running while working on this vehicle, ensure that the area is well ventilated. Never run the engine in an enclosed area.
WARNING! THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT CAN CAUSE LOSS OF CONSCIOUSNESS AND MAY LEAD TO DEATH.
Hot Components
WARNING! ENGINE AND EXHAUST SYSTEM PARTS BECOME VERY HOT AND REMAIN HOT FOR SOME TIME AFTER THE ENGINE IS RUN. WEAR INSULATED GLOVES OR WAIT UNTIL THE ENGINE AND EXHAUST SYSTEM HAVE COOLED BEFORE HANDLING THESE PARTS.
Used Engine/ Transmission Oil

WARNING! USED ENGINE OIL (OR TRANSMISSION OIL IN TWO-STROKES) MAY CAUSE SKIN CANCER IF REPEATEDLY LEFT IN CONTACT WITH THE SKIN FOR PROLONGED PERIODS. ALTHOUGH THIS IS UNLIKELY UNLESS YOU HANDLE USED OIL ON A DAILY BASIS, IT IS STILL ADVISABLE TO THOROUGHLY WASH YOUR HANDS WITH SOAP AND WATER AS SOON AS POSSIBLE AFTER HANDLING USED OIL. KEEP OUT OF REACH OF CHILDREN.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Gasoline
Work in well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored.
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. KEEP OUT OF REACH OF CHILDREN.
1-2

General Safety (contd)
Brake Dust
Never use an air hose or dry brush to clean brake assemblies. Use an OSHAapproved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers.
WARNING! INHALED ASBESTOS FIBERS HAVE BEEN FOUND TO CAUSE RESPIRATORY DISEASE AND CANCER.
1-3
10

Service Rules
Use genuine Nikota or Nikotarecommended parts and lubricants or their equivalents. Parts that don't meet Nikota's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as described on page 1-27 and subsequent, Cable and Harness Routing.
1-4
11

Model Identification
Frame Serial Number
The frame serial number is stamped on the front side of the steering head.
Engine Serial Number

The engine serial number is stamped on the lower left of the crankcase.
Vehicle Identification Number

The Vehicle Identification Number (VIN) is located on the right side of the steering head on the Safety Certification Label.
Carburetor Identification Number

The carburetor identification number is on the carburetors left side.
Color Label
The color label is attached. When ordering color-coded parts, always specify the designated color code found on the color label.
1-5
12

Specifications
General
Dimensions Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Weights Dry weight Curb weight Frame Frame type Front suspension Front wheel travel Rear suspension Rear wheel travel Back bone Telescopic fork 90 mm (3.5 in) Swingarm 88 mm (3.5 in) Intake valve opens (at 1 mm lift) Intake valve closes (at 0.04in) Compression ratio Valve train 58 kg (128 lbs) 63 kg (139 lbs) 1,565 mm (61.6 in) 694 mm (27.3 in) 917mm (36.1in) 1,067 mm (42.0 in) 655 mm (25.8 in) 226 mm (8.9 in) 162 mm (6.4 in) Fuel tank reserve capacity Engine Bore and stroke Displacement 47.0 X 41.4 mm (1.85 X 1.63 in) 71.8 cm (4.38 cu-in) 9.0:1 OHC with rocker arm 7.5 BTDC Brakes Front brake Internal expanding shoe Rear brake Internal expanding shoe Alignment Caster angle Trail length Fuel Capacities Fuel tank capacity 5.6 (1.48 US gal, 1.23 Imp gal) 1.1 (0.29 US gal, 0.24 Imp gal) 27 68 mm (2.7 in)
Rear damper Conventional type oil damper Tires Front tire size Rear tire size Tire brand (Cheng-Shin) Front/Rear 2.50-14 4PR 3.00-12 4PR C803/C803
12.5 ABDC
1-6
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Specifications (contd)
Gear ratio 1st Engine (contd) Exhaust valve opens lift Exhaust valve closes Lubrication system Oil pump type Cooling system Air filtration 22.5 BBDC 2.5 BTDC Forced pressure and wet sump Trochoid Air cooled Oiled polyurethane foam Assembled type 17.7 kg (39.0 lbs) Single cylinder inclined 80 from vertical Starting system Lubrication Engine oil capacity (draining) Engine oil capacity (draining) 0.6 (0.6 US qt, 0.5 Imp qt) 0.8 (0.8 US qt, 0.7 Imp qt) Gear ratio 2nd Gear ratio 3rd Gearshift pattern 3.272 (36/11) 1.667 (25/15) 1.190 (25/21) Left foot operated return system N- 1 23
Electrical Ignition system Condenser Discharged Ignition Kick-starter
Crankshaft type Engine dry weight Cylinder arangement Carburetor
Carburetor type Throttle bore Drivetrain Clutch system Clutch operation system Transmission Primary reduction Final reduction
Piston valve 13 mm (0.5 in)
Recommended GN4 4-stroke oil engine oil or equivalent motor oil API service classification SF or SG Viscosity: SAE 10W-30
Wet multi-plate Automatic centrifugal 3-speed 3.722 (67/18) 2.400 (36/15)
1-7
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Oil Pump
Item Oil pump rotor tip clearance (1) Body clearance (2) Side clearance (3)
Standard (Unit: mm(in)) 0.15 (0.006) 0.10-0.21 (0.004-0.008) 0.03-0.08 (0.001-0.003)
Service Limit 0.20 (0.008) 0.27 (0.011) 0.12 (0.005)
Fuel System
Item Carburetor identification number Main jet Slow jet Jet needle clip position Air screw initial opening standard Float level Idle speed Throttle grip free play PB #12H # 38 X #38 3rd groove from top 1-1/2 turns out 10.7 (0.42) 1,700 100 rpm 2.0-6.0 mm (1/12-1/4 in) Standard (Unit: mm(in)) Service Limit
1-8
15

Cylinder Head
Item Cylinder compression Standard (Unit: mm(in)) 981-1,177 kPa (10.0-12.0kgf/ cm, 142-171 psi) at 500-600 rpm 0.05 (0.002) 0.05 0.02 mm (0.002 0.001 in) 0.05 0.02 mm (0.002 0.001 in) 4.970-4.985 (0.1957-0.1963) 4.970-4.985 (0.1957-0.1963) 5.000-5.012 (0.1969-0.1973) 5.000-5.012 (0.1969-0.1973) 0.010-0.037 (0.0004-0.0015) 0.030-0.057 (0.0012-0.0022) 1.0-1.3 (0.04-0.05) 32.78 (1.291) 35.55 (1.400) 10.000-10.015 (0.3937-0.3943) 9.978-9.987 (0.3928-0.3932) 4.92 (0.194) 4.92 (0.194) 5.03 (0.198) 5.03 (0.198) 0.08 (0.003) 0.10 (0.004) 2.0 (0.08) 31.2 (1.23) 34.0 (1.34) 10.10 (0.398) 9.91 (0.390) Service Limit
Cylinder head warpage Valve Clearance IN EX Valve stem O.D. IN EX Valve Guide I.D. IN EX Stem-to-guide clearance IN EX Valve seat width Valve spring inner Valve spring outer Rocker arm I.D. Rocker arm shaft O.D.
1-9
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Cylinder Head (contd)
Item Cam lobe height IN EX Standard (Unit: mm(in)) 27.945 (1.1002) 26.076 (1.0266) Service Limit 7.55 (1.085) 25.69 (1.011)
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Cylinder/Piston
Item Cylinder I.D. Cylinder out of round Cylinder taper Cylinder warpage Piston mark direction Piston O.D. (D) Piston O.D. measurement point (H) Piston pin hole I.D. (d) Standard (Unit: mm(in))
47.005-47.015 (1.8506-1.8510)
Service Limit
47.05 (1.852) 0.10 (0.004) 0.10 (0.004) 0.05 (0.002)
"in" mark facing toward the intake side 46.980-46.995 (1.8496-1.8502) 10 mm (0.4 in) from bottom of skirt 13.002-13.008 (0.5119-0.5121)
46.90 (1.846) 13.06 (0.514)
Piston pin O.D. Piston-to-piston pin clearance Top ring-to-ring groove clearance Second ring-to-ring groove clearance Top ring end gap
12.994-13.000 (0.5116-0.5118) 0.002-0.014 (0.0001-0.0006) 0.015-0.050 (0.0006-0.0020) 0.015-0.050 (0.0006-0.0020) 0.05-0.20 (0.002-0.008)
12.98 (0.511) 0.08 (0.003) 0.12 (0.005) 0.12 (0.005) 0.5 (0.02)
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Cylinder/Piston (contd)
Item Second ring end gap Oil (side rail) Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Standard (Unit: mm(in)) 0.05-0.20 (0.002-0.008) 0.010-0.040 (0.0004-0.0016) 13.013-13.043 (0.5123-0.5135) 0.002-0.014 (0.0001-0.0006) Service Limit 0.5 (0.02) 1.1 (0.04) 0.15 (0.006) 13.10 (0.516) 0.08 (0.003)
Clutch/Gearshift Linkage
Item Clutch disc thickness A Clutch disc thickness B Clutch plate warpage Centrifugal clutch spring free length Primary drive gear I.D. Clutch center guide I.D. Clutch center guide O.D. Crankshaft O.D. at clutch center guide Standard (Unit: mm(in)) 2.52-2.68 (0.099-0.106) 3.35-3.45 (0.132-0.136) 17.3 (0.68) 21.000-21.021 (0.8268-0.8276) 16.988-17.006 (0.6688-0.6695) 20.930-20.950 (0.8240-0.8248) 16.966-16.984 (0.6680-0.6687) Service Limit 2.3 (0.09) 3.0 (0.12) 0.20 (0.008) 16.4 (0.65) 21.05 (0.829) 17.04 (0.671) 20.90 (0.823) 16.90 (0.665)
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Alternator/Cam Chain Tensioners
Item Cam chain tensioner push rod O.D. Spring free length Standard (Unit: mm(in)) 11.985-12.000 (0.4718-0.4724) 117 (4.6) Service Limit 11.94 (0.470) 100 (3.9)
Crankshaft
Item Side clearance Radial clearance Runout Standard (Unit: mm(in)) 0.010-0.350 (0.0004-0.0138) 0-0.012 (0-0.0005) Service Limit 0.60 (0.024) 0.05 (0.002) 0.10 (0.004)
Transmission
Item Gear I.D. M2 C1 C3 Bushing O.D. C1 Bushing I.D. C1 Gear-to-bushing clearance C1 Standard (Unit: mm(in)) 17.016-17.043 (0.6699-0.6710) 23.020-23.053 (0.9063-0.9076) 20.020-20.053 (0.7882-0.7895) 22.979-23.000 (0.9047-0.9055) 20.000-20.021 (0.7874-0.7882) 0.020-0.074 (0.0008-0.0029) Service Limit 17.10 (0.673) 20.10 (0.791) 20.10 (0.791) 22.93 (0.903) 20.08 (0.791) 0.10 (0.004)
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Transmission (contd)
Item Mainshaft O.D. M2 Countershaft O.D. C1 Gear-to-shaft clearance M2 Gear bushing-to-shaft clearance C1 Shift fork claw thickness Shift fork I.D Shift drum O.D. Standard (Unit: mm(in)) 16.9840-16.9860 (0.668660.66874) 19.959-19.980 (0.7858-0.7866) 0.022-0.059 (0.0009-0.0023) 0.020-0.062 (0.0008-0.0024) 4.86 4.94 (0.191 0.194) 34.075-34.100 (1.3415-1.3425) 33.950-33.975 (1.3366-1.3376) Service Limit 16.950 (0.6673) 19.94 (0.785) 0.10 (0.004) 0.10 (0.004) 4.6 (0.18) 34.14 (1.344) 33.93 (1.336)
Front Wheel/Suspension/ Steering

Item Minimum tire tread depth Cold tire pressure Axle runout Wheel rim-to-hub distance Wheel rim runout (radial) Wheel rim runout (axial) Brake lever free play Brake drum I.D Brake lining thickness Standard (Unit: mm(in)) 100 kPa (1.00 kgf/cm, 15 psi) 12.0 1.0 (0.47 0.04) 10-20 (3/8-3/4) 95.0 (3.74) 4.0 (0.16) Service Limit 1.5 (0.06) 0.20 (.008) 2.0 (0.08) 2.0 (0.08) 96.0 (3.78) 2.0 (0.08)
1-14
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Front Wheel/Suspension/Steering (contd)
Item Fork spring free length Fork spring direction Fork tube runout Recommended fork fluid Fork fluid level Fork fluid capacity Standard (Unit: mm(in)) 404.5 (15.93) With the tapered end facing down Suspension Fluid SS-8 135 (5.3) 74 1 cm (2.50 0.03 US oz, 2.60 0.04 Imp oz) Service Limit 396.4 (15.61) 0.20 (0.008) -
Rear Wheel/Brake
Item Minimum tire tread depth Cold tire pressure Axle runout Wheel rim-to-hub distance Wheel rim runout (radial) Wheel rim runout (axial) (DID) Drive chain size/linkRK Drive chain slack Brake lever free play Brake drum I.D Brake lining thickness Standard (Unit: mm(in)) 100 kPa (1.00 kgf/cm, 15 psi) 11.0 1.0 (0.43 0.04) DID420M-86RB RK420MZ-86RJ 10-20 (3/8-3/4) 20-30 (3/4-1-1/4) 95.0 (3.74) 4.0 (0.16) 2.0 (0.08) 96.0 (3.78) 2.0 (0.08) Service Limit 2.0 (0.08) 0.20 (0.008) -
1-15
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Ignition System
Item Spark plug (Standard) (for cold climate/below 5C/41F) (For extended high speed riding) Spark plug gap Ignition coil primary peak voltage Ignition pulse generator peak voltage Alternator exciter coil peak voltage Ignition timing ("F" mark) Standard (Unit: mm(in)) CR6HSA (NGK) U20FSR-U (DENSO) 5HSA (NGK) U16FSR-U (DENSO) CR7HSA (NGK) U22FSR-U (DENSO) 0.60-0.70 (0.024-0.028) 100 V minimum 0.7 V minimum 0.7 V minimum 27 BTDC at idle Service Limit
1-16
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Torque Values
General
Fastener Type 5 mm bolt and nut 6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut Torque (kg/m, ftlb) 5 (0.5, 3.5) 10 (1.0, 7) 22 (2.2, 16) 34 (3.5, 25) Fastener Type 5 mm screw 6 mm screw 6 mm flange bolt (8 mm head) 6 mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10mm flange bolt and nut The torque specifications above are for general-purpose use. Specific torque settings for specific important fasteners appear on the following pages. Only fasteners not listed below should be tightened to standard torque values listed above. Torque (kg/m, ftlb) 4 (0.4, 2.9) 9 (0.9, 6.5) 9 (0.9, 6.5) 12 (1.2, 9)
12 mm bolt and nut
54 (5.5, 40)
26 (2.7, 20 39 (4.0, 29)
1-17
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Torque Values (contd)
Engine
Notes
1 Apply a locking agent to the threads. 2 Apply oil to the threads and flange surface. 3 U-nut. 4 ALOC bolt; replace with a new one. Fastener Maintenance Spark plug Oil drain bolt Valve adjuster hole cap Valve adjuster lock nut Clutch adjuster lock nut Lubrication System Oil pump mounting screw Oil pump cover screw Cylinder Head/Valves Cylinder head cap nut Cylinder head nut Cylinder head right side cover bolt Cam sprocket bolt 3 1 2 2 6 6 6 5 11 (1.1, 8) 11 (1.1, 8) 10 (1.0, 7) 9 (0.9, 6.5) 3 3 6 5 8 (0.8, 5.8) 5 (0.5, 3.6) 1 1 2 2 1 10 12 30 5 8 12 (1.2, 9) 25 (2.5, 18) 12 (1.2, 9) 9 (0.9, 6.5) 12 (1.2, 9) Qty. Thread Dia. (mm) Torque (kg/m, ftlb) Remarks
1-18
25

Engine (contd)
Fastener Cylinder/Piston Cam chain guide roller pin bolt Clutch/Gearshift linkage Clutch outer cover screw Clutch lock nut Clutch outer spring screw Shift drum stopper arm bolt Shift return spring pin Gearshift cam bolt Alternator/cam chain tensioner Flywheel nut Cam chain tensioner sealing bolt Cam chain tensioner pivot bolt Crankshaft/Tranmission Shift drum bolt Drive sprocket fixing plate bolt 1 2 6 6 12 (1.2, 9) 12 (1.2, 9) 1 1 1 10 14 8 41 (4.2, 30) 23 (2.3, 17) 16 (1.6, 12) 4 1 4 1 1 1 5 14 5 6 8 6 4 (0.45, 3.3) 42 (4.3, 31) 6 (0.6, 4.3) 13 (1.3, 9) 29 (3.0, 22) 17 (1.7, 12) 1 8 10 (1.0, 7) Qty. Thread Dia. (mm) Torque (kg/m, ftlb) Remarks
1-19
26

Frame
Fastener Frame body panels/ exhaust system Fuel valve mounting bolt Side stand pivot bolt Muffler stay bolt Exhaust pipe protector bolt Exhaust pipe cover screw A Exhaust pipe cover screw B Fuel system Connecting tube band screw Engine removal installation Engine hanger bolt/nut (rear/ upper) Engine hanger bolt/nut (rear/ lower) 1 1 8 8 31 (3.2, 23) 31 (3.2, 23) 1 4 1 (0.1, 0.7) 2 1 1 3 2 2 6 10 8 9 (0.9, 6.5) See page 2-14 26 (2.7, 20) 6 (0.6, 4.3) 6 (0.6, 4.3) Qty. Thread Dia. (mm) Torque (kg/m, ftlb) Remarks
6 15 (1.5, 11) 5 5
1-20
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Frame (contd)
Fastener Front wheel/brake/ suspension/steering Handlebar upper holder bolt Handlebar lower holder nut Fork bottom bridge pinch bolt Brake lever pivot bolt Brake lever pivot nut Spoke Front axle nut Front brake arm pinch bolt/ nut Fork bolt Fork cap Fork socket bolt Steering stem nut Steering stem top thread 4 2 2 1 1 36 1 1 2 2 2 1 1 6 6 8 5 5 BC 2.9 12 6 10 20 8 22 22 10 (1.0, 7) 45 (4.6, 33) 32 (3.3, 24) 3 (0.3, 2.2) 3 (0.3, 2.2) 3 (0.3, 2.2) 59 (6.0, 43) 10 (1.0, 7) 23 (2.3, 17) 23 (2.3, 17) 20 (2.0, 14) 74 (7.5, 54) See page 12-18 Note 1 Note 3 Note 4 Note 3 Qty. Thread Dia. (mm) Torque (kg/m, ftlb) Remarks
1-21
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Frame (contd)
Fastener Rear wheel/ brake/ suspension Spoke Rear axle nut Driven sprocket nut Rear brake arm pinch bolt/ nut Swingarm pivot bolt/nut Shock absorber upper mounting bolt/nut Shock absorber lower mounting bolt/nut Ignition system Ignition coil mounting bolt 1 5 6 (0.6, 4.3) 36 1 4 1 1 1 1 BC 2.9 12 8 6 10 10 10 3 (0.3, 2.2) 59 (6.0, 43) 32 (3.3, 24) 10 (1.0, 7) 39 (4.0, 29) 34 (3.5, 25) 34 (3.5, 25) Note 3 Note 3 Note 3 Note 3 Note 3 Note 3 Qty. Thread Dia. (mm) Torque (kg/m, ftlb) Remarks
1-22
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Tools
Notes
1 Equivalent commercially available in the U.S.A. 2 Not available in the U.S.A. 3 Alternative tool. Description Carburetor float level gauge Spoke wrench, 4.5 X 5.1 mm Pin spanner Valve adjusting wrench, 8 X 9 mm Valve adjuster B Lock nut wrench, 20 X 24 mm Extension bar Universal holder Flywheel holder Attachment, 32 X 35 mm Attachment, 37 X 40 mm Pilot, 12 mm Pilot, 17 mm Bearing remover shaft Bearing remover head, 12 mm Fork seal driver Tool Number 07401-0010000 07701-0020200 07702-0020001 07708-0030100 07708-0030400 07716-0020100 07716-0020500 07725-0030000 07725-0040000 07746-0010100 07746-0010200 07746-0040200 07746-0040400 07746-0050100 07746-0050300 07747-0010100 Note 1 Note 1 Note 3: 079471180001 Note 1 Note 1 Note 1 Note 3: 07908KE90200 (USA) Note 1 Remarks Refer to Section 5 3 12 3 3 9 9 10 9 11, 13 10, 11, 13 12,13 11 12, 13 12, 13 12
1-23
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Tools (contd)
Description Fork seal driver attachment Driver Valve spring compressor Valve seat cutter Seat cutter, 24 mm (45 IN) Seat cutter, 20.5 mm (45 EX) Flat cutter, 24 mm (30 IN) Flat cutter, 21.5 mm (32 EX) Interior cutter, 22 mm (60 IN/EX) Flywheel puller Valve guide driver, 5.0 mm Ball race remover Steering stem driver 07780-0010600 07780-0011000 07780-0012500 07780-0012800 07780-0014202 07933GE00000 07942MA60000 07944-1150001 07946GC40000 Note 3: 07946MB00000 07946GC4000A (U.S.A. only) Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 2, 3: 07933-0010000 7 7 7 7 7 7 10 7 12 12 Tool Number 07747-0010200 07749-0010000 07757-0010000 Remarks Note 3: 079471180001 Refer to Section 12 11, 12, 13 7
Cutter holder, 5 mm 07781-0010400
Valve spring compressor attachment Valve guide reamer, 5.0 mm
07959KM30101 07984MA60001 07HGJ0020100 Note 3: 07984MA6000C (U.S.A. only) Note 3: Peak voltage tester (U.S.A. only)
7 7
Peak voltage adaptor
14
1-24
31

Lubrication & Seal Points
Engine
Location Piston pin bore Piston ring grooves Piston outer surface Piston pin outer surface Piston ring surface Valve stem sliding surface Camshaft lobes Cam chain Cam chain guide roller inner surface Rocker arm I.D. and slipper surface Cam chain tension push rod inside Oil pump rotor inside Clutch center guide surface Clutch discs Primary drive gear teeth Primary driven gear teeth, inner surface Mainshaft sliding surface Countershaft sliding surface Transmission gear rotating surface Transmission gear teeth and shift fork groove Shift drum outer surface Shift drum lock plate sliding surface Kickstarter spindle sliding surface Material Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Engine oil Fill with 0.5-1 cm oil Fill with 1-2 cm oil Remarks
1-25
32

Lubrication & Seal Points (contd)
Engine (contd)
Location Each sliding surface Oil seal lips Radial ball bearing and needle bearing O-rings Material Engine oil Engine oil Engine oil Engine oil Remarks
Frame
Location Steering stem ball race and steel ball sliding surface Swingarm pivot nut seating surface Wheel hub dust seal lips Brake panel anchor pin (brake shoe sliding surface) Brake pedal pivot surface Slide stand pivot sliding surface Brake cam dust seal Final driven sprocket stud bolt threads Fork socket bold threads Fork dust seal lip Brake cable inside Handle grip rubber inner surface Material Multi-purpose grease Multi-purpose grease Multi-purpose grease Multi-purpose grease Multi-purpose grease Multi-purpose grease Engine oil Locking agent Locking agent Fork fluid Cable lubrticant Bond A Remarks
1-26
33

Cable & Harness Routing
1-27
34

Cable & Harness Routing (contd)
1-28
35

Cable & Harness Routing (contd)
1-29
36

Emission Control System
The California Air Resources Board (CARB) requires manufactures to certify that their dirt bikes comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided. Nikota utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.
Source of emissions
The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic.
Exhaust emission control system

The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system.
Crankcase emission control system
1-30
37

Emission Control System(contd)
Vehicle Emission Control Information Label
This label is affixed to the motorcycle as shown here.
1-31
38

Memo
1-32
39
Section 2
Frame/Body Panels/ Exhaust System
SECTION 2: FRAME/BODY PANELS/EXHAUST
2-1
40
Section 2: Frame/Body Panels/Exhaust

Table of Contents
Topic Troubleshooting Torque Values Seat/Rear Fender Fuel Tank Tank Shroud Side Cover Page 2-4 2-4 2-5 2-6 2-7 2-8 Topic Number Plate Front Fender Mud Guard Muffler/Exhaust Pipe Side Stand Page 2-9 2-10 2-11 2-12 2-14
Service Information
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND EXPLOSIVE UNDER CERTAIN CONDITIONS. SERIOUS BURNS MAY RESULT IF THE EXHAUST SYSTEM IS NOT ALLOWED TO COOL BEFORE COMPONENTS ARE REMOVED OR SERVICED.
Always inspect the exhaust system for leaks after installation.
Noise Emission Control System

Federal law prohibits performing or causing the following acts: Removing or disabling (other than for maintenance, repair, or replacement) any device or design element included with any new vehicle that controls noise prior to sale or delivery to the ultimate purchaser or while in use Using the vehicle after such device or design element is removed or rendered inoperative. Acts defined as tampering include: Removing or puncturing the muffler, baffles, headers or any other part that conducts exhaust gases. Removing or puncturing any part of, the intake system. Lack of proper maintenance.
General
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. This section covers removal and installation of the body panels, fuel tank and exhaust system. Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always tighten the exhaust clamps first, and then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
2-2
41

Service Information (contd)
Noise Emission Control System (contd)
Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2-3
42

Troubleshooting
Symptom/Possible Causes Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler Symptom/Possible Causes Excessive exhaust noise Broken exhaust system Exhaust gas leak
Torque Values
Fastener Type Fuel valve mounting bolt Side stand pivot bolt Muffler stay bolt Torque (kg/m, ftlb) 9 N/m (0.9 kgfm, 6.5 lbfft) See page 2-14 26 N/m (2.7 kgfm, 20 lbfft) Fastener Type Exhaust pipe protector bolt Exhaust pipe cover screw A Exhaust pipe cover screw B Torque (kg/m, ftlb) E 15 N/m (1.5 kgfm, 11 lbfft) 6 N/m (0.6 kgfm, 4.3 lbfft) 6 N/m (0.6 kgfm, 4.3 lbfft)
2-4
43

Seat/Rear Fender
Removal
1 Remove the two mounting bolts and seat/rear fender assembly. 2 Remove the three flange nuts and rear fender from the seat.
Installation
Installation is in the reverse order of removal. Note: For seat installation, align
the seat hook with the screw on the fuel tank, and also align the seat prongs with the frame clamps.
2-5
44

Fuel Tank
Removal
3 Disconnect the fuel tank breather tube from the number plate. 4 Remove the fuel tank holder bank. 5 Remove the fuel tank mounting bolts and fuel tank.
1 Turn the fuel valve off. 2 Disconnect the fuel tube from the fuel valve.
Installation
Installation is in the reverse order of removal.
2-6
45

Tank Shroud
Removal
Note: The visual image shown
above may not match the actual parts. Use it for reference purposes only.
Installation
Installation is in the reverse order of removal. Note: Align the hole in the shroud with the fuel tank boss.
1 Remove the body panel screws. 2 Remove the body panels.
2-7
46

Side Cover
Removal
1 Remove the seat (page 2-5). 2 Remove the bolt/washer and side cover.
Installation
2-8
47

Number Plate
Removal
WARNING! DO NOT SERVICE THE EXHAUST SYSTEMWHILE IT IS HOT.
1 Unfasten the number plate from the handlebar. 2 Remove the screw, collar and number plate.
Installation
Installation is in the reverse order of removal. Note: At installation, align the lower grooves with the bracket tabs on the steering stem.
2-9
48

Front Fender
Removal
Remove the bolt, nuts, collars and front fender.
Installation
2-10
49

Mud Guard
Removal
1 Remove the seat (page 2-5). 2 Unhook the retaining clips and remove the mud guard.
Installation
2-11
50

Muffler/Exhaust Pipe
Removal
WARNING! DO NOT SERVICE THE EXHAUST SYSTEMWHILE IT IS HOT.
2 Remove the exhaust pipe joint nuts. 3 Remove the muffler mounting bolt and exhaust pipe/muffler assembly.
1 Remove the right side cover (page 2.8).
2-12
51

Muffler/Exhaust Pipe (contd)
Installation
Note: Always replace the exhaust pipe gasket with a new one. 1 Install the new exhaust pipe gasket onto the exhaust port of the cylinder head. 2 Install the exhaust pipe, and then temporarily install the exhaust pipe joint nuts and mounting bolt. Note: First tighten the exhaust pipe joint nuts.
3 Tighten the exhaust pipe/muffler mounting bolt to the specified torque.

-
Torque: 26 N-m (2.7 kgfm, 20 lbfft)
2-13
52

Side Stand
Removal
Note: Support the motorcycle
securely using a hoist or equivalent.
1 Unhook the side stand return spring. 2 Remove the pivot nut, bolt, and side stand.
Installation
1 Apply grease to the side stand sliding area and pivot bolt.Install the side stand to the main footpeg bracket. 2 Install the side stand pivot bolt and tighten it to the specified torque.
-
3 Loosen the pivot bolt about 45-90 degrees. 4 Hold the pivot bolt and tighten the pivot nut to the specified torque.
-
5 Hook the side stand return spring.
2-14
53

Memo
2-15
54

Memo
2-16
55
Section 3
Maintenance
SECTION 3: MAINTENANCE
3-1
56
Section 3: Maintenance
Table of Contents
Topic Specifications Torque Values Tools Maintenance schedule Fuel line Throttle operation Air cleaner Spark plug Valve clearance Engine oil Engine oil strainer screen Engine oil centrifugal filter Page 3-3 3-4 3-4 3-5 3-7 3-8 3-9 3-10 3-11 3-12 3-14 3-15 Topic Engine idle speed Drive chain Drive chain slider Brake shoe wear Brake system Clutch system Side stand Suspension Spark arrester Nuts, bolts, fasteners Wheels/tires Stearing head bearings Page 3-16 3-17 3-19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28
Service Information
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. KEEP OUT OF REACH OF CHILDREN. WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA.
Place the motorcycle on level ground before starting any work.
3-2
57
Specifications
Item Spark plug (standard) For cold climate/below 41 F/5C For extended high speed riding Engine oil capacity (draining) Engine oil capacity (disassembly) Recommended engine oil Standard (Unit: mm(in)) CR6HSA (NGK)/U20FSR-U (DENSO) CR5HSA (NGK) /U16FSR-U (DENSO) CR7HSA (NGK) /U22FSR-U (DENSO) 0.6? (0.6 US qt, 0.5 Imp qt) 0.8? (0.8 US qt, 0.7 Imp qt) GN4 4-stroke oil or equivalent motor oil API classification SF or SG. Viscosity: SAE 10W-30 1,700 100 rpm 2.6-6.0 mm (1/12-1/4 in) 0.05 0.02 mm (0.002 0.001 in) 0.05 0.02 mm (0.002 0.001 in) 10-20 mm (3/8-3/4 in) 10-20 mm (3/8-3/4 in) 20-30 mm (3/4-1-1/4 in) 2.50-14 4PR 3.00-12 4PR C803/C803 100 kPa (1.00 kgf/cm, 15 psi) 100 kPa (1.00 kgf/cm, 15 psi) 1.5 mm (0.06 in) 2.0 mm (0.08 in) Service Limit
Engine idle speed Throttle grip free play Valve clearance IN Valve clearance EX Drive chain slack Brake lever free play Brake pedal free play Tire size (font) Tire size (rear) Tire brand CHENG SHIN Tire air pressure (front) Tire air pressure (rear) Minimum tire tread depth (front) Minimum tire tread depth (rear)
3-3
58
Torque Values
Fastener Type Spark plug Valve adjuster hole cap Valve adjuster lock nut Oil drain bolt Torque (kg/m, ftlb) 12 N-m (1.2 kgfm, 9 lbfft) 12 N-m (1.2 kgfm, 9 lbfft) 9 N-m (0.9 kgfm, 6.5 lbfft) 25 N-m (2.5 kgfm, 18 lbfft) Fastener Type Clutch outer cover screw Clutch adjuster lock nut Rear axle nut Torque (kg/m, ftlb) 4 N-m (0.45 kgfm, 3.3 lbfft) 12 N-m (1.2 kgfm, 9 lbfft) 59 N-m (6.0 kgfm, 43 lbfft) U-nut
Tools
Description Valve adjusting wrench, 8 X 9 mm Tool Number 077080030100 Alternate Tool Equivalent commercially available in U.S.A. U.S.A only 07908KE90200 Tool Number Refer to Page
Valve adjuster B Spoke wrench, 4.5 X 5.1 mm
077080030400 077010020200
Equivalent commercially available in U.S.A
3-4
59
Maintenance Schedule
Perform the pre-ride inspection in the Owners Manual at each scheduled maintenance period according to the following codes: I: Inspect and clean, adjust, lubricate, or replace if necessary. C: Clean R: Replace Frequency (whichever comes first) Item 100mi 250km 1 month 600mi 1,000km 6 months I I C I I R C I I R C I I R C R C I C I I R C 1,200mi 1,800mi 2,400mi 2,000km 2,000km 4,000km 12 months 18 months 24 months I A: Adjust L: Lubricate The following items require some mechanical knowledge. Certain items (particularly those marked * and ** require more technical information. Consult your
authorized Nikota dealer.
Fuel Line* Throttle Operation Air Cleaner (Note 1) Spark Plug* Valve Clearance Engine Oil Engine Oil Strainer Screen** Engine Oil Centrifugal Filter** Engine Idle Speed Drive Chain (Note 1) I
I, L every 300mi (500 Km) or 50 operating hours
3-5
60
Maintenance Schedule (contd)
Frequency (whichever comes first) Item 100mi 250km 1 month I I I I 600mi 1,000km 6 months I I I I 1,200mi 1,800mi 2,400mi 2,000km 2,000km 4,000km 12 months 18 months 24 months I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
Drive Chain Slider Brake Shoe Wear Brake System Clutch System Side Stand Suspension* Spark Arrester Nuts, bolts, fasteners Wheels/Tires** Steering head bearings Drive Chain Slider Brake Shoe Wear Brake System
C: Every 1,000 mi (1,600 Km) or every 100 operating hours
* This item should be serviced by your authorized dealer, unless the owner has proper tools and service data and is mechanically qualified. ** In the interest of safety, we recommend that these items be serviced only by your authorized dealer.
Notes
1: Service more frequently when riding in dusty areas, sand or snow. 2: Service more frequently after riding in very wet or muddy conditions. 3: Refer to the Common Service Manual.
3-6
61
Fuel Line
Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary.
-
Torque: 9 N-m (0.9 kgfm, 6.5 lbfft)
7 After installation, check for fuel leaks.
Fuel Strainer Screen
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. WORK IN A WELL VENTILATED AREA. SMOKING OR ALLOWING FLAMES OR SPARKS IN THE WORK AREA OR WHERE THE GASOLINE IS STORED CAN CAUSE A FIRE OR EXPLOSION. WIPE SPILLED GASOLINE AT ONCE.
1 Turn the fuel valve off and disconnect the fuel tube at the carburetor. 2 Place a drain pan under the fuel tube and turn the fuel valve on to drain the fuel tank. 3 After the tank has drained completely, remove the two bolts and remove the fuel valve and strainer screen. 4 Wash the fuel strainer screen in nonflammable or high flash solvent. 5 Check the O-ring is in good condition, reinstall the fuel valve. 6 Tighten the fuel valve mounting bolts to the specified torque.
3-7
62
Throttle Operation
1 Check for smooth throttle grip full opening and automatic full closing in all steering positions. 2 Check the throttle cable and replace it if it is deteriorated, kinked, or damaged. 3 Lubricate the throttle cable, if throttle operation is not smooth. 4 Measure the free play at the throttle grip flange.
-
Free play: 2.0-6.0 mm (1/12-1/4 in)
5 Throttle grip free play can be adjusted at throttle housing adjuster. 6 Remove the dust cover from the adjuster. 7 Adjust the free play by loosening the lock nut and turning the adjuster. 8 Recheck the throttle operation. 9 Replace any damaged parts, if necessary.
3-8
63
Air Cleaner
1 Remove the air cleaner housing cover mounting screws. 5 Install the air cleaner housing cover by aligning its groove with the projection on the housing.
2 Remove air cleaner element holder and element from the housing.
6 Reinstall the element and air cleaner housing cover. 7 Install and tighten the housing cover screws.
3 Wash the element in non-flammable or high flash point solvent, and let it dry thoroughly. 4 Soak the element in Foam Filter Oil or equivalent, and squeeze out any excess oil.
3-9
64
Spark Plug
Removal
1 Clean around the spark plug base with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber. 2 Disconnect the spark plug cap. 3 Remove the spark plug using a spark plug wrench or an equivalent. 4 Inspect or replace as described in the maintenance schedule (page 3-10). 3 If necessary, adjust the gap by bending the side electrode carefully.
-
Spark plug gap: 0.60-0.70 mm (0.024-0.028 in)

CAUTION: TO PREVENT DAMAGE TO THE CYLINDER HEAD, HAND TIGHTEN THE SPARK PLUG BEFORE USING A WRENCH TO TIGHTEN TO THE SPECIFIED TORQUE.
Inspection
Check the following and replace if necessary (recommended spark plug: page 3-10): Insulator for damage Electrodes for wear Burning condition, coloration:
-
4 Reinstall the spark plug in the cylinder head and hand tighten, then torque it using a spark plug wrench.
-
Replacing a Spark Plug

1 Set the plug gap to specification with a wire-type feeler gauge (see above).
CAUTION: DO NOT OVER TIGHTEN THE SPARK PLUG.
dark to light brown indicates good condition. excessive lightness indicates malfunctioning ignition system or lean mixture. wet or black sooty deposit indicates over-rich mixture. 2 Install and hand tighten the new spark plug, then tighten it about of a turn after the sealing washer contacts the seat of the plug hole. 3 Install the spark plug cap.
Reusing a Spark Plug

1 Clean the spark plug electrodes with a wire brush or special plug cleaner. 2 Check the gap between the center and side electrodes with a wire-type feeler gauge.
3-10
65
Valve Clearance
Inspection
1 Inspect and adjust the valve clearance while the engine is cold (below 95 F/35C). 2 Remover the valve adjuster hole caps. 3 Remove the left crankcase cover (page 10-5). 4 Turn the crankshaft counterclockwise, align the "T" mark on the flywheel with the index notch on the left crankcase. 5 Make sure the piston is at TDC (Top Dead Center) on the compression stroke. 6 Check the valve clearance by inserting a feeler gauge between the valve adjusting screw and valve stem.
-
9 Recheck the valve clearance. 10Check that the valve adjuster hole cap O-ring is in good condition, replace if necessary. 11 Coat the O-rings with clean engine oil and install them on the valve adjuster hole caps. 12Apply clean engine oil to the threads, install and tighten the valve adjuster hole caps to the specified torque.
-
13Install the left crankcase cover (page 10-5).
Valve clearance (IN/EX): 0.05 0.02 mm (0.002 0.001 in)
Adjustment
7 Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on a feeler gauge. 8 Hold the adjusting screw and tighten the lock nut.
Tools:
-
Valve adjusting wrench, 8 X 9 mm 07708-0030100 (Equivalent commercially available in U.S.A.) Valve adjuster B 07708-0030400 or 07908-KE90200 (U.S.A. only) Torque: 9 N-m (0.9 kgfm, 6.5 lbfft)
3-11
66
Engine Oil
Oil Level Inspection
1 Support the motorcycle in an upright position on level ground. 2 Remove the oil level dipstick, wipe it clean. 3 Reinstall the oil level dipstick, but do not screw it into the case. 4 Remove the oil level dipstick and check the oil level. 5 If the level is below the lower mark on the dipstick, fill the crankcase with recommended oil.
-
Recommended engine oil: 4-stroke oil or equivalent motor oil API service classification: SF or SG Viscosity: 10W-30 Note: Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.
6 Reinstall the filler cap and dipstick.
3-12
67
Engine Oil (contd)
Engine Oil Change
WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA.
-
Torque: 25 N-m (2.5 kgfm, 18 lbfft
6 Fill the crankcase with recommended engine oil.

-
Oil capacity: 0.6 (0.6 US qt, 0.5 Imp qt) at draining.
7 Install the oil level/dipstick. 8 Start the engine and let it idle for 2 to 3 minutes. 9 Stop the engine and recheck the oil level. 10Make sure there are no oil leaks.
Change the engine oil with the engine warm and the motorcycle on level ground to assure complete draining. 1 Warm up the engine. 2 Stop the engine and remove the oil filler cap/dipstick and drain bolt. 3 Drain the oil completely.
WARNING! USED ENGINE OIL (OR TRANSMISSION OIL IN TWO-STROKES) MAY CAUSE SKIN CANCER IF REPEATEDLY LEFT IN CONTACT WITH THE SKIN FOR PROLONGED PERIODS. ALTHOUGH THIS IS UNLIKELY UNLESS YOU HANDLE USED OIL ON A DAILY BASIS, IT IS STILL ADVISABLE TO THOROUGHLY WASH YOUR HANDS WITH SOAP AND WATER AS SOON AS POSSIBLE AFTER HANDLING USED OIL. KEEP OUT OF REACH OF CHILDREN.
4 Check that the sealing washer on the drain bolt is in good condition, replace if necessary. 5 Install and tighten the drain bolt.
3-13
68
Engine Oil Strainer Screen
Requisite Service
Engine oil level inspection (page 3-12).
Procedure
Perform this maintenance before filling the engine with oil. 1 Remove the right crankcase cover (page 9-6). 2 Remove the oil strainer screen and clean it. 3 Reinstall the oil strainer screen and right crankcase cover (page 9-12). 4 Fill the crankcase with recommended engine oil (see above).
3-14
69
Engine Oil Centrifugal Filter
Cleaning
1 Remove the right crankcase cover and clutch lifter lever (page 9-6). 2 Remove the four screws and clutch outer cover. 3 Clean the clutch outer cover and inside of the clutch outer cover using a clean lint-free cloth.
CAUTION: DO NOT ALLOW DUST OR DIRT TO ENTER THE CRANKSHAFT OIL PASSAGE CAUTION: DO NOT USE COMPRESSED AIR.
4 Check the gasket is in good condition, replace if necessary. 5 Reinstall the clutch outer cover and tighten the screws to the specified torque.
-
3-15
70
Engine Idle Speed
-
Idle speed: 1,700 100 rpm
WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA.
Note: Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. Note: The engine must be warm
for accurate idle speed inspection and adjustment.
1 Warm up the engine for about 10 minutes. 2 Connect a tachometer. 3 Turn the throttle stop screw as required to obtain the specified idle speed.
3-16
71
Drive Chain
Drive Shain Slack Inspection
WARNING! NEVER INSPECT AND ADJUST THE DRIVE CHAIN WHILE THE ENGINE IS RUNNING.
3 Make sure the index marks on both adjusters are aligned with the index mark on the swingarm.
1 Turn off the engine, place the motorcycle on its side stand and shift the transmission into neutral. 2 Check the slack in the drive chain lower run midway between the sprockets.
-
Chain slack: 10-20 mm (3/8-3/4 in) 4 Tighten the rear axle nut to the specified torque.
-
5 Tighten both the adjusting nuts. 6 Recheck the drive chain slack and free wheel rotation.
CAUTION: EXCESSIVE CHAIN SLACK, 40 MM (1-1/2 IN) OR MORE, MAY DAMAGE THE FRAME.
7 Check the rear brake pedal free play (page 3-21), adjust if necessary. 8 Lubricate the drive chain with #80-90 gear oil. 9 Wipe off the excess oil.
Adjustment
1 Loosen the rear axle nut. 2 Turn both adjusting nuts until the correct drive chain slack is obtained.
3-17
72
Drive Chain (contd)
Cleaning/Inspection/ Lubrication
If the drive chain becomes extremely dirty, it should be removed and cleaned prior to lubrication. 1 Remove the left crankcase cover (page 10-5). 2 Carefully remove the retaining clip with pliers. 3 Remove the master link and drive chain. 4 Clean the chain with non-flammable or high flash point solvent and wipe it dry. 5 Be sure the chain has dried completely before lubricating. 6 Lubricate the drive chain with #80-90 gear oil. 7 Wipe off the excess gear oil. 8 Inspect the drive chain for possible damage or wear. 9 Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. 10Measure the drive chain distance between a span of 85 pins from pin center to pin center with the chain held taut and any kinked joint straightened.
-
driven sprocket teeth for wear or damage, replace if necessary.

CAUTION: NEVER USE A NEW DRIVE CHAIN ON WORN SPROCKETS. BOTH CHAIN AND SPROCKETS MUST BE IN GOOD CONDITION, OR THE NEW REPLACEMENT CHAIN WILL WEAR RAPIDLY.
12Check the attaching bolts and nuts on the drive and driven sprockets. 13If any are loose, torque them. 14Install the drive chain onto the sprockets. 15Install the master link and link plate. 16Install the retaining clip with the open end opposite the direction of chain travel.
Service limit: 1,101 mm (43.3 in)
11 Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect the drive and
3-18
73
Drive Chain Slider
1 Check the drive chain slider for wear or damage. 2 Replace the drive chain slider if it is worn to the wear limit or has been damaged.
3-19
74
Brake Shoe Wear
Front Brake Shoes
1 Check the brake shoes and brake drum. 2 Refer to page 12-12 for brake shoe replacement.
Rear Brake Shoes

1 Check the brake shoes and brake drum. 2 Refer to page 13-10 for brake shoe replacement.
3-20
75
Brake System
Front Brake
Measure the front brake lever free play at the tip of the lever. Free play: 10-20 mm (3/8-3/4 in) Minor adjustments can be made with the upper adjuster. 1 Loosen the lock nut and turn the adjuster. 2 After adjustment, tighten the lock nut. Major adjustment can be made with the lower adjuster on the brake panel. 1 Loosen the lock nut and turn the adjusting nut. 2 After adjustment, tighten the lock nut. 3 Tighten the brake cable guide bolt.
Rear Brake
Check the brake pedal free play. Free play: 20-30 mm (3/4- 1-1/4 in) 1 Make sure the cutout on the adjusting nut is seated on the brake arm pin after making the final free play adjustment. 2 Adjust the brake pedal free play by turning the adjusting nut.
3-21
76
Clutch System
If the clutch does not operate properly, adjust the following: 1 Loosen the clutch adjuster lock nut and turn the adjusting screw clockwise one full turn.
CAUTION: DO NOT TURN EXCESSIVELY.
2 Slowly turn the adjusting screw counterclockwise until resistance is felt. 3 Turn the adjusting screw 1/8 turn clockwise from this position, and tighten the lock nut while holding the adjusting screw.
-
4 Check that the clutch is not slipping and is properly disengaging by operating gearshift pedal.
3-22
77
Side Stand
1 Support the motorcycle on a level surface. 2 Check the side stand spring for damage or loss of tension. 3 Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary.
3-23
78
Suspension
WARNING! LOOSE, WORN OR DAMAGED SUSPENSION PARTS IMPAIR MOTORCYCLE STABILITY AND CONTROL. REPAIR OR REPLACE ANY DAMAGED COMPONENTS BEFORE RIDING. RIDING A MOTORCYCLE WITH FAULTY SUSPENSION INCREASES YOUR RISK OF AN ACCIDENT AND POSSIBLE INJURY.
5 Check the action of the shock absorber by compressing it several times. 6 Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. 7 Replace damaged components which cannot be repaired. 8 Tighten all nuts and bolts. 9 Refer to section 13 for shock absorber service.
Front Suspension Inspection

1 Check the action of the fork legs by operating the front brake and compressing the front suspension several times. 2 Check the entire assembly for signs of leaks, damage or loose fasteners. 3 Replace damaged components which cannot be repaired. 4 Tighten all nuts and bolts. 5 Refer to section 12 for fork service.
Rear Suspension Inspection

1 Support the motorcycle on safety stand or box and raise the rear wheel off the ground. 2 Hold the swingarm and move the rear wheel sideways with force to see if the wheel bearings are worn. 3 Check for worn swingarm bushings by grabbing the swingarm and attempting to move the swingarm from side to side. 4 Replace the bushings if looseness is noted.
3-24
79
Spark Arrester
WARNING! WAIT UNTIL THE PIPE HAS COOLED BEFORE REMOVING OR INSTALLING THE SPARK ARRESTER.. WARNING! PERFORM THIS OPERATION IN A WELL VENTILATED AREA FREE FROM COMBUSTIBLE MATERIALS..
1 Remove the three SH bolts, spark arrester, and gasket from the muffler. 2 Use a soft brush to remove carbon from spark arrester screen. 3 The spark arrester must be free of breaks and holes. 4 Replace if necessary. 5 Install the spark arrester and gasket in the muffler. 6 Tighten the three bolts securely.
3-25
80
Nuts, Bolts, Fasteners
1 Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-17). 2 Check that all safety clips, clamps and cable stays are in place and properly secured.
3-26
81
Wheels/Tires
Tire pressure should be checked when the tires are cold. Recommended tire pressure in kPa (kgf/cm, psi):
-
Front: 100 (1.00, 15) Back: 100 (1.00, 15)
Tire size
-
Front: 2.50-14 4PR Rear: 3.00-12 4PR
Tire brand (Cheng shin): C803 1 Check the tires for cuts, embedded nails, or other damage. 2 Check the front and rear wheels for trueness (refer to section 12 and 13). 3 Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits.
-
Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in)
4 Tighten any loose spokes.

-
Spoke wrench: 4.5 X 5.1 mm 07701-0020200 (Equivalent commercially available in the U.S.A.)
3-27
82
Steering Head Bearings
1 Check that the control cables do not interfere with handlebar rotation. 2 Support the motorcycle securely and raise the front wheel off the ground. 3 Check that the handlebar moves freely from side to side. 4 If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (page 12-18).
3-28
83
Section 4
Lubrication System
SECTION 4: LUBRICATION SYSTEM
4-1
84
Section 4: Lubrication System

Table of Contents
Topic Troubleshooting Specifications Torque Values Page 4-3 4-4 4-4 Topic Lubrication System Diagram Oil Pump Page 4-5 4-6
Service Information
WARNING! USED ENGINE OIL MAY CAUSE SKIN CANCER IF REPEATEDLY LEFT IN CONTACT WITH THE SKIN FOR PROLONGED PERIODS. ALTHOUGH THIS IS UNLIKELY UNLESS YOU HANDLE USED OIL ON A DAILY BASIS, IT IS STILL ADVISABLE TO THOROUGHLY WASH YOUR HANDS WITH SOAP AND WATER AS SOON AS POSSIBLE AFTER HANDLING USED OIL. KEEP OUT OF REACH OF CHILDREN. WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA.
When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. After the oil pump has been installed, check that there are no oil leaks.
The oil pump can be serviced with the engine installed in the frame. The service procedures in this section most be performed with the engine oil drained.
4-2
85

Troubleshooting
Symptom/Possible Causes Oil level too low Symptom/Possible Causes Oil contamination
Normal oil consumption Oil not changed or filter not cleaned often enough External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Low oil pressure Oil pump worn or damaged Oil not changed often enough Oil pump drive sprocket broken Worn piston rings
4-3
86

Specifications
Item Engine oil capacity At draining At disassembly Recommended engine oil 0.6 (0.6 US qt, 0.5 Imp qt) 0.8 (0.8 US qt, 0.7 Imp qt) GN4 4-stroke oil or equivalent motor oil API service classification SF or SG Viscosity: AE 10W-30 0.15 (0.006) 0.10-0.21(0.004-0.008) 0.03-0.08 (0.001-0.003) Standard (Unit: mm(in)) Service Limit
Oil pump rotor Tip clearance Body clearance Side clearance 0.20 (0.008) 0.27 (0.011) 0.12 (0.005)
Torque Values
Fastener Type Oil pump mounting screw Oil pump cover screw Torque (kg/m, ftlb) 8 N-m (0.8 kgfm, 5.8 lbfft) 5 N-m (0.5 kgfm, 3.6 lbfft) Fastener Type Oil drain bolt Torque (kg/m, ftlb) 25 N-m (2.5 kgfm, 18 lbfft)
4-4
87

Lubrication System Diagram
4-5
88

Oil Pump
Removal
Requisite Service
1 Drain the engine oil (page 3-12). 1 Install the oil pump shaft. Measure the tip clearance between the inner and outer rotors.
-
Service limit: 0.20 mm (0.008 in)
Procedure
2 Remove the following:
-
2 Measure the pump body clearance between the outer rotor and pump body.
-
Right crankcase cover (page 9-6) Clutch assembly (page 9-7)
3 Remove the three screws and oil pump assembly.
3 Measure the side clearance using a straight edge and feeler gauge.
-
Disassembly
1 Remove the three screws and oil pump cover. 2 Remove the oil pump shaft, and then remove the inner and outer rotor from the oil pump body.
Inspection
If any portion of the oil pump is worn beyond the specified service limit, replace the oil pump as an assembly. Temporarily install the outer and inner rotors into the oil pump body.
4-6
89

Oil Pump (contd)
Assembly
1 Install the inner and outer rotors into the oil pump body. 2 Install the oil pump shaft aligning the flats between the shaft and inner rotor. 3 Fill the oil pump with 0.5-1 cm of engine oil. 4 Install the oil pump cover and tighten the screws to the specified torque.
-
3 Install the oil pump into the crankcase while aligning the pump shaft groove with the cam chain guide spindle lug. 4 Install and tighten the three screws to the specified torque.
-
5 Install the following:

-
Clutch assembly (page 9-7) Right crankcase cover (page 9-12)
Installation
1 Install the rotor shaft collar into the crankcase. 2 Install a new gasket onto the oil pump body.
6 After installation, fill the crankcase with recommended oil (page 3-12) and check that there is no oil leak.
4-7
90

Memo
4-8
91
Section 5
Fuel System
SECTION 5: FUEL SYSTEM
5-1
92
Section 5: Fuel System

Table of Contents
Topic Troubleshooting Specifications Tools Air cleaner housing Carburetor removal Page 5-3 5-4 5-4 5-5 5-6 Topic Carburetor disassembly Carburetor assembly Carburetor installation Air screw adjustment Crankcase breather Page 5-8 5-9 5-10 5-11 5-12
Service Information
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. KEEP OUT OF REACH OF CHILDREN. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss of vehicle control. Note: If vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor drivability. When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. Before disassembling the carburetor, place a suitable container under the carburetor drain screw, loosen the screw and drain the carburetor. After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with piece of tape to prevent any foreign material from dropping into the engine. For fuel tank remove/install, see page 2-6
5-2
93

Troubleshooting
Symptom/Possible Causes Engine wont start No fuel to carburetor No fuel in fuel tank Fuel strainer clogged Fuel line clogged Float valve stuck Float level misadjusted Fuel tank breather tube clogged Air cleaner clogged Flooded engine Intake air leak Fuel contaminated/deteriorated Slow circuit clogged Improper choke operation Afterburn during engine braking Lean mixture in slow circuit Backfiring or misfiring during acceleration Ignition system faulty Fuel mixture too lean Poor performance (drivability) and poor fuel economy Fuel system clogged Ignition malfunction Too much fuel getting to the engine Rich mixture Choke valve stuck closed Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetor Fuel line restricted Ignition malfunction Fuel mixture too lean/ rich Fuel contaminated/ deteriorated Intake air leak Idle speed misadjusted Air screw misadjusted Slow circuit clogged Float level misadjusted Fuel tank breather tube clogged Symptom/Possible Causes Lean mixture Fuel jets clogged Float valve faulty Float level too low Fuel line restricted Carburetor air vent tube clogged Intake air leak Throttle valve operation faulty
No spark at spark plug (ign. problem) Engine stalls, hard start, rough idling
5-3
94

Specifications
Item Carburetor identification number Main jet Slow jet Jet needle clip position Air screw initial opening Idle speed Throttle grip free play Standard (Unit: mm(in)) PB12H #62 #38 x #38 3rd groove from top 10.7mm (0.42 in) 1,700 100 rpm 2.0 - 6.0 mm (1/12 - 1/4inch) Service Limit
Tools
Description Carburetor float level gauge Tool Number 074010010000 Alternate Tool Tool Number Refer to Page
5-4
95

Air Cleaner Housing
Requisite Service
Refer to page 3 - 9 for air cleaner element service.
Installation
Removal
1 Disconnect the crankcase breather tube from the air cleaner housing. 2 Loosen the connecting tube band screw. 3 Remove the bolt and air cleaner housing assembly 4 At installation, secure the ground eyelet with the air cleaner housing mounting bolt.
5-5
96

Carburetor Removal
5-6
97

Carburetor Removal (contd)
Throttle Valve
1 Loosen the carburetor top. 2 Remove the carburetor top and throttle valve from the carburetor. 3 Remove the throttle cable from the throttle valve while compressing the throttle valve spring. 4 Remove the jet needle retainer and jet needle. 5 Check the throttle valve and jet needle for scratches, wear or damage.
Carburetor Body
WARNING! GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. KEEP OUT OF REACH OF CHILDREN. 1 Loosen the drain screw and drain the fuel from float chamber into the approved gasoline container. 2 Disconnect the fuel tube, air vent tube, and drain tube from the carburetor body. 3 Loosen the carburetor connecting tube band screw. 4 Remove the carburetor mounting bolts, carburetor and insulator.
5-7
98

Carburetor Disassembly
1 Remove the screws and float chamber. 2 Remove the float pin, float and float valve. 3 Inspect the float for deformation or damage. 4 Inspect the float valve seat for scores, scratches, clogging and damage. 5 Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination. 6 Replace the valve if the tip is worn or contaminated. 7 Check the operation of the float valve. 8 Remove the following:
-
Needle jet Slow jet Throttle stop screw/spring
9 Turn the air screw in and record the number of turns it takes before it seats lightly. 10Remove the air screw and spring.
CAUTION: DAMAGE TO THE AIR SCREW SEAT WIL OCCUR IF THE AIR SCREW IS TIGHTENED AGAINST THE SEAT.
11 Inspect each jet for wear or damage and replace if necessary.
Main jet Needle jet holder
5-8
99

Carburetor Assembly
1 Blow open each air and fuel passage in the carburetor body with compressed air. 2 Install the following:
-
2 Install a new O-ring in the float chamber. 3 Install the float chamber. 4 Install and tighten the float chamber screws.
Throttle stop screw/spring Slow jet Needle jet Needle jet holder Main jet
CAUTION: HANDLE ALL JETS WITH CARE; THEY CAN BE EASILY SCRATCHED OR SCORED.
3 Install the air screw and return it to its original position as noted during removal. 4 Perform the air screw adjustment procedure if a new air screw is installed (page 5-11). 5 Install the float and float valve in the carburetor body, then install the float pin through the body and float.
Float Level Inspection

1 With the float valve seated and the float arm just touching the valve, measure the float level with the special tool.
-
Float Level: 10.7mm (0.42in) Tool: Carburetor float level gauge 07401-0010000
The float cannot be adjusted. Replace the float assembly if the float level is out of specification.
5-9
100

Carburetor Installation
Carburetor Body
1 Install the new O-rings into the insulator and carburetor body grooves. 2 Install the insulator and carburetor body to the intake manifold and tighten the bolts securely. Tighten the connecting tube band screw. 3 Install the fuel tube, drain tube and air vent tube.
Throttle Valve
1 Install the needle clip on the jet needle
-
Standard Position: 3rd groove from top.
2 Install the jet needle into the throttle valve and secure it with a needle clip retainer. 3 Install the throttle valve spring onto the throttle cable. 4 Connect the throttle cable to the throttle valve while compressing the throttle valve spring. 5 Install the throttle valve into the carburetor body, aligning its cut-out with the throttle stop screw. 6 Tighten the carburetor top securely. 7 After installing the carburetor, check for the following:
-
Throttle grip free play (page 3-8) Engine idle speed (page 3-16) Air screw adjustment (page 5-11)
5-10
101

Air Screw Adjustment
Idle Drop Procedure
2 Turn the air screw clockwise until it seats lightly, and then back it out to the specification given.
CAUTION: DAMAGE TO THE AIR SCREW SEAT WILL OCCUR IF THE AIR SCREW IS TIGHTENED AGAINST SEAT.
-
Initial Opening: 1 turns out
3 Attach a tachometer according to its manufacturer's instructions. WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA. Note: The air screw is factory pre-set and no adjustment is necessary unless the air screw is replaced. Note: The engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient. Note: Use a tachometer with graduations of 50rpm or less that will accurately indicate a change of 50rpm. 1 Warm up the engine until drain bolt is at operating temperature. 4 Adjust the idle speed with the throttle stop screw.
-
Idle Speed: 1,700 100rpm.
5 Turn the air screw in or out slowly to obtain the highest engine speed. 6 Snap the throttle 2 or 3 times and readjust the idle speed with the throttle stop screw. 7 Turn the air screw in gradually until the engine speed drops 100rpm. 8 Turn the air screw counterclockwise to the final opening from the position in step 7.
-
Final Opening: turns out
9 Readjust the idle speed with the throttle stop screw. 10Repeat steps 5 through 9 if the idle is not smooth.
5-11
102

Crankcase Breather
Remove the crankcase breather tube plug from the tube end and drain deposits into a suitable container. Then install the tube plug securely.
5-12
103
Section 6
Engine Remove/Install
SECTION 6:ENGINE REMOVE/INSTALL
6-1
104
Section 6: Engine Remove/Install

Table of Contents
Topic Specifications Torque values Page 6-3 6-3 Topic Engine removal/installation Page 6-4
Service Information
During the engine removal and installation, support the motorcycle securely using a hoist. Support the engine using a jack or other adjustable support to ease the engine hanger bolt removal. The following components can be serviced with the engine installed in the frame. Alternator/cam chain tensioner (Section 10) Clutch (Section 9) Cylinder/piston (Section 8) Cylinder head/valves (Section 7) Gearshift linkage (Section 9) Oil pump (Section 4) The following components require engine removal for service. Crankshaft/transmission (Section 11) Shift forks/shift drum (Section 11).
6-2
105

Specifications
Item Engine dry weight Engine oil capacity (disassembly) Standard (Unit: mm(in)) 17.7 kg (39.0 lbs) 0.8 l (0.8 US qt., 0.7 lmp qt) Service Limit
Torque Values
Fastener Type Drive sprocket fixing plate bolt Engine hanger bolt/nut (upper) Torque (kg/m, ftlb) 12 Nm (12 kgfm, 9 lbfft) 31 Nm (32 kgfm, 23 lbfft Fastener Type Engine hanger bolt/nut (lower) Torque (kg/m, ftlb) 31 Nm (3.2 kgfm, 23 lbfft
6-3
106

Engine Removal/Installation
Support the motorcycle securely with a hoist or equivalent
Requisite Service
Drain the engine oil (page 3-12). Remove the following:
-
Right side cover (page 2-8) Muffler (page 2-12) Kickstarter pedal (page 11-11) Left crankcase cover (page 10-5)
6-4
107

Engine Removal/Installation (contd)
Removal
1 Disconnect the spark plug cap. 2 Remove the intake manifold mounting bolts. 3 Disconnect the crankcase breather tube from the breather separator. 4 Disconnect the alternator and the ignition pulse generator connectors. 5 Loosen the rear axle nut and drive chain adjusting nuts. 6 Push the rear wheel forward and fully slacken the drive chain. 7 Remove the fixing plate bolts, fixing plate and drive sprocket. 8 Remove the bolts and foot-peg bar. 9 Unhook the brake pedal return spring. 10Loosen the engine hanger bolts/nuts. 11 Support the engine using a jack or other adjustable support to ease the engine hanger bolts removal. Remove the engine hanger bolts and engine from the frame. 1 Place the engine into the frame, and install the engine hanger bolts from the left side.
CAUTION:BE CAREFUL NOT TO DAMAGE THE FRAME.
2 Install the spring washers and nuts, and then tighten the nuts to the specified torque.
-
Torque: 31 Nm (3.2 kgfm, 23 lbfft)
3 Hook the brake pedal return spring to the tip of the lower engine hanger bolt. 4 Install the foot-peg bar and tighten the bolts. 5 Install the drive sprocket onto the countershaft. 6 Install the fixing plate and tighten the bolts to the specified torque. 7 Torque: 12 Nm (1.2 kgfm, 9 lbfft)Connect the crankcase breather tube from the breather separator. 8 Connect the alternator and ignition pulse generator connectors.
-
Installation
Note: Note the direction of the hanger bolts. Note: Use a floor jack or other adjustable support to carefully maneuver the engine into place. The lower engine hanger bolt has a spring hook.
Install a new O-ring into the groove of the intake manifold and install and tighten the intake manifold mounting bolts.
6-5
108

Engine Removal/Installation (contd)
Installation (contd)
9 Install the spark plug cap to the spark plug. 10Install the following:
-
Left crankcase cover (page 10-5) Kickstarter pedal (page 11-11) Muffler (page 2-12) Right side cover (page 2-8)
11 Pour recommended engine oil up to the proper level (page 3-12). 12Adjust the drive chain slack (page 317).
6-6
109
Section 7
Cylinder Head/Valves
SECTION 7: CYLINDER HEAD/VALVES
7-1
110
Section 7: Cylinder Head/Valves

Table of Contents
Topic Troubleshooting Specifications Torque values Tools Page 7-3 7-4 7-5 7-6 Topic Cylinder compression test Camshaft removal Cylinder head Camshaft installation Page 7-7 7-8 7-10 7-18
Service Information
This section covers service of the cylinder head, valves and camshaft. The cylinder head, valves and camshaft services can be done with the engine installed in the frame. When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Camshaft lubrication oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head. Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head.
7-2
111

Troubleshooting
Symptom/Possible Causes Compression too low, hard starting or poor performance at low speed Valves Incorrect valve clearance Burned or bent valve Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head -Leaking or damaged cylinder head gasket -Warped or cracked cylinder head -Loose spark plug Cylinder, piston Worn, stuck or broken piston ring Worn or damaged cylinder and piston Rough idle Low cylinder compression Cylinder, piston Worn cylinder, piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Excessive noise Incorrect valve clearance Sticking valve or broken valve spring Worn or damaged camshaft Worn or damaged rocker arm and/ or shaft Worn or damaged cam sprocket teeth Loose or worn cam chain Worn or damaged cam chain tensioner Loose spark plug Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noises with a sounding rod or stethoscope. If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for a seized piston ring (Section 8). Symptom/Possible Causes Compression too high, overheating, or knocking Excessive carbon built-up on piston or combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal
7-3
112

Specifications
Item Cylinder compression Standard (Unit: mm(in)) 981-1,177 kPa (10.0-12.0kgf/ cm, 142-171 psi) at 500-600 rpm 0.05 (0.002) 0.05 0.02 mm (0.002 0.001 in) 0.05 0.02 mm (0.002 0.001 in) 4.970-4.985 (0.1957-0.1963) 4.970-4.985 (0.1957-0.1963) 5.000-5.012 (0.1969-0.1973) 5.000-5.012 (0.1969-0.1973) 0.010-0.037 (0.0004-0.0015) 0.030-0.057 (0.0012-0.0022) 1.0-1.3 (0.04-0.05) 32.78 (1.291) 35.55 (1.400) 10.000-10.015 (0.3937-0.3943) 9.978-9.987 (0.3928-0.3932) 4.92 (0.194) 4.92 (0.194) 5.03 (0.198) 5.03 (0.198) 0.08 (0.003) 0.10 (0.004) 2.0 (0.08) 31.2 (1.23) 34.0 (1.34) 10.10 (0.398) 9.91 (0.390) Service Limit
Cylinder head warpage Valve Clearance IN EX Valve stem O.D. IN EX Valve Guide I.D. IN EX Stem-to-guide clearance IN EX Valve seat width Valve spring inner Valve spring outer Rocker arm I.D. Rocker arm shaft O.D.
7-4
113

Item Cam lobe height IN EX Standard (Unit: mm(in)) 27.945 (1.1002) 26.076 (1.0266) Service Limit 7.55 (1.085) 25.69 (1.011)
Torque Values
Fastener Type Valve adjuster hole cap Valve adjuster lock nut Cylinder head cap nut Torque (kg/m, ftlb) 12 Nm (1.2 kgfm, 9 lbfft) 9 Nm (0.9 kgfm, 6.5 lbfft) 11 Nm (1.1 kgfm, 8 lbfft) Fastener Type Cylinder head right side cover bolt Cam sprocket bolt Torque (kg/m, ftlb) 10 Nm (1.0 kgfm, 7 lbfft) 9 Nm (0.9 kgfm, 6.5 lbfft)
7-5
114

Tools
Description Valve adjusting wrench, 8 X 9 mm Valve adjuster B Valve spring compressor Valve spring compressor attachment Valve guide driver, 5.0 mm Valve guide reamer, 5.0 mm Tool Number 07708-0030100 Remarks Commercially available in USA 07908-KE90200 (USA) Refer to Section
07708-0030400 07757-0010000 07959KM30101 07942MA60000 07984MA60001
07984MA6000C (U.S.A. only)
Valve seat cutter Seat cutter, 24 mm (45 IN) Seat cutter, 20.5 mm (45 EX) Flat cutter, 24 mm (30 IN) Flat cutter, 21.5 mm (32 EX) Interior cutter, 22 mm (60 IN/EX) 07780-0010600 07780-0011000 07780-0012500 07780-0012800 07780-0014202
Cutter holder, 5 mm 07781-0010400
7-6
115

Cylinder Compression Test
WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA. 1 Warm up the engine to normal operating temperature. 2 Stop the engine and remove the spark plug. 3 Install a compression gauge. 4 Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising.
-
Compression Pressure: 981 1,177 kPa (10.0 - 12.0 kgf/cm2, 142 - 171 psi) at 500 - 600 rpm Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder Carbon deposits in combustion chamber or on piston head
Low compression can be caused by:

-
High compression can be caused by:

-
7-7
116

Camshaft Removal
1 Disconnect the spark plug cap. 2 Remove the valve adjuster hole caps. 3 Loosen the cylinder head side cover 6 mm bolt. Tap the head of the 6 mm bolt and release the cylinder head left side cover from the cylinder head.
4 Remove the 6 mm bolt, sealing washer and cylinder head left side cover.
7-8
117

Camshaft Removal (contd)
-
IN: 27.55 mm (1.085 in) EX: 25.69 mm (1.011 in)
Left crankcase cover (page 10-5) Cam chain tensioner (page 10-7)
6 Turn the crankshaft counterclockwise and align the "O" mark on the cam sprocket with the index notch on the cylinder head. 7 Suspend the cam chain with a piece of wire to prevent it from falling into the cylinder. 8 Remove the bolts, cam sprocket and dowel pin. 9 Loosen the valve adjusting screw fully to make a valve clearance maximum. 10Temporarily install the cam sprocket bolts onto the camshaft, and then remove the camshaft from the cylinder head.
Inspection
1 Turn the outer race of each camshaft bearing with your finger. 2 The outer race should turn smoothly and quietly. 3 Also check that the bearing inner race fits tightly on the camshaft. 4 Replace the camshaft assembly if the outer race does not turn smoothly and quietly, or if it fits loosely on the camshaft. 5 Using a micrometer, measure each cam lobe height. Service Limits:
7-9
118

Cylinder Head
Removal
-
Gasket Dowel pins Collar, 14.8 mm O-ring, 14.5 mm
Muffler/exhaust pipe (page 2-12) Camshaft (page 7-8)
2 Remove the intake manifold mounting bolts. 3 Remove the following:

-
Cap nuts/sealing washers Nut/sealing washer Cylinder head cover Gasket
4 Remove the cylinder head mounting bolt and cylinder head. 5 Remove the following:
7-10
119

Disassembly
1 Remove the bolts and cylinder head right side cover. 2 Temporarily install a 8 mm bolt to the rocker arm shaft and remove the rocker arm shafts and rocker arms. 3 Remove the valve spring cotters using the special tools. Tools:
-
Inspection
Cylinder Head
Avoid damaging the gasket surface. 1 Remove carbon deposits from the combustion chamber. 2 Check the spark plug hole and valve areas for cracks. 3 Check the cylinder head for warpage with a straight edge and feeler gauge.
-
Valve spring compressor: 07757 0010000 Valve spring compressor attachment: 07959 - KM30101 CAUTION: TO PREVENT LOSS OF TENSION, DO NOT COMPRESS THE VALVE SPRINGS MORE THAN NECESSARY TO REMOVE THE COTTERS.
Service Limit: 0.05 mm (0.002 in)
Rocker Arm
1 If either rocker arm requires service or replacement, inspect the cam lobes for scoring, chipping or flat spots. 2 Inspect the rocker arm slipper surfaces for wear or damage. 3 Also check that the oil holes are not clogged. 4 Measure the rocker arm I.D.
-
4 Mark all parts during disassembly so they can be placed back in their original locations. 5 Remove the following:
-
Spring retainer Outer and inner valve springs Valve Stem seal Valve spring seat
5 Inspect the rocker arm shafts for wear or damage. 6 Measure the O.D. of the rocker arm shaft.
-
7-11
120

Inspection (contd)
Valve Spring
1 Measure the free length of the inner and outer valve springs. Service Limits:
-
Service Limit (IN/EX): 5.03 mm (0.198 in)
6 Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. Service Limits:
-
Inner: 31.2 mm (1.23 in)

-
IN: 0.08 mm (0.003 in) EX: 0.10 mm (0.004 in)
Outer: 34.0 mm (1.34 in)
2 Replace the springs if they are shorter than the service limits.
7 Replace the valve seats whenever the valve guides are replaced (pages 7 14). 8 If the stem-to-guide clearance is out of specification, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to fit. If the stem-to-guide clearance is out of specification with the new guides, replace the valves and guides.
Valve
1 Inspect each valve for bending, burning or abnormal stem wear. 2 Check valve movement in the guide, measure and record each valve stem O.D.
-
Service Limit (IN/EX): 4.92 mm (0.194 in)
3 Ream the guides to remove any carbon deposits before checking clearances. 4 Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise.
-
Tool: Valve guide reamer, 5.0mm 07984 - MA60001 or 07984 MA6000C (U.S.A. only)
5 Measure and record each valve guide I.D.
7-12
121

Valve Guide Replacement
1 Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 212-302F (100 - 150C) with a hot plate or oven. WARNING! TO AVOID BURNS, WEAR HEAVY GLOVES WHEN HANDLING THE HEATED CYLINDER HEAD. CAUTION: DO NOT USE A TORCH TO HEAT THE CYLINDER HEAD; IT MAY CAUSE WARPING. 2 Support the cylinder head and drive out the valve guides from combustion chamber side of the cylinder head.
-
Tool: Valve guide reamer, 5.0m 07984 - MA60001 Note: use cutting oil on the reamer during the operation.
7 Clean the cylinder head thoroughly to remove any metal particles. 8 Reface the valve seat (see below).
Valve Seat Inspection

1 Clean the intake and exhaust valves thoroughly to remove carbon deposits. 2 Apply a light coating of Prussian Blue to the valve seats. Lap the valves and seats using a rubber hose or other hand-lapping tool. 3 Remove and inspect the valves.
CAUTION: THE VALVES CANNOT BE GROUND. IF A VALVE FACE IS BURNED OR BADLY WORN O RIF IT CONTACTS THE SEAT UNEVENLY, REPLACE THE VALVE.
Tool: Valve guide driver, 5.0mm 07942 - MA60000
3 Drive in the guide from the top of the head using the special tool.
-
Tool: Valve guide driver, 5.0 mm 07942 - MA60000
4 Let the cylinder head cool to room temperature. 5 Ream the new valve guide after installation. 6 Insert the reamer from the combustion chamber side of the head and also always rotate the reamer clockwise.
4 Inspect the width of each valve seat.

-
Standard: 1.0 - 1.3mm (0.04 - 0.05 in) Service Limit: 2.0 mm (0.08 in)
If the seat is too wide, too narrow or has low spots, the seat must be ground.
7-13
122

Valve Seat Refacing
Valve seat cutters/grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seats. Note: Follow the refacing manufacturers operating instructions. Use the following valve seat cutters (equivalent commercially available in U.S.A.): 30/32
-
5 Remove the cutter and inspect the area you have refaced.
Old Seat Width 60

1 Install a 45-degree finish cutter and cut the seat to the proper width. 2 Make sure that all pitting and irregularities are removed. Refinish if necessary.
-
1.2 mm (0.0n) 45
IN: 07780 - 0012500 (24 mm/30) EX: 07780 - 0012800 (21.5 mm/ 32)
3 Apply a thin coating of Prussian Blue to the valve seat. 4 Press the valve through the valve guide and onto the seat to make a clear pattern. Note: The location of the valve seat in relation to the valve face is very important for good sealing. If the contact area is too high on the valve, the seat must be lowered using a 32-degree flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60-degree inner cutter.
45
-
IN: 07780 - 0010600 (24 mm) EX: 07780 - 0011000 (20.5 mm)
60
-
IN, EX 07780 - 0014202 (22 mm)
1 Reface the seat with a 45-degree cutter whenever a valve guide is replaced. 2 Use a 45-degree cutter to remove any roughness or irregularities fro the seat. 3 Use a 32-degree (IN: 30) cutter to remove the top of the existing valve seat material.
Old seat width 30/32

4 Use a 60-degree cutter to remove the bottom of the old seat.
7-14
123

Valve Seat Refacing (contd)
5 Refinish the seat to specifications, using a 45-degree finish cutter. 6 After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. Do not allow lapping compound to enter guides. After lapping, wash all residual compound off the cylinder head and valve.
7-15
124

Assembly
1 Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air. 2 Install the valve spring seats. 3 Install the new stem seals. 4 Lubricate the valve stems with engine oil and insert the valve into the valve guide. 5 To avoid damage to the stem seal, turn the valve slowly when inserting. 6 Install the valve springs with the tightly wound coils facing the combustion chamber. 7 Install the valve spring retainer. 8 Install the valve cotters using the special tools. Tools:
-
CAUTION: SUPPORT THE CYLINDER HEAD ABOVE THE WORK BENCH SURFACE TO PREVENT POSSIBLE VALVE DAMAGE. 10Install the rocker arm shaft with its threaded end facing the right side 11 Install the rocker arms and rocker arm shafts. 12Install a new gasket onto the cylinder head right side cover. 13Install the right side cover onto the cylinder head. 14Install and tighten the right side cover mounting bolts.
-
Installation
1 Clean off the gasket material from the cylinder surface. 2 Install the following:
-
Valve spring compressor: 07757 0010000 Valve spring compressor attachment: 07959 - KM30101 CAUTION: TO PREVENT LOSS OF TENSION, DO NOT COMPRESS THE VALVE SPRINGS MORE THAN NECESSARY.
New O-ring, 14.5 mm Collar, 14.8 mm Dowel pins New gasket
9 Tap the valve stems gently with two plastic hammers to seat the cotters firmly.
7-16
125

3 Install the cylinder head 4 Install a new gasket onto the cylinder head and then install the cylinder head cover. 5 Install the cylinder head cover with its "arrow" mark facing down. 6 Install the following:
-
Cap nuts/new sealing washers Nut/new sealing washer Note: Note the position of the new copper washer.
7 Tighten the cylinder head cover nuts to the specified torque.

-
8 Install and tighten the cylinder head mounting bolt. 9 Install a new O-ring into the groove of the intake manifold. 10Install and tighten the intake manifold mounting bolts. 11 Install the following:
-
Muffler/exhaust pipe (page 2-12) Camshaft (see below)
7-17
126

Camshaft Installation
1 Apply clean engine oil to the camshaft and bearings. 2 Install the camshaft into the cylinder head with its cam lobes facing the combustion chamber. 3 Turn the crankshaft counterclockwise and align the "T" mark with the index notch on the left crankcase. 4 Install the dowel pin and cam sprocket. Note: Install the cam sprocket with its O mark index notch on the cylinder head.
7-18
127

Camshaft Installation (contd)
5 Install and tighten the cam sprocket bolts to the specified torque.
-
Torque: 9 Nm (0.9 kgfm, 6.5 lbfft)
6 Install a new gasket and the cylinder head left side cover onto the cylinder head. Align the tab on the side cover with the stopper on the cylinder head. 7 Install the 6mm bolt with a new sealing washer on the cylinder head and tighten it. 8 Adjust the valve clearance (page 311). 9 Apply oil to the valve adjuster hole cap threads. 10Check that the O-ring is in good condition, replace if necessary. 11 Coat the O-rings with clean engine oil and install them onto the valve adjuster hole caps. 12Install and tighten the valve adjuster hole caps to the specified torque.
-
13Install the spark plug cap. 14Install the left crankcase cover (page 10-8).
7-19
128

Memo
7-20
NIKOTA USA: PANTERRA 50 / 90CC DIRT BIKE SERVICE MANUAL
129
Section 8
Cylinder/Piston
SECTION 8: CYLINDER/PISTON
8-1
130
Section 8: Cylinder/Piston
Table of Contents
Topic Troubleshooting Specifications Torque values Cylinder removal Page 8-3 8-4 8-5 8-6 Topic Piston removal Cylinder/piston inspection Piston installation Cylinder installation Page 8-7 8-8 8-9 8-11
Service Information
This section covers the centrifugal clutch, change clutch and gearshift linkage service. These parts can be serviced with the engine installed in the frame.
8-2
131
Troubleshooting
Symptom/Possible Causes Cylinder compression is too low, or engine is hard to start Blown cylinder head gasket Worn, stuck or broken piston ring Worn or damaged cylinder or piston Excessive smoke Work, stuck or broken piston ring If the performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for a seized piston ring. Symptom/Possible Causes Piston rattle Worn cylinder, piston and/or piston ring Worn piston pin hole and piston pin Worn connecting rod small end
8-3
132
Specifications
Item Cylinder I.D. Cylinder out of round Cylinder taper Cylinder warpage Piston mark direction Piston O.D. (D) Piston O.D. measurement point (H) Piston pin hole I.D. (d) Standard (Unit: mm(in))
47.005-47.015 (1.8506-1.8510)
Service Limit
47.05 (1.852) 0.10 (0.004) 0.10 (0.004) 0.05 (0.002)
"in" mark facing toward the intake side 46.980-46.995 (1.8496-1.8502) 10 mm (0.4 in) from bottom of skirt 13.002-13.008 (0.5119-0.5121)
46.90 (1.846) 13.06 (0.514)
Piston pin O.D. Piston-to-piston pin clearance Top ring-to-ring groove clearance Second ring-to-ring groove clearance Top ring end gap
12.994-13.000 (0.5116-0.5118) 0.002-0.014 (0.0001-0.0006) 0.015-0.050 (0.0006-0.0020) 0.015-0.050 (0.0006-0.0020) 0.05-0.20 (0.002-0.008)
12.98 (0.511) 0.08 (0.003) 0.12 (0.005) 0.12 (0.005) 0.5 (0.02)
8-4
133
Item Second ring end gap Oil (side rail) Cylinder-to-piston clearance Connecting rod small end I.D. Connecting rod-to-piston pin clearance Standard (Unit: mm(in)) 0.05-0.20 (0.002-0.008) 0.010-0.040 (0.0004-0.0016) 13.013-13.043 (0.5123-0.5135) 0.002-0.014 (0.0001-0.0006) Service Limit 0.5 (0.02) 1.1 (0.04) 0.15 (0.006) 13.10 (0.516) 0.08 (0.003)
Torque Values
Fastener Type Cam chain guide roller pin bolt Torque (kg/m, ftlb) 10 Nm (1.0 kgfm, 7 lbfft) Fastener Type Torque (kg/m, ftlb)
8-5
134
Cylinder Removal
1 Remove the cylinder head (page 710). 2 Remove the cam chain guide roller pivot bolt, washer and guide roller. 3 Remove the mounting bolt and cylinder. 4 Remove the following:
-
Rubber packing Gasket Dowel pins
8-6
135
Piston Removal
Do not let the piston pin clips fall into the crankcase. 1 Remove the piston pin clip with pliers. 2 Press the piston pin out of the piston and remove the piston. 3 Do not damage the piston rings during removal. 4 Remove the piston rings.
8-7
136
Cylinder/Piston Inspection
Cylinder
1 Inspect the cylinder bore for wear or damage. 2 Measure the cylinder I.D. in X and Y axis at three levels. 3 Take the maximum reading to determine the cylinder wear.
-
10Temporarily install the piston rings to their proper position with the mark facing up. 11 Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves. Service Limits:
-
Top: 0.12 mm (0.005 in) Second: 0.12 mm (0.005 in)
4 Calculate the piston-to-cylinder clearance. 5 Take a maximum reading to determine the clearance. 6 Refer to page 8-7 for measurement of the piston O.D.
-
7 Calculate the taper and out of round at three levels in X and Y axis. Take the maximum reading to determine them. Service Limits:
-
Taper: 0.10 mm (0.004 in) Out of round: 0.10 mm (0.004 in)
The cylinder must be rebored and an oversize piston must be: 0.010 - 0.040 mm (0.004 - 0.0016 in). 8 Inspect the top of the cylinder for warpage.
-
Service Limit: 0.05mm (0.002 in)
9 Remove any carbon deposits from the piston ring grooves, using an old piston ring.
8-8
137
Cylinder/Piston Inspection (contd)
Cylinder (contd)
12Inspect the piston for wear or damage. 13Measure the diameter of the piston at 10 mm (0.4 in) from the bottom and 90-degrees to the piston pin hole.
-
Note: Apply oil to the piston rings.

CAUTION: AVOID PISTON AND RING DAMAGE DURING INSTALLATION.
Note: Notes give helpful information.

CAUTION: DO NOT MIX THE TOP AND SECOND RINGS; THE TOP RING IS NARROWER THAN THE SECOND RING IN WIDTH.
14Measure the piston pin bore.

-
15Measure the O.D. of the piston pin.

-
16Calculate the piston-to-piston pin clearance.

-
2 Space the piston ring end gaps 120 degrees apart. 3 Do not align the gaps in the oil rings (side rails). 4 After installation, the rings should rotate freely in the ring grooves.
17Measure the connecting rod small end I.D.

-
18Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder. 19Insert the piston ring squarely into the bottom of the cylinder and measure the ring end gap. Service Limits:
-
Top: 0.5 mm (0.02 in) Second: 0.5 mm (0.02 in) Oil (side rail): 1.1 mm (0.04 in)
Piston Ring Installation

1 Clean the piston ring grooves thoroughly and install the piston rings.
8-9
138
Piston Installation
1 Apply oil to the piston pin outer surface. 2 Install the piston with its "IN" mark facing the intake side. 3 Install the piston pin and secure it with new piston pin clips. Note: Do not align the piston pin clips end gap with the piston cut-out. Note: Do not let the piston pin clips fall into the crankcase.
8-10
139
Cylinder Installation
1 Clean off any gasket materials from the crankcase surface. 2 Install the dowel pins, new gasket, and new rubber packing. 3 Coat the cylinder bore, piston outer surface and piston ring grooves with clean engine oil. 4 Install the cylinder while compressing the piston rings.
CAUTION: AVOID PISTON AND RING DAMAGE DURING INSTALLATION.
Note: Do not the cam chain fall into the crankcase. 5 Install the cam chain guide roller, new sealing washer and pin bolt. 6 Tighten the cam chain guide roller pin bolt to the specified torque.
-
7 Install the cylinder mounting bolt, but do not tighten it yet. 8 Install the cylinder head and tighten the bolt and nuts (page 7-10). 9 Tighten the cylinder mounting bolt. 10Install the removed parts in the reverse order of removal.
8-11
140
Memo
8-12
141
Section 9
Clutch/Gearshift Linkage
SECTION 9: CLUTCH/GEARSHIFT LINKAGE
9-1
142
Section 9: Clutch/Gearshift Linkage

Table of Contents
Topic Troubleshooting Specifications Torque values Tools Page 9-3 9-4 9-4 9-5 Topic Right crankcase cover removal Clutch Gearshift linkage Right crankcase cover installation Page 9-6 9-7 9-11 9-12
Service Information
CAUTION: DO NOT OPERATE THE STARTER FOR MORE THAN 5 SECONDS AT A TIME. LET IT REST APPROXIMATELY 10 SECONDS, THEN USE IT AGAIN.
The overhaul of a starter motor is best left to an expert. The disassembly, inspection and assembly procedures show how to detect a defective starter.
9-2
143

Troubleshooting
Symptom/Possible Causes Clutch slips when accelerating Incorrect clutch adjustment Worn clutch disc Weak clutch springs Faulty clutch weight Transmission oil mixed with molybdenum or graphite additive Hard to shift Incorrect clutch adjustment Loose stopper plate bolt Damaged stopper plate and pin Damaged gearshift spindle Symptom/Possible Causes Motorcycle creeps with clutch disengaged Incorrect clutch adjustment Clutch plate warped Faulty clutch lifter Incorrect engine oil weight Transmission jumps out of gear Worn shift drum stopper arm Weak or broken shift arm return spring Loose stopper plate bolt Gearshift pedal will not return Weak or broken gearshift spindle return spring Bent gearshift spindle
9-3
144

Specifications
Item Clutch disc thickness A Clutch disc thickness B Clutch plate warpage Centrifugal clutch spring free length Primary drive gear I.D. Clutch center guide I.D. Clutch center guide O.D. Crankshaft O.D. at clutch center guide Standard (Unit: mm(in)) 2.52-2.68 (0.099-0.106) 3.35-3.45 (0.132-0.136) 17.3 (0.68) 21.000-21.021 (0.8268-0.8276) 16.988-17.006 (0.6688-0.6695) 20.930-20.950 (0.8240-0.8248) 16.966-16.984 (0.6680-0.6687) Service Limit 2.3 (0.09) 3.0 (0.12) 0.20 (0.008) 16.4 (0.65) 21.05 (0.829) 17.04 (0.671) 20.90 (0.823) 16.90 (0.665)
Torque Values
Fastener Type Clutch outer cover screw Clutch lock nut Clutch outer spring screw Torque (kg/m, ftlb) 4 (0.45, 3.3) 42 (4.3, 31) 6 (0.6, 4.3) Fastener Type Shift drum stopper arm bolt Shift return spring pin Gearshift cam bolt Torque (kg/m, ftlb) 13 (1.3, 9) 29 (3.0, 22) 17 (1.7, 12)
9-4
145

Tools
Description Flywheel holder Lock nut wrench, 20 X 24 mm Extension bar Tool Number 07725-0040000 07716-0020100 07716-0020500 Remarks Refer to Section
9-5
146

Right Crankcase Cover Removal
Requisite Service
1 Drain the engine oil (page 3-12). 2 Remove the footpeg bar.
Removal
1 Remove the bolt and kickstarter pedal. 2 Unhook the brake pedal return spring. 3 Loosen the rear brake pedal adjusting nut and lower the brake pedal. 4 Remove the bolts and right crankcase cover. 5 Remove the gasket and dowel pins. 6 Remove the clutch adjusting nut, washer and O-ring. 7 Remove the clutch lifter/adjusting bolt assembly. 8 Check the kickstarter oil seal for damage, replace if necessary.
9-6
147

Clutch
Removal
1 Remove the clutch lifter lever, ball retainer and spring. 2 Remove the oil trough and spring. 3 Remove the clutch lifter cam plate. 4 Remove the screws and clutch outer cover and bearing.
Flywheel holder: 07725 - 0040000 (Equivalent commercially available in U.S.A.) Lock nut wrench, 20 x 24 mm: 07716 - 0020100 Extension bar: 07716 - 0020500 (Equivalent commercially available in the U.S.A.)
Removal (contd)
5 Bend up the tab of the lock washer. 6 Hold the clutch outer with the flywheel holder and remove the lock nut using the special tools. Tools:
7 Remove the lock washer B, 14 mm lock washer and clutch assembly. 8 Remove the primary drive gear. 9 Remove the clutch center guide.
9-7
148

Clutch (contd)
Removal (contd)
10Remove the snap ring and primary driven gear from the mainshaft. 11 Remove the collar from the crankshaft. 2 The bearing should turn smoothly and freely without excessive play. 3 Also check that the bearing fits tightly in the clutch outer cover. 4 If necessary, replace the bearing.
Disassembly
-
Clutch Spring
Measure the clutch spring free length. Service Limit: 16.4 mm (0.65 in)
Set ring Clutch plate B Clutch disc A Clutch disc B Clutch disc A Free springs Clutch plate A
Clutch Disc
1 Replace the clutch discs if they show signs of scoring or discoloration. 2 Measure the disc thickness of each disc. Service Limits:
-
2 Remove the drive gear outer and clutch center. 3 Remove the four damper springs. 4 Remove the four screws and plain washers. 5 Remove the drive plate assembly and clutch springs. 6 Remove the clutch weight stopper ring. 7 Remove the clutch weights and the center ring.
Clutch disc A: 2.3 mm (0.09 in) Clutch disc B: 3.0 mm (0.12 in)
Inspection
Clutch Lifter Bearing
1 Turn the inner race of the lifter bearing with your finger.
9-8
149

Clutch (contd)
Inspection (contd)
Clutch Plate
Check each disc plate for warpage on a surface plate using a feeler gauge. Service Limit: 0.20 mm (0.008 in) 2 Install the clutch springs onto the clutch outer bosses. 3 Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs. 4 Install the plain washers and screws. 5 Tighten the screws in a crisscross pattern in 2-3 steps.
-
Primary drive gear/clutch center guide

1 Check the primary drive gear and clutch center guide for excessive wear or damage. 2 Measure the I.D. of the primary drive gear.
-
Torque: 6 N.m (0.6 kgf.m, 4.3 lbf.ft)
6 Install the damper springs. 7 Note the direction of the drive gear outer. 8 Install the clutch center and drive gear outer. 9 Install the following:
-
3 Measure the O.D. and the I.D. of the clutch center guide. Service Limits:
-
Clutch plate A Free springs Clutch disc A Clutch disc B Clutch disc A Clutch plate B Note: Install the clutch plate A with its flat surface facing the clutch plate B. Note: Install the clutch plate B with its chamfered surface facing the clutch plate A.
I.D.: 17.04 mm (0.671 in) O.D.: 20.90 mm (0.823 in)
Crankshaft
Measure the crankshaft O.D. at clutch center guide. Service Limit: 16.90 mm (0.665 in)
Drive gear outer/clutch center

Check the drive gear outer and clutch center for excessive wear or damage.
Assembly
1 Install the clutch weights and center ring onto the drive plate and secure them with the stopper ring.
10Install the clutch set ring with its chamfered end facing the clutch plate B.
9-9
150

Clutch (contd)
Installation
1 Install the collar onto the crankshaft. 2 Install the primary driven gear onto the mainshaft and secure it with the snap ring. 3 Install the clutch center guide onto the crankshaft. 4 Install the primary drive gear. 5 Install the clutch assembly onto the crankshaft. 6 Install the new 14 mm lock washer aligning its tab with the groove in the clutch outer. 7 Install the lock washer B with its "OUT SIDE" mark facing out. 8 Install the lock nut. 9 Hold the clutch outer with the flywheel holder and tighten the lock nut to the specified torque using the special tools. Tools:
-
11 Bend the tab of the 14 mm lock washer into the groove of the lock nut. 12Clean the inside of the clutch outer and outer cover. 13Install the bearing and new gasket onto the clutch outer cover. 14Install the clutch outer cover and tighten the screws to the specified torque.
-
Torque: 4 Nm (0.45 kgfm, 3.3 lbfft)
15Install the clutch lifter cam plate. 16Install the oil through spring and oil through. 17Install the cam plate side spring. 18Install the ball retainer and clutch lifter lever. 19Install the right crankcase cover (page 9-12).
Flywheel holder: 07725 - 0040000 (Equivalent commercially available in U.S.A.) Lock nut wrench, 20 x 24 mm: 07716 - 0020100 Extension bar: 07716 - 0020500 (Equivalent commercially available in U.S.A. Torque: 42 Nm (4.3 kgfm, 31 lbfft)
10If the lock nut groove does not align with the lock washer tab, further tighten the lock nut and align.
9-10
151

Gearshift Linkage
Removal
1 Clean the gearshift spindle end to prevent dirt from entering the crankcase. 2 Remove the clutch and primary driven gear (page 9-7). 3 Remove the bolt and gearshift pedal. 4 Remove the bolt, stopper arm and return spring. 5 Pull down the gearshift arm, and then pull out the gearshift spindle from the crankcase. 6 Remove the bolt and shift cam plate. 7 Remove the dowel pins and gearshift drum pins.
Installation
1 Install the fourth gearshift drum pins and two dowel pins. 2 Install the stopper plate and tighten the bolt to the specified torque.
-
3 Install the gearshift spindle while pushing down the gearshift arm and align the return spring end with the crankcase stopper pin. 4 Install the return spring and stopper arm; tighten the bolt to the specified torque.
-
Inspection
Check the gearshift spindle for bending or other damage.
5 Install the gearshift pedal and tighten the bolt. 6 Install the following:
-
Clutch (page 9-7) Right crankcase cover (see below)
9-11
152

Right Crankcase Cover Installation
1 Install the clutch lifter plate/adjusting bolt into the right crankcase cover while aligning its pin with the hole in the crankcase cover. 2 Remove the clutch and primary driven gear (page 9-7). 3 Remove the bolt and gearshift pedal. 4 Install the dowel pins and new gasket. 5 Install the right crankcase cover. 6 Install and tighten the right crankcase cover SH bolts. 7 Install the kickstarter pedal and tighten the bolt. Hook the return spring to the brake pedal and lower engine hanger bolt. 8 Adjust the brake pedal free play (page 3-21). 9 Install the footpeg bar. 10Pour the recommended engine oil (page 3-12) and make sure there are no oil leaks. 11 Adjust the clutch (page 3-22).
9-12
153
Section 10
Alternator/Cam Chain Tensioner
SECTION 10: ALTERNATOR/CAM CHAIN TENS.
10-1
154
Section 10: Alternator/Cam Chain Tens.

Table of Contents
Topic Troubleshooting Specifications Torque values Tools Page 10-3 10-4 10-4 10-4 Topic Flywheel/stator removal Cam chain tensioner Stator/flywheel installation Page 10-5 10-7 10-8
Service Information
This section covers service of the flywheel, alternator, and cam chain tensioner. All service can be done with the engine installed in the frame. Refer to section 14 for alternator stator inspection.
10-2
155

Troubleshooting
Symptom/Possible Causes Loose cam chain Weak or damaged cam chain tensioner spring Improper push rod operation Clogged one-way valve Air in cam chain tensioner chamber Symptom/Possible Causes Excessive engine noise Worn or damaged cam chain tensioner Clogged one-way valve Weak or damaged cam chain tensioner spring
10-3
156

Specifications
Item Cam chain tensioner push rod O.D. Spring free length Standard (Unit: mm(in)) 11.985-12.000 (0.4718-0.4724) 117 (4.6) Service Limit 11.94 (0.470) 100 (3.9)
Torque Values
Fastener Type Flywheel nut Cam chain tensioner sealing bolt Torque (kg/m, ftlb) 41 (4.2, 30) 23 (2.3, 17) Fastener Type Cam chain tensioner pivot bolt Torque (kg/m, ftlb) 16 (1.6, 12)
Tools
Description Universal holder Flywheel puller Tool Number 07725-0030000 07933GE00000 079330010000 in USA Remarks Refer to Section
10-4
157

Flywheel/Stator Removal
1 Disconnect the alternator and ignition pulse generator connectors. 2 Remove the bolt and gearshift pedal. 3 Remove the SH bolts and left crankcase cover.
4 Hold the flywheel using the universal holder, and then remove the flywheel nut.
-
Tool: Universal holder 07725 0030000
10-5
158

Flywheel/Stator Removal (contd)
5 Remove the washer. 6 Remove the flywheel using the special tool.
-
Tool: Flywheel puller 07933GE00000 (Not available in U.S.A.) Flywheel puller 07933- 0010000 (U.S.A. only)
7 Remove the woodruff key. 8 Remove the bolt and wire clamp. 9 Release the wire grommet from the crankcase groove. 10Remove the ignition pulse generator mounting bolts and wire clamp. 11 Remove the stator mounting bolts. 12Remove the ignition pulse generator and stator as an assembly. 13Drain the engine oil (page 3-12). 14Remove the screws and stator base. 15Remove the 0-rings.
10-6
159

Cam Chain Tensioner
Removal
1 Remove the stator base (page 10-5). 2 Remove the sealing bolt, tensioner spring and pushrod. 3 Remove the pivot bolt, tensioner arm and tensioner roller. 7 Check the sealing washer is in good condition, install the sealing washer and bolt. 8 Tighten the bolt securely.
Inspection
1 Measure the tensioner spring free length.
-
Service Limit: 100 mm (3.9 in)
2 Check the push rod for wear or damage. 3 Measure the push rod O.D.
-
Installation
1 Install the cam chain tensioner roller, tensioner arm and pivot bolt. 2 Tighten the pivot bolt to the specified torque.
-
Torque: 16 N (1.6 kgfm, 12 lbfft)
3 Install the push rod and tensioner spring. Check to see if the sealing washer is in good condition, install the cam chain tensioner sealing bolt. 4 Tighten the sealing bolt to the specified torque.
-
5 Remove the crankcase sealing bolt and washer. 6 Pour 1 - 23 cm of engine oil into the push rod.
10-7
160

Stator/Flywheel Installation
1 Check the stator base oil seal for damage, replace if necessary. 2 Apply grease to the lip of the oil seal. 3 Apply engine oil to the new 0-rings; install them onto the crankcase grooves and stator base groove. 4 Install the stator base and tighten the screws securely.
CAUTION: BE CAREFUL NOT TO DAMAGE THE OIL SEAL LIPS.
5 Install the stator, wire clamp and ignition pulse generator, then tighten the bolts securely. 6 Set the wire grommet into the crankcase groove. 7 Install the wire clamp and tighten the bolt. 8 Clean any oil from the crankshaft taper. 9 Install the woodruff key on the crankshaft. 10Install the flywheel by aligning the key way in the flywheel with the woodruff key on the crankshaft. Install the washer and flywheel nut. 11 Hold the flywheel using the universal holder, and then tighten the nut to the specified torque.
-
Tool: Universal holder 077250030000 Torque: 41 N (4.2 kgfm, 30 lbfft)
10-8
161
Section 11
Crankshaft/ Transmission/Kickstarter
SECTION 11: CRANK/TRANS/KICKSTARTER
11-1
162
Section 11: Crank/Trans/Kickstarter

Table of Contents
Topic Troubleshooting Speciifcations Torque values Tools Crankcase separation Page 11-3 11-4 11-5 11-5 11-6 Topic Crankshaft Transmission Kickstarter Crankcase assembly Page 11-7 11-8 11-11 11-12
Service Information
The crankcase must be separated to service the crankshaft, transmission and kickstarter. The following parts must be removed before separating the crankcase. Alternator/cam chain tensioner (Section 10) Clutch/gearshift linkage (Section 9) Cylinder head (Section 7) Cylinder/piston (Section 8) Engine (Section 6) Oil pump (Section 4)
11-2
163

Troubleshooting
Symptom/Possible Causes Hard to shift Incorrect clutch adjustment Bent shift fork Bent fork claw Damaged shift drum cam groove Incorrect transmission oil weight Excessive noise Worn crankshaft big end bearing Worn crankshaft journal bearing Symptom/Possible Causes Transmission jumps out of gear Worn gear dogs and slots Bent fork shaft Broken shift drum stopper
11-3
164

Specifications
Crankshaft
Item Side clearance Radial clearance Runout Standard (Unit: mm(in)) 0.010-0.350 (0.0004-0.0138) 0-0.012 (0-0.0005) Service Limit 0.60 (0.024) 0.05 (0.002) 0.10 (0.004)
Transmission
Item Gear I.D. M2 C1 C3 Bushing O.D. C1 Bushing I.D. C1 Gear-to-bushing clearance C1 Mainshaft O.D. M2 Countershaft O.D. C1 Gear-to-shaft clearance M2 Standard (Unit: mm(in)) 17.016-17.043 (0.6699-0.6710) 23.020-23.053 (0.9063-0.9076) 20.020-20.053 (0.7882-0.7895) 22.979-23.000 (0.9047-0.9055) 20.000-20.021 (0.7874-0.7882) 0.020-0.074 (0.0008-0.0029) 16.9840-16.9860 (0.668660.66874) 19.959-19.980 (0.7858-0.7866) 0.022-0.059 (0.0009-0.0023) Service Limit 17.10 (0.673) 20.10 (0.791) 20.10 (0.791) 22.93 (0.903) 20.08 (0.791) 0.10 (0.004) 16.950 (0.6673) 19.94 (0.785) 0.10 (0.004)
11-4
165

Item Gear bushing-to-shaft clearance C1 Shift fork claw thickness Shift fork I.D Shift drum O.D. Standard (Unit: mm(in)) 0.020-0.062 (0.0008-0.0024) 4.86 4.94 (0.191 0.194) 34.075-34.100 (1.3415-1.3425) 33.950-33.975 (1.3366-1.3376) Service Limit 0.10 (0.004) 4.6 (0.18) 34.14 (1.344) 33.93 (1.336)
Torque Values
Fastener Type Shift drum bolt Torque (kg/m, ftlb) 12 (1.2, 9) Fastener Type Torque (kg/m, ftlb)
Tools
Description Driver Attachment, 37 X 40 mm Pilot, 17 mm Tool Number 07749-0010000 07746-0010200 07746-0040400 Remarks Refer to Section
11-5
166

Crankcase Separation
Requisite Service
Please refer to Service Information on page 11-2.
Separation
1 Remove the snap ring from the kickstarter spindle. 2 Unhook the return spring and remove the retainer and return spring. 3 Remove the rubber cap. 4 Hold the shift drum and remove the shift drum bolt and washer. 5 Remove the crankcase breather tube and cam chain. 6 Loosen the crankcase bolts in a crisscross pattern in 2 - 3 steps. 7 Place the left crankcase down. Separate the right and left crankcase halves. 8 Remove the gasket and dowel pins.
11-6
167

Crankshaft
Removal
1 Remove the crankshaft from the left crankcase. 2 If necessary, remove the cam chain guide spindle and guide sprocket. 2 Install the crankshaft into the left crankcase.
Inspection
3 Measure the connecting rod big end side clearance with a feeler gauge.
-
4 Measure the connecting rod big end radial clearance at symmetrical points.
-
5 Turn the outer race of the crankshaft bearing with your finger. 6 The bearing should turn smoothly and quietly. 7 Also check that the inner race of the bearing fits tightly on the crankshaft. 8 Check the timing sprocket for wear or damage. 9 If you replace the timing sprocket, align the center of the sprocket teeth with the center of woodruff key groove. 10Place the crankshaft on a stand or Vblocks and measure the run-out using a dial gauge.
-
Installation
1 Install the guide sprocket and guide spindle.
11-7
168

Transmission
Removal
1 Remove the kickstarter spindle (page 11-11). 2 Remove the mainshaft, countershaft, and shift drum as an assembly. 3 Measure the I.D. and the O.D. of C1 gear bushing. Service Limits:
-
Disassembly
1 Disassemble the mainshaft, countershaft, and shift drum.
O.D.: 22.93 mm (0.903 in) I.D.: 20.08 mm (0.791 in)
Inspection
1 Check the gear dogs, dog holes, and teeth for abnormal wear or lack of lubrication. 2 Measure the I.D. of each gear. Service Limits:
-
4 Check the shift fork groove of the shifter gear for excessive wear or damage. Measure the O.D. of the mainshaft and countershaft. Service Limits:
-
At M2 gear: 16.950 mm (0.6673 in) At C1 gear: 19.94 mm (0.785 in)
M2: 17.10 mm (0.673 in) C1: 23.10 mm (0.909 in) C3: 20.10 mm (0.791 in)
11-8
169

Assembly
Assembly is in the reverse order of removal. 1 C3 Gear (25T) 2 C2 Gear (25T) 3 C1 Gear (36T) 4 Countershaft 5 Mainshaft/M1 Gear (11T) 6 M2 Gear (15T) 7 M3 Gear (21T) 1 Right Shift Fork 2 Washer 3 Clip 4 Guide Pin 5 Left Shift Fork 6 Shift Drum 7 Install the shift forks onto the gearshift drum. 8 Install the guide pins and secure them with clips. 9 If the washer has been removed, install the new washer and bend the tab to lock the washer. 10Drive new bearings into the crankcases using the special tools. Tools:
-
Shift Drum Assembly
Gearshift Drum Disassembly

1 Remove the guide pin clips. 2 Remove the guide pins, then remove the shift forks. 3 Inspect the shift drum grooves for wear or damage. 4 Measure the O.D. of the shift drum.
-
5 Measure the shift for I.D.

-
6 Measure the shift fork claw thickness.

-
Driver: 07749 - 0010000 Attachment, 37x40 mm: 07746 0 0010200 Pilot, 17 mm: 07746 - 0040400
11 Apply grease to the new countershaft oil seal lip. 12Install the countershaft oil seal. 13
11-9
170

Transmission Installation
1 Apply clean engine oil to the transmission gears and shift drum. 2 Assemble the mainshaft, countershaft and shift drum. 3 Install the mainshaft, countershaft, and shift drum as an assembly into the left crankcase. 4 Rotate the shift drum to check the transmission operation.
11-10
171

Kickstarter
Removal
Remove the kickstarter spindle from the right crankcase.
Disassembly
1 Remove the washer. 2 Remove the snap ring and remove the starter ratchet and ratchet spring. 3 Remove the snap ring, washer and starter pinion gear.
Inspection
1 Check the kickstarter spindle for bending. 2 Check the friction spring for fatigue. 3 Check each part for wear or damage and replace if necessary.
Assembly
Assembly is in the reverse order of disassembly.
Installation
Install the kickstarter spindle aligning its friction spring with the groove in the left crankcase.
11-11
172

Crankcase Assembly
1 Clean the crankcase mating surfaces before assembling. Note: Dress the surfaces with an oil stone if necessary to remove any minor roughness or irregularities. Note: After cleaning, lubricate the crankshaft bearings and other contacting surfaces with clean engine oil. 2 Install the dowel pins and new gasket onto the left crankcase. 3 Make sure that the gasket stays in place. 4 Install the right crankcase over the left crankcase. 5 Install and tighten the crankcase bolts in a criss-cross pattern in 2-3 steps. 6 Install the crankcase breather tube and cam chain. 7 Install the washer and bolt to the shift drum. Then tighten the bolt to the specified torque.
-
8 Install the rubber cap. 9 Install the retainer with its tab with the groove in the crankcase. 10Install the return spring and the retainer onto the kickstarter spindle. 11 Install the snap ring into he groove on the kickstarter spindle securely.
11-12
173
Section 12
Front Wheel/Brake/ Suspension/Steering
SECTION 12: FRONT WHEEL/BRAKE/SUSP.
12-1
174
Section 12: Front Wheel/Brake/Susp.

Table of Contents
Topic Troubleshooting Specifications Torque Values Tools Handlebar Page 12-3 12-4 12-5 12-6 12-7 Topic Front wheel Front brake Fork Steering stem Page 12-9 12-12 12-14 12-18
Service Information
WARNING! A CONTAMINATED BRAKE DRUM OR SHOE REDUCES STOPPING POWER. DISCARD CONTAMINATED SHOES AND CLEAN A CONTAMINATED DRUM WITH A HIGH-QUALITY BRAKE DEGREASING AGENT.
When servicing the front wheel and suspension, support the motorcycle securely with a jack or other support under the frame.
12-2
175

Troubleshooting
Symptom/Possible Causes Hard steering Faulty or damaged steering head bearings Insufficient tire pressure Steering head bearing adjustment nut too tight Steers to one side or does not track straight Bent fork Bent axle Wheel installed incorrectly Faulty steering head bearings Bent frame Hard suspension Worn wheel bearing Worn swingarm pivot components Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel Improperly installed brake shoes Bent fork tubes Clogged for fluid passage Front suspension noisy Insufficient fluid in fork Loose fork fasteners Soft suspension Insufficient fluid in fork Weak fork springs Tire pressure too low Incorrect fluid weight Symptom/Possible Causes Wheel turns hard Faulty wheel bearing Bent front axle Brake drag
12-3
176

Specifications
Item Minimum tire tread depth Cold tire pressure Axle runout Wheel rim-to-hub distance Wheel rim runout (radial) Wheel rim runout (axial) Brake Brake lever free play Brake drum I.D. Brake lining thickness Fork Spring free length Spring direction Tube runout Recommended fork fluid Fluid level Fluid capacity Suspension Fluid SS-8 135 (5.3)
74 1 cm3 (2.50 + 0.03 US oz, 2.60 0.04 lmp oz)
Standard (Unit: mm(in)) 1.5 (0.06) 100 kPa (1.00 kgf/cm2, 15 psi)
Service Limit
0.20 (0.008) 12.0 + 1.0 (0.47 + 0.04) 2.0 (0.08) 2.0 (0.08) 10 - 20 (3/8 - 3/4) 95.0 (3.74) 4.0 (0.16) 404.5 (15.93) With the tapered end facing down 0.20 (0.008) 96.0 (3.78) 2.0 (0.08) 396.4 (15.61)
12-4
177

Torque Values
Fastener Type Handlebar upper holder bolt Torque (kg/m, ftlb) 10 N/m (1.0 kgfm, 7 lbfft) Fastener Type Front brake arm pinch bolt/nut Torque (kg/m, ftlb) 10 N/m (1.0 kgfm, 7 lbfft) Apply a locking agent to the threads 23 N/m (2.3 kgfm, 15 lbfft) 23 N/m (2.3 kgfm, 17 lbfft) 20 N/m (2.0 kgfm, 14 lbfft) 74 N/m (7.5 kgfm, 54 lbfft) 29 N/m (3.0 kgfm, 22 lbfft)
Handlebar lower holder nut Fork bottom bridge pinch bolt Brake lever pivot bolt Brake lever pivot nut Spoke nipple Front axle nut
45 N/m (4.6 kgfm, 33 lbfft) U-nut 32 N/m (3.3 kgfm, 24 lbfft) 3 N/m (0.3 kgfm, 2.2 lbfft) 3 N/m (0.3 kgfm, 2.2 lbfft) 2 N/m (0.3 kgfm, 2.2 lbfft) 59 N/m (6.0 kgfm, 43 lbfft) U-nut
Fork bolt Fork cap Fork socket bolt Steering stem nut Steering stem top thread
12-5
178

Tools
Description Spoke wrench, 4.5 x 5.1 mm Bearing remover shaft Bearing remover head, 12 mm Driver Attachment, 32 x 35 mm Pilot, 12 mm Fork seal driver Fork seal driver attachment Ball race remover Attachment, 37 x 40 mm Steering stem drive Tool Number 07701 0020200 07446 0050100 07746 0050300 07749 0010000 07746 0010100 07746 0040200 07747 0010100 07747 0010200 07944 1150001 07746 0010200 07946 GC40000 Steering stem driver attachment 7946GC4000A (U.S.A. only) 07947 1180001 Alternate Tool Commercially available in U.S.A. Commercially available in U.S.A Tool Number Refer to Page
12-6
179

Handlebar
Removal
1 Remove the number plate (page 2-9). 2 Remove the wire bands. 3 Remove the screw and engine stop switch. 4 Remove the throttle housing screw. 5 Disconnect the throttle cable end from the throttle pipe and remove the housing. 6 Remove the throttle pipe from the handlebar.
nut before removing the upper holder bolts. 11 Remove the handlebar upper holder bolts and holder. 12Remove the handlebar. 13Remove the nuts and handlebar lower holders.
Installation
1 Install the lower holders onto the top bridge. 2 Temporarily install the nuts but do not tighten them yet. 3 Place the handlebar onto the lower holders, aligning the punch marks on the handlebar with the top surface of the lower holder. 4 Install the upper holders with their punch marks facing forward. 5 Install the holder bolts.
7 Slide the dust cover off from the brake lever pivot. 8 Disconnect the brake cable from the brake lever. 9 Remove the screws, holder and brake lever bracket. 10If you plan to remove the handlebar lower holders, loosen the lower holder
12-7
180

Handlebar (contd)
6 Tighten the forward bolts first, then the rear bolts.
-
Torque: 3 N/m (0.3 kgm, 2.2 lbft)
18Apply grease to the sliding surface of the throttle pipe. 19Install the throttle pipe on the handlebar. 20Apply grease to the throttle cable end and sliding surface. 21Connect the throttle cable to the throttle pipe. 22Install the throttle housing by aligning its locating pin with the hole in the handlebar. 23Align the hooks between the housing and cover, install the housing cover. 24Tighten the screw securely. 25Install the engine stop switch and mounting screws. 26Align the mating surface of the switch and holder with the punch mark on the handlebar, tighten the screws. 27Secure the engine stop switch wire with wire bands. 28Install the number plate (page 2-9).
Torque: 10 N/m (1.0 kgm, 7 lbft)
7 If you remove the lower holder, tighten the lower holder nuts to the specified torque.
-
8 Apply Bond A or Hand Grip Cement (U.S.A. only) to inside of the grip and to the clean surfaces of the left handlebar and throttle grip. 9 Wait 3-5 minutes and install the grip. 10Rotate the grip for even application of the adhesive. 11 Allow the adhesive to dry for an hour before using. 12Place the brake lever bracket onto the handlebar. 13Install the holder with its punch mark facing up. 14Align the mating surface of the bracket with the punch mark on the handlebar. Tighten the upper bolt first, then the lower bolt. 15Connect the brake cable to the brake lever. 16If the brake lever is removed, install the brake lever and tighten the pivot bolt to the specified torque.
-
17Hold the pivot bolt, tighten the pivot nut to the specified torque.
12-8
181

Front Wheel
Removal
WARNING! A CONTAMINATED BRAKE DRUM OR SHOE REDUCES STOPPING POWER. DISCARD CONTAMINATED SHOES AND CLEAN A CONTAMINATED DRUM WITH A HIGH-QUALITY BRAKE DEGREASING AGENT.
1 Support the motorcycle securely using a safety stand or hoist. 2 Disconnect the brake cable from the brake panel and brake arm. 3 Remove the axle nut, axle and front wheel.
12-9
182

Front Wheel (contd)
Removal (contd)
4 Remove the side collar from the right wheel hub. 5 Remove the brake panel from the left wheel hub.
-
Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
Disassembly
1 Remove the dust seal. 2 Install the bearing remover head into the bearing. 3 From the opposite side, install the bearing remove shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. Tools:
-
Inspection
Axle
Set the axle in V-block and measure the runout.
-
Actual runout is the total indicator reading. Service limit: 0.20 mm (0.008 in)
Wheel Bearing
Always replace the bearings in pairs. 1 Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing out race fits tightly in the hub. 2 Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. 3 Install the new bearings into the hub using special tools (page 12-6).
-
Bearing remover head, 12 mm 07746 - 0050300 (Equivalent commercially available in U.S.A.) Bearing remover shaft 07746 0050100 (Equivalent commercially available in the U.S.A.)
Assembly
WARNING! NEVER INSTALL THE OLD BEARINGS. ONCE THE BEARINGS HAVE BEEN REMOVED, THE BEARINGS MUST BE REPLACED WITH NEW ONES.
Wheel rim runout

Check the rim runout by placing the wheel in a turning stand. Spin the wheel by hand, and read the runout using a dial indicator. Actual runout is the total indicator reading. Service Limits:
1 Drive in a new right bearing squarely with its sealed end facing out. Install the distance collar then drive in the left bearing using the special tools. Tools:
-
Driver 07749 - 0010000 Attachment, 32 x 35 mm 07746 0 0010100 Pilot, 12 mm 07746 - 0040200

12-10
183

Front Wheel (contd)
Assembly (contd)
2 Place the rim on the work bench. Place the hub with the left side down and begin lacing with new spokes. 3 Adjust the hub position so that the distance from the hub left end surface to the side of the rim is 12.0 + 1 mm (0.47 + 0.04 in).
-
8 Adjust the front brake lever free play (page 3-21). 9 With the front brake applied, pump the fork up and down several times to seat the axle and check brake operation. 10Tighten the axle nut to the specified torque.
-
Spoke wrench, 4.5 x 5.1 mm 07701-0020200 (Equivalent commercially available in U.S.A) Torque: 3 N/m (0.3 kgm, 2.2 lbft)
4 Check the rim runout (page 12-4). 5 Apply grease to the dust seal lips, then install it into the right wheel hub.
Installation
1 Install the brake panel into the left wheel hub. 2 Install the side collar into the right wheel hub. 3 Install the front wheel between the fork legs while aligning the brake panel groove with the boss on the left fork slider. 4 Apply a thin layer of grease to the front axle surface. Install the front axle from the right side. 5 Hold the axle and temporarily tighten the axle nut. 6 Install the brake cable to the brake panel. 7 Install the spring and connect the cable end to the brake arm.
12-11
184

Front Brake
Removal
Remove the brake panel from the front wheel (page 12-9).
Assembly
1 Apply grease to the anchor pin and brake cam. 2 Install the brake cam into the brake panel. 3 Apply oil to the dust seal and install it onto the brake panel. 4 Install the wear indicator plate on the brake cam aligning its wide tooth with the wide groove on the brake cam. 5 Install the brake arm aligning the punch marks between the arm and the brake cam. 6 Apply a locking agent to the pinch bolt threads.
Inspection
1 Measure the front brake drum I.D.
-
2 Measure the brake lining thickness.

-
Disassembly
1 Remove the brake shoes and springs. 2 Remove the nut, bolt and brake arm. 3 Remove the indicator plate, dust seal and brake cam.
12-12
185

Front Brake (contd)
Assembly (contd)
7 Install the brake arm pinch bolt and tighten the nut to the specified torque.
-
8 Install the brake shoes and springs.
Installation
Install the brake panel into the left wheel hub (page 12-9).
12-13
186

Fork
Removal
1 Remove the front wheel (page 12-9). 2 Remove the bolt and brake cable guide from the left fork slider. 3 Remove the fork top bolt and washer. 4 Loosen the fork bottom pinch bolt.
5 When the fork is to be disassembled, lower the fork leg and tighten the bottom pinch bolt. 6 Loosen the fork bolt, but do not remove it yet. 7 Loosen the fork bottom pinch bolt and remove the fork leg.
12-14
187

Fork (contd)
Disassembly
1 Remove the fork bolt.
WARNING! THE FORK BOLT IS UNDER SPRING PRESSURE. USE CARE WHEN REMOVING IT.
Fork tube/slider/piston
1 Check the fork tube, fork slider and fork piston for score marks, and excessive or abnormal wear. 2 Check the fork piston ring for wear or damage. 3 Check the rebound spring for fatigue or damage. 4 Replace the components if necessary.
2 Remove the fork spring. 3 Pour out the fork fluid by pumping the fork tube up and down several times. 4 Remove the dust seal. 5 Remove the oil seal stopper ring. 6 Hold the fork slider in a vice with soft jaws or a shop towel. 7 If the fork piston turns with the socket bolt, temporarily install the fork spring and fork bolt. 8 Remove the fork socket bolt with a hex wrench. 9 Pull the fork tube out from the fork slider. Remove the oil lock piece. 10Remove the fork piston and rebound spring from the fork tube. 11 Remove the oil seal using a commercially available oil seal remover.
Fork tube/slider/piston (contd)

5 Place the fork tube in the V-block and measure the runout.
-
Actual runout is the total indicator reading. Service Limit: 0.20 mm (0.008 in)
Assembly
Dust Seal Fork Tube Fork Bolt
-
Piston Ring Fork Spring Fork Piston Rebound Spring
Inspection
Fork spring
Measure the fork spring free length. Service Limit: 396.4 mm (15.61 in)
Oil Lock Piece

-
Fork Slider Oil Seal Stopper Ring
12-15
188

Fork (contd)
Assembly (contd)
1 Before assembly, wash all parts with a high flash or non-flammable solvent and wipe them dry. 2 Install the rebound spring and fork piston into the fork tube. 3 Install the oil lock piece to the end of the fork piston. 4 Install the fork tube into the fork slider. 5 Hold the fork slider in a vise with soft jaws or a shop towel. 6 If the fork piston turns with the socket bolt, temporarily install the fork spring and fork bolt. 7 Apply a locking agent to the fork socket bolt threads and install and tighten the socket bolt with a new sealing washer into the fork piston.
-
11 Install the dust seal. 12Pour the specified amount of recommended fork fluid into the fork tube.
-
Recommended Fork Fluid: Suspension Fluid SS-8 Fork Fluid Capacity:74 1 cm3 (2.50 0.03 US oz, 2.60 0.04 lmp oz)
13Pump the fork tube several times to remove trapped air from the lower portion of the fork tube. 14Compress the fork leg fully and measure the oil level from the top of the fork tube.
-
Fork Oil Level: 135 mm (5.3 in)
15Pull the fork tube up and install the fork spring with its tapered (narrow coil pitch) end facing down. 16Apply fork fluid to a new O-ring and install it onto the fork bolt. 17Install the fork bolt onto the fork tube.
8 Apply for fluid to the oil seal lips, then install it into the fork slider with its marking facing up. 9 Drive the oil seal into the fork slider using the special tools. Tools:
-
Installation
1 Install the fork tube into the steering stem. 2 Temporarily tighten the fork bottom pinch bolt. 3 Tighten the fork bolt to the specified torque.
-
Fork seal driver body 07747 0010100 Fork seat driver attachment 07747 - 0010200 Fork seal driver, 27 mm 07497 1180001 (U.S.A. only)
10Install the oil seal stopper ring into the fork slider groove securely.
4 Loosen the fork bottom pinch bolt and pull up the fork leg until it seats bottom of the top bridge.
12-16
189

Fork (contd)
5 Install the washer and fork top bolt, tighten the bolt to the specified torque.
-
6 Loosen the fork bottom pinch bolt and pull up the fork leg until it seats bottom of the top bridge. 7 Install the washer and fork top bolt, tighten the bolt to the specified torque.
-
8 Tighten the fork bottom pinch bolt to the specified torque.

-
9 Install the front wheel (page 12-9). 10Adjust the brake lever free play (page 3-21). 11 Install the brake cable guide to the left fork slider, tighten the bolt securely.
12-17
190

Steering Stem
Removal
-
Tool: Pin spanner 07702 - 0020001

-
Handlebar (page 12-7) Front wheel (page 12-9) Front fender (page 2-10)
Dust seal Upper bearing inner race Upper bearing Steering stem Lower bearing
2 Remove the steering stem and nut washer. 3 Remove the fork leg (page 12-14). 4 Remove the top bridge. 5 Remove the steering stem top thread using the special tool.
12-18
191

Steering Stem (contd)
Bearing Race Replacement
Always replace the bearings and races as a set. 1 Drive out the upper and lower bearing outer races using the special tool.
-
8 Install a new lower bearing inner race using a special tool and a hydraulic press. Tools:
-
Tool: Ball race remover 07944 1150001
Steering stem driver 07946 GC40000 Steering stem driver 07946 MB00000 with Steering stem driver attachment 07946 - GC4000A (U.S.A. only)
2 Drive a new lower bearing out races into the steering head pipe using the special tools. Tools:
-
Installation
1 Apply grease to the upper and lower bearings and races. 2 Install the lower bearing onto the lower bearing race. 3 Insert the steering stem into the steering head pipe. 4 Install the upper bearing, inner race, dust seal and top thread. 5 Hold the steering stem and tighten the stem top thread to the initial torque.
-
Driver 07749 - 0010000 Attachment, 37 x 40 mm 07746 0010200
3 Temporarily install the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem. 4 Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem. 5 Remove the dust seal and washer. 6 Install the washer over the steering stem. 7 Apply grease to the new dust seal lips and install it over the steering stem.
6 Move the steering stem right and left, lock-to-lock, five times to seat the bearings. 7 Make sure the steering stem moves smoothly, without play or binding; then loosen the top thread. 8 Retighten the top thread to the specified torque.
-
12-19
192

Steering Stem (contd)
9 Recheck that the steering stem moves smoothly without play or binding. 10Install the top bridge and fork leg (page 12-14). 11 Install the washer and stem nut. 12Tighten the steering stem nut to the specified torque.
-
13Install the following:

-
Front fender (page 2-10) Front wheel (page 12-9) Handlebar (page 12-7)
12-20
193
Section 13
Rear Wheel/Brake/ Suspension
SECTION 13: REAR WHEEL/BRAKE/SUSP.
13-1
194
Section 13: Rear Wheel/Brake/Susp.

Table of Contents
Topic Troubleshooting Specifications Torque values Tools Rear wheel Page 13-3 13-4 13-5 13-5 13-6 Topic Rear brake Shick Absorber Swingarm Brake pedal Page 13-10 13-12 13-14 13-16
Service Information
WARNING! A CONTAMINATED BRAKE DRUM OR SHOE REDUCES STOPPING POWER. DISCARD CONTAMINATED SHOES AND CLEAN A CONTAMINATED DRUM WITH A HIGH-QUALITY BRAKE DEGREASING AGENT. When servicing the rear wheel, support the motorcycle using a safety stand or hoist.
13-2
195

Troubleshooting
Symptom/Possible Causes Rear wheel wobbling Bent rim Worn rear wheel bearings Faulty tire Unbalanced tire and wheel Tire pressure too low Faulty swing-arm pivot bushings Soft suspension Weak shock absorber spring Oil leakage from damper unit tire pressure too low Symptom/Possible Causes Hard suspension Bent damper rod Damaged swing-arm pivot bushings Bent swing-arm pivot Tire pressure too high Steers to one side or does not track straight Bent rear axle Axle alignment/chain adjustment not equal on both sides
13-3
196

Specifications
Item Minimum tire tread depth Cold tire pressure Axle runout Wheel rim-to-hub distance Wheel rim runout (radial) Wheel rim runout (axial) (DID) Drive chain size/linkRK Drive chain slack Brake lever free play Brake drum I.D Brake lining thickness Standard (Unit: mm(in)) 100 kPa (1.00 kgf/cm, 15 psi) 11.0 1.0 (0.43 0.04) DID420M-86RB RK420MZ-86RJ 10-20 (3/8-3/4) 20-30 (3/4-1-1/4) 95.0 (3.74) 4.0 (0.16) 2.0 (0.08) 96.0 (3.78) 2.0 (0.08) Service Limit 2.0 (0.08) 0.20 (0.008) -
13-4
197

Torque Values
Fastener Type Spoke Rear axle nut Torque (kg/m, ftlb) 3 (0.3, 2.2) 59 (6.0, 43) Fastener Type Swingarm pivot bolt/nut Shock absorber upper mounting bolt/nut Shock absorber lower mounting bolt/nut Torque (kg/m, ftlb) 39 (4.0, 29) 34 (3.5, 25)
Driven sprocket nut
32 (3.3, 24)
34 (3.5, 25)
Rear brake arm pinch bolt/nut
10 (1.0, 7)
Tools
Description Spoke wrench, 4.5 X 5.1 mm Bearing remover shaft Bearing remover head, 12 mm Attachment, 32 X 35 mm Attachment, 37 X 40 mm Tool Number 07701-0020200 07746-0050100 07746-0050300 07746-0010100 07746-0010200 Remarks Refer to Section
13-5
198

Rear Wheel
Removal
1 Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground. 2 Remove the rear brake adjusting nut and disconnect the rear brake rod from the brake arm. 3 Remove the axle nut. 4 Push the rear wheel forward. 5 Derail the drive chain from the driven sprocket. 6 Remove the axle from the left side and remove the rear wheel. 7 Remove the left side collar from the left wheel hub.
8 Remove the brake panel from the right wheel hub.
Inspection
Axle
Place the axle in V-blocks and measure the runout. Actual runout is the total indicator reading. Service Limit: 0.20 mm (0.008 in)
13-6
199

Rear Wheel (contd)
Inspection (contd)
Wheel Bearing
1 Turn the inner race of each bearing with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. 2 Replace the wheel bearings in pairs. 3 Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub. 4 Install the new bearings into the hub using the special tools (page 13-5). CAUTION: NEVER INSTALL A NEW DRIVE CHAIN ON A WORN SPROCKET OR A WORN CHAIN ON NEW SPROCKETS. BOTH CHAIN AND SPROCKET MUST BE IN GOOD CONDITION OR THE RPLACEMENT CHAIN/ SPROCKET WILL WEAR RAPIDLY.
Disassembly
1 Remove the nuts, bolts and driven sprocket. 2 Remove the left dust seal.
Wheel Bearing Removal

1 Install the bearing remover head into the bearing. 2 From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub.
Wheel Rim Runout

1 Check the rim runout by placing the wheel in a turning stand. 2 Spin the wheel slowly and read the runout using a dial indicator. Actual runout is the total indicator reading. Service limits:
-
Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)
Driven Sprocket
1 Check the condition of the final driven sprocket teeth. 2 Replace the sprocket if worn or damaged. Note: If the final driven sprocket requires replacment, inspect the drive chain and drive sprocket
13-7
200

Rear Wheel (contd)
Wheel Bearing Removal (contd)
3 Remove the distance collar and drive out the other bearing. Tools:
-
3 Place the rim on the work bench. 4 Place the hub with the left side down and begin lacing with new spokes. 5 Adjust the hub position so that the distance from the left end surface to the side of rim is 11.0 + 1.0 mm (0.43 + 0.04 in).
-
Bearing remover head, 12 mm 07746 - 0050300 (Equivalent commercially available in U.S.A.) Bearing remover shaft 07746 0050100 (Equivalent commercially available in U.S.A.)
Tool: Spoke wrench, 4.5 x 5.1 mm 07701 - 0020200 (Equivalent commercially available in U.S.A.) Torque: 3 Nm (0.3 kgfm, 2.2 lbfft)
Wheel Bearing Installation

CAUTION: NEVER INSTALL THE OLD BEARINGS. ONCE THE BEARINGS HAVE BEEN REMOVED, THE BEARINGS MUST BE REPLACED WITH NEW ONES 1 Drive a new right bearing squarely using the special tools. Tools:
-
6 Check the rim runout (page 13-5) 7 Apply grease to the dust seal lips, then install it into the left wheel hub. 8 Apply oil to the driven sprocket mounting nut threads and seating surface. 9 Install the driven sprocket, bolts and nuts, then tighten the nuts to the specified torque while holding the bolts.
-
Driver: 07749 - 0010000 Attachment, 32 x 35mm: 07746 0010100 Pilot, 12 mm: 07746 - 0040200
Installation
1 Install the left side collar into the left wheel hub. 2 Install the brake panel into the right wheel hub. 3 Place the rear wheel into the swingarm, aligning the brake panel groove with the swing-arm boss. 4 Install the drive chain over the driven sprocket.
2 Install the distance collar, then drive in the new left side bearing using the special tools. Tools:
-
Driver:07749 - 0010000 Attachment, 37 x 40 mm:07746 0010200 Pilot, 12 mm: 07746 - 0040200
13-8
201

Rear Wheel (contd)
5 Apply a thin layer of grease to the axle. 6 Install the axle and right drive chain adjuster from the right side. 7 Install he left drive chain adjuster and axle nut. 8 Adjust the drive chain slack (page 317). 9 Tighten the axle nut to the specified torque.
-
10Install the spring onto the brake rod. 11 Install the joint pin to the brake arm. 12Install the brake rod and adjusting nut. 13Adjust the brake pedal free play (page 3-21).
13-9
202

Rear Brake
Removal
Remove the brake panel from the rear wheel (page 13-6).
Inspection
1 Measure the rear brake drum I.D.
-
2 Measure the brake lining thickness.

-
13-10
203

Rear Brake (contd)
Disassembly
1 Remove the brake shoes and springs. 2 Remove the nut, bolt and brake arm. 3 Remove the indicator plate, dust seal and brake cam.
Assembly
1 Apply grease to the anchor pin and brake cam. 2 Install the brake cam into the brake panel. 3 Apply oil to the dust seal and install it onto the brake panel. 4 Install the wear indicator plate on the brake cam aligning its wide tooth with the wide groove on the brake cam. 5 Install the brake arm aligning the punch marks between the arm and the brake cam. 6 Install the brake arm pinch bolt and tighten the nut to the specified torque.
-
Torque: 10 Nm (1.0 kgfm, lbfft)
7 Install the brake shoes and springs.
Installation
1 Install the brake panel into the right wheel hub (page 13-6).
13-11
204

Shock Absorber
Removal
1 Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground. 2 Remove the seat (page 2-5).
3 Remove the shock absorber lower mounting bolt/nut. 4 Remove the upper mounting bolt/nut and shock absorber.
13-12
205

Shock Absorber (contd)
Inspection
1 Visually inspect the shock absorber unit for damage:
-
Spring for fatigue or damage Damper rod for bending or damage Damper unit for deformation or oil leaks Bump rubber for wear or damage Mounting bushings for damage
2 Inspect all the other parts for wear or damage.
Installation
1 Install the shock absorber into the frame. 2 Install the upper and lower mounting bolts and nuts. Tighten the upper mounting bolts/nuts to the specified torque.
-
3 Tighten the lower mounting bolts/nuts to the specified torque.

-
13-13
206

Swingarm
Removal
-
3 Remove the bolts, nuts and drive chain guard. 4 Remove the shock absorber lower mounting bolt/nut. 5 Remove the swing-arm pivot nut, bolt and swing-arm.
Rear wheel (page 13-6) Drive chain (page 3-17)
2 Remove the bolts and drive chain case.
13-14
207

Swingarm (contd)
Removal (contd)
6 Remove the bolt/nut and drive chain slider.
Inspection
1 Inspect the swing-arm for wear or damage. 2 Inspect the pivot bushing for wear or damage.
Installation
1 Install the drive chain slider and tighten the bolt and nut. 2 Install the swing-arm into the frame, then install the pivot bolt from the right side. 3 Install and tighten the pivot nut to the specified torque.
-
4 Install the drive chain guard, bolts and washers and tighten the bolts. 5 Install the rear wheel (page 13-6).
13-15
208

Brake Pedal
Removal/Disassembly
1 Remove the rear brake adjusting nut. 2 Push the brake pedal down and remove the brake rod from the brake arm. 3 Remove the spring and joint pin. 4 Unhook the brake pedal return spring from the lower engine hanger bolt. 5 Remove the cotter pin, washer and brake pedal/rod. Remove the cotter pin and joint pin, then separate the brake rod from the brake pedal. 11 Install the brake adjusting nut and adjust the brake pedal free play (page 3-21).
Assembly/Installation
1 Note the installation direction of the brake rod. 2 Install the brake rod to the brake pedal. 3 Install the joint pin and secure it with a new cotter pin. 4 Apply grease to the brake pedal pivot sliding surface. 5 Install the brake pedal/rod onto the frame. 6 Install the washer and secure it with a new cotter pin. 7 Hook the return spring to the lower engine hanger bolt. 8 Install the spring onto the brake rod. 9 Install the joint pin onto the brake arm. 10Push down the brake pedal and install the brake rod into the joint pin.
13-16
209
Section 14
Ignition System
SECTION 14: IGNITION SYSTEM
14-1
210
Section 14: Ignition System

Table of Contents
Topic Troubleshooting Specifications Torque values Tools Ignition system inspection Page 14-3 14-4 14-4 14-4 14-5 Topic Ignition coil Ignition control module Engine stop switch Ignition switch Ignition timing Page 14-9 14-10 14-11 14-12 14-14
Service Information
WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL-VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. WARNING! THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT MAY CAUSE LOSS OF CONSCIOUSNESS AND LEAD TO DEATH. RUN THE ENGINE IN AN OPEN AREA OR WITH AN EXHAUST EVACUATION SYSTEM IN AN ENCLOSED AREA. WARNING! SOME ELECTRICAL COMPONENTS MAY BE DAMAGED IF TERMINALS OR CONNECTORS ARE CONNECTED OR DISCONNECTED WHILE THE IGNITION SWITCH IS ON AND CURRENT IS PRESENT. When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 14-3. The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset. The ICM may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may damage the module. Always turn off the engine stop switch before servicing. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine.
14-2
211

Troubleshooting
Symptom/Possible Causes No spark at plug faulty spark plug Poorly connected/loose spark plug wire Loose spark plug cap Loose/Poorly connected ignition coil primary wire connectors. Poorly connected ICM connectors Faulty ICM Faulty ignition coil Faulty alternator exciter coil Symptom/Possible Causes No spark at plug (contd) Faulty ignition pulse generator Faulty ignition switch Faulty engine stop switch Faulty neutral switch Faulty top gear switch Poorly connected component connector Broken wire harness between unit and component
14-3
212

Specifications
Item Spark plug (Standard) (for cold climate/below 5C/41F) (For extended high speed riding) Spark plug gap Ignition coil primary peak voltage Ignition pulse generator peak voltage Alternator exciter coil peak voltage Ignition timing ("F" mark) Standard (Unit: mm(in)) CR6HSA (NGK) U20FSR-U (DENSO) 5HSA (NGK) U16FSR-U (DENSO) CR7HSA (NGK) U22FSR-U (DENSO) 0.60-0.70 (0.024-0.028) 100 V minimum 0.7 V minimum 0.7 V minimum 27 BTDC at idle Service Limit
Torque Values
Fastener Type Ignition coil mounting bolt Torque (kg/m, ftlb) 6 (0.6, 4.3) Fastener Type Torque (kg/m, ftlb)
Tools
Description Peak voltage adaptor Tool Number 07HGJ0020100 Remarks Note 3: Peak voltage tester (U.S.A. only) Refer to Section
14-4
213

Ignition System Inspection
Ignition Coil Primary Peak Voltage
Note: If there is no spark at plug, check all connections for loose or poor contact before measuring each peak voltage. Note:Use recommended digital
multimeter or commercially available digital multimeter with an impedance of 10 M/DCV minimum.
WARNING! AVOID TOUCHING THE SPARK PLUG AND TESTER PROBES TO PREVENT ELECTRIC SHOCK. Note: Check cylinder compression and check that the spark plug is installed correctly. 1 Shift the transmission into neutral and disconnect the spark plug cap from the spark plug. 2 Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test.
Note: The display value differs depending on the internal impedance of the multimeter.
If using peak voltage tester (U.S.A. only), follow the manufacturer's instructions.
Connect the peak voltage adaptor to the digital multimeter, or use the peak voltage tester (U.S.A. only).
14-5
214

Ignition System Inspection (contd)
Ignition Coil Primary Peak Voltage (contd)
3 With the ignition coil primary wire connected, connect the peak voltage adaptor or peak voltage tester to the ignition coil.
Ignition Pulse Generator Peak Voltage
Note:Check cylinder compression and check that the spark plug is installed correctly.
-
Connection: Black/Yellow terminal (+) Body ground (-)
1 Remove the seat and side covers (page 2-5, 2-8). 2 Disconnect the 3P connector from the ICM. 3 Connect the peak voltage adaptor or peak voltage tester probes to the connector terminals of the wire harness side.
-
1 Turn the engine stop switch to "Run". 2 Turn the ignition switch to "On". 3 Crank the engine with the kickstarter and read ignition coil primary peak voltage.
-
Peak Voltage: 100 V minimum
4 If the peak voltage is abnormal, check for an open circuit or poor connection in the Black/Yellow wire. 5 If no defects are found in the harness, refer to the troubleshooting chart on page 14-3.
-
Tool: Peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ - 0020100 (not available in U.S.A.) with commercially available digital multimeter (impedance 10 M/DCV minimum) Connection: Black/Yellow terminal (+) - Green (-)
14-6
215

Ignition Pulse Generator Peak Voltage (contd)
4 Crank the engine with the kickstarter and read the peak voltage.
-
Alternator Exciter Coil Peak Voltage

Note:Check cylinder compression and check that the spark plug is installed correctly. 1 Remove the left side cover (page 28). 2 Disconnect the 3P and 2P connectors from the ICM. 3 Connect the peak voltage adaptor or peak voltage tester probes to the connector terminals of the wire harness side. Tools:
-
Peak Voltage: 0.7 V minimum
5 If the peak voltage measured at ICM connector is abnormal, measure the peak voltage at the pulse generator connector. 6 Disconnect the ignition pulse generator connector and connect the tester probes to the terminal (Blue/ Yellow and Ground). 7 In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector.
-
Peak voltage tester (U.S.A. only) or Peak voltage adaptor 07HGJ 0020100 (not available in U.S.A.) with commercially available digital multimeter (impedance 10 M/DCV minimum) Connection: Black/Red terminal (+) - Green (-)
If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal, the wire harness has an open circuit or loose connection. If both peak voltage measures are abnormal, check each item in the troubleshooting chart on page 143. If all items are normal, the ignition pulse generator is faulty. See section 10 for ignition pulse generator replacement.
4 Crank the engine with kickstarter and read the peak voltage.
-
Peak Voltage: 100 V minimum
5 If the peak voltage measured at ICM connector is abnormal, measure the peak voltage at the alternator exciter coil connector. 6 Disconnect the alternator exciter coil connector and connect the tester probe to the Black/Red terminal and Ground.
14-7
216

Alternator Exciter Coil Peak Voltage (contd)
7 In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector.
-
If the peak voltage measured at the ICM is abnormal and the one measured at the alternator exciter coil is normal, the wire harness has an open circuit or loose connection. If both peak voltage measures are abnormal, check each item in the troubleshooting chart (page 14-3). If all items are normal, the alternator exciter coil is faulty. See section 10 for stator replacement.
14-8
217

Ignition Coil
Removal/Installation
1 Disconnect the spark plug cap from the plug. 2 Disconnect the primary wires from the ignition coil. 3 Remove the bolt and ignition coil. 4 Installation is in the reverse order of removal.
14-9
218

Ignition Control Module
1 Remove the seat and left side cover (page 2-5, 2-8). 2 Disconnect the ignition control module (ICM) connectors. 3 Remove the ICM from the frame. 4 Installation is in the reverse order of removal.
14-10
219

Engine Stop Switch
Inspection
1 Disconnect the engine stop switch connectors. 2 Check for continuity between the terminals.
3 There should be no continuity when the engine stop switch is in the "Off" position and there should be continuity when the engine stop switch is in the "Run" position.
14-11
220

Ignition Switch
Inspection
1 Disconnect the ignition switch connectors. 2 Adjust the idle speed with the throttle stop screw.
2 Check for continuity at the connectors on the ignition switch side.
3 Release the tabs on the ignition switch body; remove the ignition switch.
3 There should be no continuity when the ignition switch is in the "On" position and continuity when the ignition switch is in the "Off" position.
1 Attach a tachometer according to its manufacturer's instructions.
14-12
221

Ignition Switch (contd)
Removal/Installation (contd)
4 Installation is in reverse order of removal.
Note: At installation, align the

guide on the ignition switch and groove of the frame.
14-13
222

Ignition Timing
WARNING! WHEN THE ENGINE MUST BE RUNNING TO DO SOME WORK, MAKE SURE THE AREA IS WELL-VENTILATED. NEVER RUN THE ENGINE IN AN ENCLOSED AREA. 1 Stop the engine and remove the left crankcase cover (page 10-5). 2 Read the instructions for timing light operation. 3 Connect the timing light to the spark plug wire. 4 Start the engine and let it idle.
-
Idle Speed: 1700 +/- 100 rpm
5 The ignition timing is correct if the "F" mark aligns with the index notch of the left crankcase (representative sample shown).
6 Increase the engine speed by turning the throttle stop screw and make sure that the "F" mark begins to move clockwise. 7 Install the left crankcase cover (page 10-5).
14-14
223
Section 15
Wiring Diagram
SECTION 15: WIRING DIAGRAM
15-1
224
Section 15: Wiring Diagram
15-2
SECTION 15: WIRING DIAGRAM
225
Section 16
Troubleshooting
SECTION 16: TROUBLESHOOTING
16-1
226
Section 16: Troubleshooting

Table of Contents
Topic Engine Does Not Start or is Hard to Start Engine Lacks Power Poor Performance at Low and Idle Speeds Page 16-3 16-4 16-7 Topic Poor Performance at High Speed ly Poor Handling Page 16-8 16-9
16-2
227

Engine Does Not Start or is Hard to Start
16-3
228

Engine Lacks Power
16-4
229

Engine Lacks Power (contd)
16-5
230

Engine Lacks Power (contd)
16-6
231

Poor Performance at Low and Idle Speeds
16-7
232

Poor Performance at High Speed
16-8
233

Poor Handling
16-9
234

Memo
16-10
235
Appendix
Diagrams
APPENDIX
A-1
236
Appendix
Table of Contents
Topic 50cc Left Side 50cc Right Side Page A-3 A-4 Topic 90cc Left Side 90cc Right Side Page A-5 A-6
A-2
APPENDIX
237
Appendix
50cc Left Side
APPENDIX
A-3
238
Appendix
50cc Right Side
A-4
APPENDIX
239
Appendix
90cc Left Side
APPENDIX
A-5
240
Appendix
90cc Right Side
A-6
APPENDIX
241
Index
Index
INDEX
I-1
242
Index
Topic Air cleaner housing Air cleaner Air screw adjustment Brake pedal Brake shoe wear Brake system Cable & harness routing Cam chain tensioner Camshaft installation Camshaft removal Carburetor assembly Carburetor disassembly Carburetor installation Carburetor removal Clutch system Clutch Crankcase assembly Crankcase breather Crankcase separation Crankshaft Cylinder compression test Cylinder head Cylinder installation Cylinder removal Cylinder/piston inspection Diagram - 50cc left side Diagram - 90cc left side Page 95 63 101 208 74 75 33 159 126 116 99 98 100 96 76 147 172 102 166 167 45 118 139 134 136 237 239
I-2
INDEX
243
Index
Topic Diagram - 50cc right side Diagram - 90cc right side Drive chain slider Drive chain Emission control system Engine idle speed Engine oil centrifugal filter Engine oil strainer screen Engine oil Engine removal/installation Engine stop switch Flywheel/stator removal Fork Front brake Front fender Front wheel Fuel line Fuel tank Gearshift linkage General safety Handlebar Ignition coil Ignition control module Ignition switch Ignition system inspection Ignition timing Kickstarter Lubrication & seal points Page 238 240 73 71 36 70 69 68 66 106 219 157 186 184 48 181 61 44 151 8 179 217 218 220 213 222 171 31
INDEX
I-3
244
Index
Topic Lubrication system diagram Maintenance schedule Model identification Mud guard Muffler/exhaust pipe Number plate Nuts, bolts, fasteners Oil pump Piston installation Piston removal Rear brake Rear wheel Right crankcase cover installation Right crankcase cover removal Seat/rear fender Service rules Shock absorber Side cover Side stand Side stand Spark arrester Spark plug Specifications Alternator/cam chain tensioner Clutch/gearshift linkage Crankshaft/transmission/kick starter Cylinder head/valves Cylinder/piston Page 87 59 11 49 50 47 80 88 137 135 202 198 152 146 43 10 204 46 52 77 79 64 12 156 144 164 112 132
I-4
INDEX
245
Index
Topic Engine remove/install Front wheel/brake/suspension Fuel system Ignition system Lubrication system Maintenance Rear wheel/brake/suspension Stator/flywheel installation Stearing head bearings Steering stem Suspension Swingarm Tank shroud Throttle operation Tools Alternator/cam chain tensioner Clutch/gearshiftllinkage Crankshaft/transmission/kickstarter Cylinder head/valves Front wheel/brake/suspension Fuel system Ignition system Maintenance Rear wheel/brake/suspension Torque Values Alternator/cam chain tensioner Clutch/gearshift linkage Crankshaft/transmission/kickstarter Page 105 176 94 212 86 57 196 160 82 190 78 206 45 62 29 156 133 165 114 178 94 212 58 197 23 156 144 165
INDEX
I-5
246
Index
Topic Cylinder head/valves Cylinder/piston Engine remove/install Frame/body panels/exhaust system Front wheel/brake/suspension Ignition system Lubrication system Maintenance Rear wheel/brake/suspension Transmission Troubleshooting Alternator/cam chain tensioner Clutch/gearshift linkage Crankshaft/transmission/kickstarter Cylinder head/valves Cylinder/piston Engine does not start or is hard to start Engine lacks power Frame/body panels/ exhaust system Front wheel/brake/suspension Rear wheel/brake/suspension Fuel system Ignition system Lubrication system Poor handling Poor performance at high speed Poor performance at low and idle speeds Valve clearance Page 113 133 105 42 177 212 86 58 197 168 225 155 143 163 111 131 227 228 41 175 195 93 211 85 233 232 231 65
I-6
INDEX
247
Index
Topic Wheels/tires Wiring diagram Page 81 224
INDEX
248
Index
INDEX

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NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

PanTerra 49cc & 90cc Dirt Bikes

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

About the Illustrations

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Molykote BR-2 Plus manufactured by Dow Corning, U.S.A.

Molykote G-n Paste manufactured by Dow Corning, U.S.A.

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

Used Engine/ Transmission Oil

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

Engine Serial Number

Vehicle Identification Number

Carburetor Identification Number

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

Electrical Ignition system Condenser Discharged Ignition Kick-starter

Crankshaft type Engine dry weight Cylinder arangement Carburetor

Piston valve 13 mm (0.5 in)

Wet multi-plate Automatic centrifugal 3-speed 3.722 (67/18) 2.400 (36/15)

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

Standard (Unit: mm(in)) 0.15 (0.006) 0.10-0.21 (0.004-0.008) 0.03-0.08 (0.001-0.003)

Service Limit 0.20 (0.008) 0.27 (0.011) 0.12 (0.005)

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL

Section 1: General Information

46.90 (1.846) 13.06 (0.514)

SECTION 1: GENERAL INFORMATION

NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL