Sym Jolie Service Manual

SERVICE MANUAL
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HOW TO USE
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This service manual contains the technical data of each component inspection
and repair for the SANGANG FT05 series motorcycle. The manual is shown
with illustrations and focused on Service Procedures, Operation Key Points,
and Inspection Adjustment so that provides technician with service guidelines.
If the style and construction of the motorcycle, FT05 series, are different from
that of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.
Service Department
Sanyang Industry Co., LTD.
HOME PAGE CONTENTS
How to Use This Manual
This service manual describes basic information of different system parts and
system inspection & service for Sanyang FT05 series motorcycles. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information.
Th third to the tenth chapters cover engine and driving systems.
The eleventh to the fourteenth is contained the parts set of assembly body.
The fifteenth chapter is electrical equipment.
The sixteenth chapter is emission control system.
The seventeenth chapter is wiring diagram
Please see index of content for quick having the special parts and system
information.
All information, illustration, directions and specifications included in this manual
are current as at the time of publication. Sanyang reserves the rights to make
changes at any time without prior notice and without incurring any obligation
whatever. Without written consent by SANGANG can not copy any part of this
manual.
HOME PAGE CONTENTS
CONTENTS
Page Cont ent I ndex
1-1 ~ 1-14 GENERAL INFORMATION 1
2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 2
3-1 ~ 3-6 LUBRICATION SYSTEM 3
4-1 ~ 4-4 ENGINE REMOVAL 4
5-1 ~ 5-8 CYLINDER HEAD/CYLINDER/PISTON 5
6-1 ~ 6-4 ALTERNATOR 6
7-1 ~ 7-14 V TYPE BELT DRIVING SYSTEM/KICK-STARTER 7
8-1 ~ 8-6 FINAL DRIVING MECHANISM 8
9-1 ~ 9-6 CRANKCASE/CRANKSHAFT 9
10-1 ~ 10-10 FUEL SYSTEM 10
11-1 ~ 11-13 BRAKE SYSTEM 11
12-1 ~ 12-12 BODY COVER 12
13-1 ~ 13-10 STEERING/FRONT WHEEL/SUSPENSION 13
14-1 ~ 14-6 REAR WHEEL/SUSPENSION 14
15-1 ~ 15-16 ELECTRICAL EQUIPMENT 15
16-1 ~ 16-2 ELECTRICAL DIAGRAM 16
HOME PAGE
MODEL ILLUSTRATION
FT05U
FT05V
FT05T
HOME PAGE CONTENTS
1. GENERAL INFORMATION
1-1
Symbols and marks 1-1 Torque values 1-6
General safety 1-2 Cables and harness routing 1-8
Service precautions 1-3 Troubleshooting 1-11
Specifications 1-5
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are
needed, in case supplemental information is procedures needed for these symbols and marks,
explanations will be added to the text instead of using the symbols or marks.
Warning
Means that serious injury or even death may result if procedures are not
followed.
Caution
Means that equipment damages may result if procedures are not
followed.
Engine oil
Limits to use SAE 20 JASO FC class oil. Warranty will not cover the
damage that caused by not apply with the limited engine oil.
(Recommended oil: MAX-2 serial oils)
Grease King Mate G-3 is recommended.
Gear oil
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR
OIL # 140)
Locking sealant
Apply sealant, medium strength sealant should be used unless otherwise
specified.
Oil seal Apply with lubricant.
Renew Replace with a new part before installation.
Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools Special tools.
Correct Meaning correct installation.
Wrong Meaning wrong installation.
Indication Indication of components.
Directions Indicates position and operation directions.
Components assembly directions each other.
Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).
1
HOME PAGE CONTENTS
1-2
General safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area, if you
have to run your engine in a closed area, be sure
to use an extractor.
Caution
Gasoline
Gasoline is a low ignition point and explosive
material. Work in a well-ventilated place, no
flame or spark should be allowed in the work
place or where gasoline is being stored.
Caution
Used engine oil
Caution
Hot components
Caution
Battery
Caution
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Brake fluid
Caution
Exhaust contains toxic gas which may cause
one to lose consciousness and even result in
death.
Battery emits explosive gases; flame is
strictly prohibited. Keep the place well
ventilated when charging the battery.
Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be
careful do not be spray on your eyes or
skin. If you get battery acid on your skin,
flush it off immediately with water. If you
get battery acid in your eyes, flush it off
immediately with water and then go to
hospital to see an ophthalmologist.
If you swallow it by mistake, drink a lot of
water or milk, and take some laxative such
as castor oil or vegetable oil and then go
to see a doctor.
Keep electrolyte beyond reach of children.
Gasoline is highly flammable, and may
explode under some conditions, keep it away
from children.
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer
although it might not be verified.
We recommend that you wash your hands
with soap and water right after contacting.
Keep the used oil beyond reach of children.
Inhaling dust may cause disorders and
cancer of the breathing system.
Spilling brake fluid on painted, plastic, or
rubber parts may cause damage to the parts.
Place a clean towel on the above-mentioned
parts for protection when servicing the brake
system. Keep the brake fluid beyond reach of
children.
Components of the engine and exhaust
system can become extremely hot after
engine running. They remain very hot even
after the engine has been stopped for some
time. When performing service work on these
parts, wear insulated gloves and wait until
cooling off.
TO THIS CHAPTER CONTENTS
1-3
Service Precautions
Always use with Sanyang genuine parts and
recommended oils. Using non-designed parts
for Sanyang motorcycle may damage the
motorcycle.
Special tools are designed for remove and
install of components without damaging the
parts being worked on. Using wrong tools may
result in parts damaged.
When servicing this motorcycle, use only
metric tools. Metric bolts, nuts, and screws are
not interchangeable with the English system,
using wrong tools and fasteners may damage
this vehicle.
Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on
the part's surface may fall into the engine,
chassis, or brake system to cause a damage.
Wash and clean parts with high ignition point
solvent, and blow dry with compressed air.
Pay special attention to O-rings or oil seals
because most cleaning agents have an
adverse effect on them.
Never bend or twist a control cable to prevent
stiff control and premature worn out.
Rubber parts may become deteriorated when
old, and prone to be damaged by solvent and
oil. Check these parts before installation to
make sure that they are in good condition,
replace if necessary.
When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
Store complex components such as
transmission parts in the proper assemble
order and tie them together with a wire for
ease of installation later.
Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
Components not to be reused should be
replaced when disassembled including
gaskets metal seal rings, O-rings, oil seals,
snap rings, and split pins.
Caution
In addition to damaging paint finish, brake oil
can also damage the structural integration of
plastic or rubber parts.
1-4
The length of bolts and screws for assemblies,
cover plates or boxes is different from one
another, be sure they are correctly installed. In
case of confusion, Insert the bolt into the hole
to compare its length with other bolts, if its
length out side the hole is the same with other
bolts, it is a correct bolt. Bolts for the same
assembly should have the same length.
Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, check the shaft
on which the oil seal is to be installed for
smoothness and for burrs that may damage
the oil seal.

Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can
go to their connections so that there is enough
room below the enlarged ends for tightening
the clamps.
Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner
race or outer race). In this case, the bearing
should be replaced. To avoid damaging the
bearing, use equal force on both races.
Both of these examples can result in bearing damage.
Lubricate the rotation face as assembling.
Check if positions and operation for installed
parts is in correct and properly.
Manufacturer's
name
Groove
Clamp
Connection
Boots
1-5
Specifications
Make SANYANG MODEL FT05W
Overall Length 1660 mm Front TELESCOPIC
Overall Width 630 mm
Suspension
System
Rear UNlT SWING
Overall Height 1020 mm Front 3.00 - 10 42J(T/L)
D
I
M
E
N
S
I
O
N
Wheel Base 1155 mm
Tire
Specifications
Rear 3.00 - 10 42J(T/L)
Front 32 kg DlSK ( 160mm)
Rear 48 kg
Brake
System
Front
DRUM ( 110mm)
C
u
r
b
W
e
i
g
h
t
Total 80 kg Rear DRUM ( 95mm)
Passengers/
Weight
Two /110 kg Max. Speed 48 km/hr Below
Front 54 kg Climb Ability 20 Below
Rear 136 kg Primary Reduction BELT
W
E
I
G
H
T
T
o
t
a
l

W
e
i
g
h
t
Total 190 kg
Secondary
Reduction
GEAR
Type Gasoline Clutch Centrifugal, dry type
Installation and
arrangement
Vertical, below center,
incline
P
E
R
F
O
R
M
A
N
C
E
Transmission C.V.T.
Fuel Used Unleaded(92/95) Speedometer 0 ~ 90 km/hr
Cycle/Cooling
2-stroke/forced air
cooled
Horn 80 112 dB/A
Bore 39 mm Muffler Expansion & Pulse Type
Stroke 41.4 mm
Exhaust Pipe Position
and Direction
Right side, and Backward
C
y
l
i
n
d
e
r
Number/Arran
gement
Single Cylinder Lubrication System Separated-lubrication
Displacement 49.4 cc Solid Particulate 15 %
Compression
Ratio
7.1 : 1 CO 3.5 %
Max. HP 2.7 kw / 6250 rpm
E
x
h
a
u
s
t
C
o
n
c
e
n
t
r
a
t
i
o
n
HC Below 4000 ppm
Max. Torque 4.41 Nm / 5000 rpm E.E.C. Below 2g / test
Ignition C.D.I. P.C.V. X
E
N
G
I
N
E
Starting System Electrical & kick
Catalytic reaction
control system

1-6
Torque values
Standard Torque Values for Reference
Type Torque value Type Torque value
5 mm Bolt, nut 0.45 - 0.6 kg-m 5 mm Bolt 0.35 - 0.5 kg-m
6 mm Bolt, nut 0.8 - 1.2 kg-m 6 mm Bolt, SH nut 0.7 - 1.1 kg-m
8 mm Bolt, nut 1.8 - 2.5 kg-m 6 mm Flange bolt, nut 1.0 - 1.4 kg-m
The torque values listed in below table are for more important tighten torque values. Please see above
standard values for not listed in the table.
Engine
Item Qty
Thread Dia.
(mm)
Torque Value
(Kg-m)
Remarks
Cylinder head bolt
4 6 1.0
When engine
cooled
Spark plug 1 14 1.4
Flywheel nut 1 10 3.8
Sliding driving disc nut 1 10 3.8
Sliding driving disc nut 1 28 5.5
Clutch outer cover nut 1 10 3.8
Drain bolts 1 8 1.3
Crankcase bolts 6 6 1.0
1-7
Frame
Item Qty
Thread Dia.
(mm)
Torque Value
(Kg-m)
Remarks
Bolt for engine suspension
1 10 5.0
Bolt for engine suspension bracket
1 12 6.0
Upper bolt for rear shock absorber
1 10 4.0
Lower bolt for rear shock absorber
1 8 2.7
Mounting screws for exhaust pipe
connection
2 6 1.2
Nut for exhaust
2 8 3.3
Brake hose bolts
2 10 3.5
Brake caliper mounting bolts
2 8 3.1
Brake cushion guide bolts
2 6 1.8
Brake cushion guide bolts cap
2 6 1.0
Brake drain valve
1 6 0.6
Rear brake arm bolts
1 5 0.55
Tightening nut for steering rod
1 25.4 7.0
Front shaft nut
1 12 6.0
Mounting bolt for handle
1 10 5.0
Mounting nut for front hub
4 8 2.5
Mounting bolt for front brake disc
3 8 4.5
Rear shaft nut
1 14 11.0
Nut for rear hub
4 8 2.5
1-8
Cables and Harness Routing
Note the following when routing cables
and wire harnesses:
A loose wire, cable or harness may cause
safety hazard. After clamping, check each
wire to make sure it is secured.
Do not squeeze wires against the weld or its
clamp.
Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
Route harnesses so that they neither pull too
tight nor have excessive slack.
Protect wires or wire harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
Route wire harnesses to avoid sharp edges or
corners.
Avoid the projected ends of bolts and screws.
Keep wire harnesses far away from the
exhaust pipes and other hot parts.
Be sure grommets are seated in their groves
properly.
After clamping, check each harness to be
certain that it is not interfered with any moving
or sliding parts.
After routing, check that the wire harnesses
are not twisted or kink.
Wire harnesses routed along the handlebar
should not be pulled too tight or have
excessive slack, be rubbed against or
interfere with adjacent or surrounding parts in
all steering positions.
Thoroughly clean the surface where tape is to
be applied.
Wrap electrical tape around the damaged
parts or replace them.
O Correct
X Wrong
1-9
High/low beam switch
Horn switch
Rear brake lamp
switch
Turn signal
lamp switch
Turn signal lamp
relay
Speedometer
Headlamp switch
Starting switch
Throttle cable
Headlamp
Rear brake cable
Speedometer cable
Throttle cable
Main switch
Regulator
Resistor
Horn
Front brake
cable
Throttle
cable
Front brake cable
Front brake
lamp switch
1-10
Throttle cable
Spark plug cap
Engine oil operation cable
Engine oil filling pipe
Fuel unit
Oil pump
Engine oil return pipe
Rear brake cable
Carburetor
Throttle cable
Fuel filter
Fuel pump
Battery/fuse/starting
relay/CDI set
1-11
Troubleshooting
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt
to check if there is gasoline
inside the carburetor
Fuel supplied tom
carburetor sufficient
No fuel is supplied to
carburetor
Remove spark plug, install
it into spark plug cap, and
perform a spark test
against engine ground.
Perform cylinder
compression pressure test.
Check if sparks
Week sparks or no spark
at all
cylinder compression pressure normal Low compression
pressure or no pressure
Re-start by following the
starting procedures
No ignition
There are some signs of
ignition, but engine can
not be started
Remove the spark plug
again and check it.
Remove carburetor after 30
minutes and connect a hose
onto fuel supplement circuit.
Then blow the hose with air
Dry spark plug Wet spark plug
Blowing in normal
Blowing clogged
1. No fuel in fuel tank
2. Check if the pipes, fuel tank to
carburetor and intake vacuum, are
clogged.
3. Float valve clogged
4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump
vacuum hose
7. Fuel filter clogged
1. Malfunction of spark plug
2. Spark plug foul
3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
6. Ignition coil leads open or short circuit
7. Malfunction of main switch
1. Piston ring seized
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
5. Sand hole in compression parts
6. Crankcase leakage for pre-compression
1. Malfunction of throttle valve
operation
2. Air sucked into intake manifold
3. Incorrect ignition timing
1. Fuel level in carburetor too high
2. Malfunction of throttle valve operation
3. Throttle valve opening too wide
1. Malfunction of auto-starter
1-12
B. Engine run sluggish (Speed does not pick up, lack of power)
Try gradual acceleration
and check engine speed
Engine speed can be
increased.
Engine speed can not be
increased.
Check ignition timing
(Using ignition lamp)
Check cylinder compression
pressure (using compression
pressure gauge)
Ignition timing correct Incorrect ignition timing
Compression pressure correct No compression pressure
Check if carburetor is
clogged
Normal Clogged
Remove spark plug
Check if engine over heat
No foul or discoloration Fouled and discoloration
No knock Knock
1. Air cleaner clogged
2. Poor fuel supply
3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
1. Malfunction of CDI
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
3. Sand hole in compression parts
4. Valve deterioration
5. Crankcase leakage for pre-
compression
1. Remove dirt
1. Remove dirt
2. Incorrect spark plug heat range
1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
Normal Engine overheat
Continually drive in
acceleration or high speed
1. Too much carbon deposited in
combustion chamber
2. Lean mixture
3. Poor fuel quality
4. Lean mixture
1-13
C. Engine runs sluggish (especially in low speed and idling)
D. Engine runs sluggish (High speed)
(using ignition lamp)
Check for fuel supplying
system in automatic fuel cup
Check if carburetor clogged
1. Incorrect ignition timing (malfunction of
CDI or AC generator)
1. Rich mixture (loosen the screw)
2. Lean mixture (tighten the screw)
1. Poor heat insulation gasket
2. Carburetor lock loose
3. Poor intake gasket
4. Poor carburetor O-ring
1. Spark plug fouled
4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
1. Insufficient fuel in fuel tank
2. Fuel filter clogged
3. Restricted fuel tank vent
Good Poor
Good spark Poor
No air sucked Air sucked
Good Poor
Normal Abnormal
Air sucked through
carburetor gasket
Adjust the air screw of
carburetor
Remove spark plug, install
spark plug into spark plug
cap and perform spark test
against engine ground
CHECK AND ADJUSTMENT FAULT CONDITION PROBABLE CAUSES
Normal Abnormal
Normal Clogged
1. Cleaning
1-14
E. CLUTCH, DRIVING AND DRIVING PULLEY
1. Clutch ling spring broken
2. Clutch outer cover stuck with clutch balance weights
3. Connection parts in clutch and shaft worn out or
burned
Engine can be started but
motorcycle can not be driving
FAULT CONDITION PROBABLE CAUSES
1. Driving belt worn out or deformation
2. Driving disk damaged
3. Driving pulley spring broken
4. Clutch ling broken
5. Driving slide-shaft gear groove broken
6. Transmission gear damage
7. Transmission gear worn out or burned
Engine running and misfire as
motorcycle initial forward moving
or jumping sudden (rear wheel
rotating as engine in running)
Poor initial driving (Poor climbing
performance)
1. Driving belt worn out or deformation
2. Balance weight roller worn out
3. Driving sliding gear shaft worn out
4. Driving disk spring deformation
5. Driving sliding gear shaft worn out
6. Greased in driving belt and sliding gear.
2. SERVICE MAINTENANCE INFORMATION
2-1

General information............................. 2-1
Periodical maintenance schedule ...... 2-2
Air cleaner - air cleaner cover ............ 2-3
Fuel lines.............................................. 2-3
Fuel filter .............................................. 2-4
Engine oil line ...................................... 2-4
Oil pump control cable........................ 2-5
Tire........................................................ 2-6
Battery .................................................. 2-6
Brake system....................................... 2-7
Steering system................................. 2-10
Suspension ........................................ 2-10
Transmission oil ................................ 2-11
Spark plug ............................................ 2-11
Control cable lubrication..................... 2-12
Driving belt ........................................... 2-12
Ignition timing...................................... 2-12
Throttle valve operation ...................... 2-12
Carbutrtor idle speed adjustment....... 2-13
Idle speed adjustment ......................... 2-13
Carbon removing for exhaust pipe &
muffle.................................................... 2-13
Cylinder compression pressure test.. 2-13
Evaporation emission control system2-14
Headlamp adjustment.......................... 2-14

General Information
Specification
Tire dimension
Front: 3.00-10 42J
Rear: 3.00-10 42J
Tire pressure at cold Only rider
Front: 1.5kg/cm
2

Rear: 2.25 kg/cm
2

Front brake lever free play 10~20 mm
Rear brake lever free play 10~20 mm
Transmission oil Recommendation
Type: HYPOID GEAR OIL
Oil: SAE #140
Quantity: 0.1 L
Spark plug Recommendation
Type: NGK BR8HSA
Plug gap: 0.6-0.7mm
Driving belt width
Standard 18.0mm
Allowable limit: replace it if below 16.5mm
Ignition timing F mark 17, BTDC/1500 rpm
Acceleration operation 2~6 mm
Idle speed 2000100 rpm
Cylinder compression pressure 71 kgf/cm

2
HOME PAGE CONTENTS
2-2
Periodical Maintenance Schedule
Maintenance
kilometer
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
Check item
Maintenance
interval
New 1 month 3 month 6 month 1 year
Reference
1. Air cleaner I C C R
2. Fuel filter C C
3. Engine oil filter cleaning C C C
4. Oil pump linkage operation

check
I I I I
5. Tire pressure I I I I I
6. Battery inspection I I I I I
7. Brake & free play check I I I I I
8. Steering handle check I I I
9. Cushion operation check I I I
10. Every screw tightening check I I I I I
11. Gear oil check for leaking I I I I I
12. Spark plug check or change I R R R
13. Gear oil change R Replacement for every 5000km
14. Frame lubrication L L
15. Exhaust pipe I I I I I
16. Carburetor I I I I I
17. Driving belt check I
18. Ignition timing I I I I I
19. emission check in Idling I I I I I
20. Idle speed check I I I I I
21. fuel lines I I I I
22. Throttle operation I I I I
23. Engine bolt tightening I I I I
24. engine screw torque I
25. Carbon cleaning for cylinder

head, cylinder, piston head,
and exhaust system.
I I I
Have your motorcycle checked, adjusted periodically by your SYM Authorized Dealer to maintain the motorcycle
at the optimum condition
Code:I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~
Lubrication
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which
ever comes first.
Remarks:
1. Clean or replace the air cleaner element more often for pro-long engine life-span when the
motorcycle is operated on dusty roads or in the Heavily- polluted environment.
2. Maintenance should be performed more often if the motorcycle is frequently operated in high
speed and after the motorcycle has accumulated a higher mileage.
2-3
AIR CLEANER - AIR CLEANER
COVER
Remove the mounting screw from the air
cleaner cover
Remove the air cleaner cover
Remove the air cleaner element
Clean the element with non-flammable or high-
flash point solvent and then squeeze it for dry.
Caution
Soap the element into cleaning engine oil and
then squeeze it out. Install the element onto the
element seat and then install the air cleaner
cover.
Limit to use SAE 20 JASO FC class engine oil,
otherwise, SYM is no responsible for the
warranty.
Recommended engine oil: MAX-2 serial oils.
FUEL LINES
Remove the body cover
Check fuel lines and replace damaged lines if
found.
Install the body cover.
Never use gasoline or acid organized
solvent to clean the element.
Air cleaner element
Squeeze out remaining oil
Soap Clean
Squeeze oil out
Fuel pump
Carburetor
Fuel line
Mounting screw X 7
2-4
FUEL FILTER
Remove the luggage box.
Remove the fuel line from the fuel filter.
Replace the fuel filter with new one.
Install the fuel filter. The arrow indicates the fuel
flowing direction.
Check the fuel line for leaking.
ENGINE OIL LINE
Remove the body cover.
Check the engine oil line and replace damaged
parts.
Remove the filling pipe from the oil pump, and
drain oil into a cleaning container.
Loosen the clamp under the engine oil tank, and
then remove the oil pipe.
Bleed the air inside the oil pump and oil pipe if air
found.
Fuel filter
Oil filling pipe
Engine oil pipe
Oil pump
2-5
OIL PUMP CONTROL CABLE
Caution
Wide open the throttle valve, and check if the
calibration point aligns on the oil pump lever with
the mark of pump body.
Loosen the adjustment nut of the oil pump control
cable.
Turn the adjustment nut and align with the point,
then tighten the nut.
To adjust the oil pump control cable after
adjusted the throttle grip play.
Mounting nut
Adjustment nut
2-6
TIRE
Caution
Check tire for cracks, damage, nail, or other
object stuck in tread.
Recommended tire and tire pressure
Tire size
Front:
3.00-10 42J
Rear:
3.00-10 42J
Tire pressure
(cold) kg/cm
2
1.50 2.25
Check if the tire tread and wall rubber for crack or
damage, and replace if necessary.
Check if foreign materials such as nail, metal
pieces, and stones stuck on tire.
The thread depth can be checked by visual
inspection or by a depth gauge.
If the tread bend too much, replace the tire.
If tire wear exceeds limitation, replace the tire,
and check it for un-even wear.
Caution
BATTERY
Open the seat.
Loosen two screws of battery cap and then
remove the cap. Check if the battery terminals
are loosen. Remove the battery if its terminals
are corroded obviously.
BATTERY REMOVAL
1. Remove the Negative (-) battery cable at first.
2. Then, remove the Positive (+) battery cable.
3. Remove the battery.
Clean the rust with steel brush.
Install the battery in reverse order of removal, and
apply with grease onto two terminals.
Caution
Tire pressure should be checked when
cold.
Wear indicator is distributed on
average along the wall rubber for check.
The electrolyte is contained sulfuric acid so
be careful not to let it touch to eyes, skin, or
clothes. If touched by accident, flush them
with clean water immediately. However, if
the electrolyte sprays to eyes, medical care
should be done quickly.
Wear indicator
Mark
2-7
BRAKE SYSTEM
FRONT BRAKE FREE PLAY: (DRUM BRAKE
TYPE)
Measure the free play of the front brake lever at
the end of the lever.
Free play: 10-20 mm (3/8-3/4 in)
Adjust the free play by turning the front brake
adjustment nut if necessary.
REAR BRAKE FREE PLAY: (DRUM
BRAKE TYPE)
Measure the free play of the rear brake lever at
the end of the lever.
Free play: 10-20 mm (3/8-3/4 in)
Adjust the free play by turning the front brake
adjustment nut if necessary.
BRAKE CONFIRAMTION
Caution
After brake adjustment, it has to check the
brake operation to make sure the front and
rear wheel can be braked.
1020mm
(3/83/4 in)
Adjustment nut
Increasing free
play
Decreasing free
play
1020mm
(3/83/4 in)
Adjustment nut
Increasing
free play
Decreasing
free play
2-8
BRAKE SYSTEM HOSE: (FRONT
DISC BRAKE TYPE)
Make sure that the brake hose is corrosion or
damage, and also check the system for leaking.
BRAKE FLUID:
Check brake fluid level in the brake fluid reservoir.
If the level is lower than the LOWER limit, add
brake fluid DOT-3 to UPPER limit. Also check
brake system for leaking if low brake level found.
Caution
BRAKE LINING WEAR:
Replace the brake lining if the wear limit mark
on the brake arm aligning with the indicator of
brake drum.
BRAKE LINING WEAR: (FRONT
DISC BRAKE TYPE)
The arrow mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.
Caution
In order to maintain brake fluid in the
reservoir in horizontal position, do not
remove the cap until handle bar stop.
Do not operate the brake lever after the
cap had been removed. Otherwise,
the brake fluid will spread out if
operated the lever.
Do not mix non-compatible brake fluid
together.
Brake fluid
reservoir cap
Lower limit
Brake lining
Brake
caliper
Brake disc
Front drum brake
type
Wear limit
mark
Arrow
Wear limit mark
Arrow
In order to maintain brake power balance,
the brake lining must be replaced with one
set.
2-9
Remove the pin bolt cap.
Loosen the bolt.
Remove the front wheel shaft bolt.
Take out the front wheel.
Remove brake caliper mounting bolt and then
remove the brake caliper.
Caution
Pry out the brake lining with a flat driver if lining is
clipped.
Remove brake lining bolt.
Take out the lining.
Tighten Torque:
Mounting bolt: 2.9-3.5 kg-m
Pin bolt: 1.5-2.0 kg-m
Pin bolt cap: 0.8-1.2 kg-m
The brake lamp switch is to light up brake lamp as
brake applied. Replace the switch if the lamp
does not light up in properly.
Caution
Do not operate the brake lever after the
clipper removed to avoid clipping the brake
lining.
The brake lamp switch is un-adjustable.
Pin bolt cap
Pin bolt
Mounting
bolt
Pin bolt
Brake lining
2-10
STEERING SYSTEM
Caution
Lift the front wheel out of ground, and check if the
steering handle turning is smoothly.
If handle turning is uneven and bending, stuck, or
the handle can be operated in vertical direction,
then adjust the handle top bearing by adjusting
the steering nut.
SUSPENSION
Warning
FRONT SHOCK ABSORBER
Press down the front shock absorber for several
times to check it operation.
Check if the shock absorber assembly is damage.
Replace it if damage found and can not be
repaired.
Tighten all nuts and bolts.
REAR SHOCK ABSORBER
Park the motorcycle with its main stand.
Shake the rear wheel side to side to check engine
suspension bushing for wear.
Replace the bushing if looseness found. Check
the shock absorber for damage.
Tighten all nuts and bolts.
NUTS, BOLTS TIGHTNESS
Check if all bolts and nuts on the frame are
tightened to specified torque in accord with the
interval of Periodical Maintenance Schedule.
Check all split pins, snap rings, hose clamps, and
wire holders for security.
The control cables can not interfere with the
rotation of steering handle.
Do not ride the motorcycle with poor
suspension. Looseness, wear or damage
suspension system will make poor stability
and drive-ability.
2-11
TRANSMISSION OIL
LEAK
Check if the transmission is leak.
CHECK
Caution
Remove the oil level check bolt, and check if the
oil level is placed on the hole of check bolt.
REPLACEMENT
Remove the oil level check bolt.
Remove the oil draining bolt, and then drain oil
out.
Install the oil draining bolt.
Tighten torque: 1.3 kg-m
Caution
Replacement Quantity: 0.09 L (90 cc)
Recommended oil: King Bramax HYPOID
GEAR OIL #140
SPARK PLUG
Recommended plug: NGK BR8HSA
Remove the luggage box.
Remove the spark plug cap.
Clean any dirt on the spark plug seat.
Remove the spark plug.
Visually inspect the spark plug electrodes for
wear.
The center electrode should have square
edges and side electrode should have a
constant thickness. Replace the spark plug if
there is apparent wear or if the insulator is
cracked and/or chipped. If the spark plug
deposits can be removed by sandpaper, the
spark plug can be reused.
Measure the spark plug gap with feeler
gauge.
Spark plug gap: 0.6-0.7mm (0.024-0.028in)
Adjust the gap by careful bending the side
electrode.
Install the spark plug by screwing it with
hands after installed the spark plug washer
so that can prevent the plug from out of
thread. Then, tighten the spark plug with a
spark plug wrench.
Install the spark plug cap.
Park the motorcycle on flat ground with its
main stand.
Check if oil seal and washer is in good
condition.
Oil level check bolt
Draining bolt
Oil level check bolt hole
0.6~0.7mm
Side electrode
Center electrode
2-12
CONTROL CABLE LUBRICATION
Remove the throttle control and the brake cables
periodically, and lubricate the moving parts of the
cables thoroughly.
DRIVING BELT
Remove left crankcase cover.
Check if the belt is crack or worn out.
Replace the belt if necessary.
Measure the driving belt width
Allowable limit: 16.5mm
IGNITION TIMING
Caution
Remove the right-side cooling fan cover.
Check ignition timing with the timing lamp.
When engine speed setting to 1800 rpm, and if
the mark aligns with F mark, then it means that
the ignition timing is correct.
THROTTLE VALVE OPERATION
Check if each steering positions are operated in
smooth, and handle bar if its operation is smooth
as the throttle valve wide opening or fully closed.
Check throttle cable and replace it if deteriorated,
twisted or damaged.
Lubricate the cable if operation is not smooth
Measure throttle valve handle free play.
Free play 2~6 mm (1/8-1/4 in)
Loosen the mounting nut, and turn the free play
adjustment nut of the throttle valve handle for
adjustment.
Replace the cable if it can not be adjusted.
C.D.I ignition timing can not be
adjusted. If the ignition timing is
incorrect, check the C.D.I. device and
the alternator and replace damaged
components.
Check ignition timing with standard
instrument.
Tooth face
Belt width
Mounting nut
Adjustment nut
Ignition
lamp
F mark
2-13
CARBUTRTOR IDLE SPEED
ADJUSTMENT
Caution
Park the motorcycle with main stand after warned
up engine. According to the required idling and air
screw to adjust to specified idle speed.
Idle speed: 2000100 rpm (rotation per
minute)
IDLE SPEED ADJUSTMENT
Adjust the idling after warn up engine for 10 minutes.
1. Connect tachometer.
2. Adjust the idle speed screw to let engine speed
in 2000100 rpm.
3. Insert the sampling pipe of the CO/HC meter to
the test hole on the front end of exhaust pipe.
Adjust the idling emission value to standard
range. (CO: 1.8-2.6%)
4. Slightly accelerate the throttle valve and release
it. Repeat this operation for 1-2 times.
5. Read the engine idle speed and the emission
value after engine speed in stable. Repeat the
operation on step No. 2 No. 4. until these value
within standard range.
CARBON REMOVING FOR EXHAUST
PIPE & MUFFLE
Remove the exhaust pipe & muffler.
Clean the carbon deposits on the muffler &
cylinder exhaust edge.
CYLINDER COMPRESSION
PRESSURE TEST
Remove the left body cover, and warn up engine.
Stop the engine and remove the spark plug.
Insert the compression gauge and wide open the
throttle, and then rotate the engine by means of
the starting motor.
Compression pressure: 13.02 kg/cm
2
Probable causes for low compression pressure.
Damaged cylinder head gasket.
Worn piston ring
Worn cylinder
Probable causes for high compression pressure.
Carbon on the combustion chamber or
cylinder head
Inspection & adjustment for idle speed
have to be performed after all parts in
engine had been adjusted in
specification.
Idle speed check and adjustment have
to be done after engine is being warn
up. It around operates engine from stop
to running for 10 minutes.
Pilot screw
Idle speed adjustment screw
Compression
pressure gauge
2-14
EVAPORATION EMISSION
CONTROL SYSTEM
Check if hoses are corroded, plugged, or
damaged, and also check hose connection for
loosen.
Replace the damaged hoses.
Check if the canister crack or damage.
HEADLAMP ADJUSTMENT
Loosen headlamp mounting bolt.
Move the headlamp for adjustment its light beam.
Tighten the headlamp mounting bolt after
adjusted.
Caution
Improper headlamp beam adjustment will
make in coming driver dazzled or
insufficient lighting for safety distance.
Headlamp
mounting bolt
3. LUBRICATION SYSTEM
3-1

Lubrication system diagram 3-1 Oil pump inspection 3-3
Precautions in operation 3-2 Oil pump installation 3-3
Lubricant 3-2 Oil pump / oil tube air bleeding 3-4
Troubleshooting 3-2 Oil tank removal 3-5
Oil pump removal 3-3

Oil pump
Oil output tube
Oil tube
Oil indicator switch
Oil tank

3
LUBRICATION SYSTEM DIAGRAM
HOME PAGE CONTENTS
3-2

PRECAUTIONS IN OPERATION
Be careful not let dirt enter into engine or oil hoses when removing or installing the oil pump.
If air is found in the oil tube (from oil tank to oil pump) or oil tube is removed, the oil pump should
be conducted air-bleeding operation.
It should bleed the oil output tube (from oil pump to carburetor) as hose removed.
The adjustment of oil pump control cable.

LUBRICANT
Appointed to apply SAE 20 JASO FC class oil. Otherwise, warranty shall not cover the damage.
Recommended Oil: MAX-2 oil

TROUBLESHOOTING
Too much smoke, carbon in spark plug
1. Improperly oil pump adjustment (too much oil)
2. Poor quality oil.
3. Applying with poor quality oil.

Over heat
1. Improperly oil pump adjustment (insufficient oil)
2. Poor quality oil.
3. Applying with poor quality oil.

Piston seized
1. No oil in oil tank or clogged hose.
2. Improperly oil pump adjustment (insufficient oil)
3. air in oil hose
4. malfunction of oil pump

Oil did not flow out the oil tank
1. clogged breath hole on the oil tank cover.

3-3

OIL PUMP REMOVAL
Caution

Remove the oil tube, and clip its end side to
prevent oil from flowing out.
Remove the oil output tube form intake manifold.
Remove the oil pump mounting bolts, and then
take out the oil pump.

OIL PUMP INSPECTION
Inspect the following items on the removed oil
pump.
Check if O-ring is damaged or softening.
Check if crankcase interface is damaged.
Check if pump body is damaged.
Check if pump gear is damaged.
Check for oil leaking.
Caution

OIL PUMP INSTALLATION
Install the oil pump onto the crankcase.
Caution

Tighten the oil pump mounting bolt security.
Install the oil tube.
Installation in the reverse order of removal.
Caution

Before removing the oil pump, clean the oil
pump and crankcase.
Oil tube

Control
cable
Oil output tube
Oil tube
Control cable
Oil output tube

O-ring
Interface
Control
lever The oil pump can not be disassembled.
Apply with some grease onto oil pump
oil ring.
The connection between both oil pump
and crankcase has to be installed in
position security.
Inspection and Adjustment following items
as installed.
The adjustment operation of control
cable.
Air bleeding operation of oil pump.
Air bleeding operation of oil tube.
Check each section for leaking.
3-4

OIL PUMP/OIL TUBE AIR BLEEDING
Caution

Caution

OIL TUBE/OIL PUMP
It has to add some oil into the oil tank.
Place a piece of dry cloth around the oil
pump.
Disconnect the oil tube.
Fill out oil to oil pump connection section by
means of the oil pot so that the oil pump
body is full with oil.
Fill out oil to oil tube connection section so
that the oil tube is full with oil. Then, install
the tube onto oil pump.
Make sure whether air is in the oil tube or
not after installation.
Caution

OIL TUBE AIR BLEEDING
Remove the oil output tube and plug its input
connector. Bend the oil tube into U shape,
and fill out new oil into the output tube.
Connect the oil output tube to the oil pump
connection part.
Start engine, and run it in idling as the oil control
lever in wide open position. Make sure oil flows
out from the oil output tube.
Caution

Oil tube

Oil output tube
Recommended oil
Oil tube

Control
cable
Oil output tube
The oil tube system has to be
conducted air bleeding operation
because air will clog or restraint oil
flowing so that cause serious engine
damage.
After disconnect the oil tube, air enters oil
tube due to oil leak out without added oil.
There is why the oil tube and oil pump
have to conduct air bleeding operation.
After bleeding the oil tube and oil pump,
the oil tube has to be conducted air
bleeding operation too.
Motorcycles exhaust gas includes with
CO which causes human to coma or
death so perform this operation in
well-ventilation place.
Run the engine in extreme low speed
to avoid to damaging the engine
caused from clogged oil tube
3-5

OIL TANK
REMOVAL/INSTALLATION
Remove the luggage box and seat.
Remove the oil input tube from oil pump, and
then drain oil to a clean container.
Remove the oil switch wire of the oil indicator.
Remove the mounting bolt on the oil tank upper
side, and then remove the oil tank.
Installation in the reverse order of removal.
Air bleeding the oil tubes after installation.

M
o
u
n
t
i
n
g

b
o
l
t

3-6

NOTES

4. ENGINE REMOVAL
4-1
Maintenance Information 4-1
Engine removal 4-2
Engine installation 4-3
There are parts that require removal of
engine for maintenance.
Crankcase
Crankshaft
4
4.0 Kg-m
3.3 Kg-m
1.2 Kg-m
6.0 Kg-m
Related bolts tightening torque for removal of engine :
Engine hanger bolt 5.0 kg-m
Engine bracket bolt 6.0 kg-m
Rear shock absorber upper mounting bolts 4.0 kg-m
Rear shock absorber lower mounting bolts 2.7 kg-m
Exhaust pipe connection nut 1.2 kg-m
Muffle mounting bolt 3.3 kg-m
HOME PAGE CONTENTS
4. ENGINE REMOVAL
4-2
ENGINE REMOVAL
Remove body cover.
Remove the spark plug cap from the spark plug
section.
Remove the fuel output and the vacuum tubes
from fuel pump.
Remove the oil control cable from oil pump.
Remove the oil tube from oil pump and then clip
the tube.
Remove the wire connectors of auto by starter
and ACG.
Remove the upper part of the carburetor from its
top side.
Remove the vapor emission vacuum tube from
carburetor intake manifold.
Remove rear brake cable from engine rear-lower
side.
Oil control cable
Oil tube
Fuel pump
Vacuum tube
Fuel output tube
Wire connector
Vapor emission vacuum
Carburetor top side
Spark plug
Brake cable
Cable clamp
4. ENGINE REMOVAL
4-3
Support the engine and then remove shock
absorber lower mounting bolt.
Remove two exhaust pipe connection nuts.
Remove two bolts beside fan cover and exhaust
pipe.
Remove engine mounting nut and bolt.
ENGINE INSTALLATION
Install in the reverse order of removal procedures.
Tighten the engine mounting and rear shock
absorber upper/lower bolts.
Torque value:
Engine hanger bolt:
Rear shock absorber upper
mounting bolts:
Rear shock absorber lower
mounting bolts:
Exhaust pipe connection nut:
Muffle mounting bolt:
5.0 kg-m
4.0 kg-m
2.7 kg-m
1.2 kg-m
3.3 kg-m
Perform the following inspection and adjustment
after installation.
Check if control cable is correct.
Check if throttle valve cable is correct.
Check if oil pump control cable is correct.
Oil input and output of the oil pump.
Adjust rear brake.
Shock absorber lower
mounting bolt
Exhaust pipe
Bolt
Connection nut
Engine mounting bolt
Shock absorber upper
mounting bolt
4. ENGINE REMOVAL
4-4
NOTES
5. CYLINDER HEAD/CYLINDER/PISTON
5-1
Mechanism diagram 5-1
Troubleshooting 5-2
Cylinder head 5-3
Cylinder/piston 5-5
5
HOME PAGE CONTENTS
5-2

MAINTENANCE INFORMATION
PRECAUTIONS IN OPERATION
The inspection and maintenance of the cylinder head, cylinder and piston can be carried as
engine mounted on the body.
It should clean the engine to prevent dirt from entering into cylinder and crankcase before
removal.
Remove all washes from the interfaces of cylinder head, cylinder and crankcase.
Be careful do not damage cylinder head, cylinder and piston when removing.
Inspect the removed & cleaned parts thoroughly, and apply with oil onto the rotation surfaces
before installation.

SPECIFICATION
Item Standard value
(mm)
Limit (mm)
Cylinder head Deformation 0.10
Piston OD 39.030~39.045 38.935
Clearance between cylinder and piston 0.040~0.050 0.100
Piston pin hole 12.002~12.008 12.030
Piston pin OD 11.994~12.000 11.970
Clearance between piston and piston pin 0.002~0.014 0.03
Piston ring end gap 0.10~0.25 0.40
Piston
ID of connecting rod small end 17.005~17.015 17.025
ID 39.000~39.035 39.050 Cylinder
DEFORMATION 0.10
ID: inner diameter
OD: outer diameter

Tighten torque value
Cylinder head 1.0 kg-m Exhaust pipe connection nut 1.2 kg-m
Spark plug 1.4 kg-m Exhaust muffler mounting bolt 3.3 kg-m

TROUBLESHOOTING
Compression Pressure Too Low/Difficult
To Start/Rough Idling
1. cylinder head gasket leaking
2. spark plug not tighten enough
3. worn, seized or crack piston ring
4. damaged, worn cylinder or piston
5. poor reed

Compression Pressure Too
High/Overheat/Knock
1. too much carbon deposit built up in
combustion chamber
Piston Noise
1. cylinder and piston worn out
2. piston pin or piston pin hole worn out
3. connecting rod small end bearing worn out

Piston Ring Noise
1. worn, seized or crack piston ring
2. cylinder worn out or damaged

5-3

CYLINDER HEAD
CYLINDER REMOVAL
Removal body cover.
Remove spark plug cap.
Remove fan cover.
Remove engine shield.

Remove two connection nuts of the exhaust pipe.
Remove exhaust muffle mounting bolt, and then
remove the exhaust pipe.

CYLINDER HEAD REMOVAL
Remove the 4 cylinder head bolts and then
remove the cylinder head.
Caution

CLEANING CARBON IN
COMBUSTION CHAMBER
Clean carbon deposit in which built up in
combustion chamber with shown chisel.
Caution

Loosen the cylinder head bolts with
diagonal direction to avoid to damaging it.
Do not scratch to the interfaces of
combustion chamber and cylinder.
Engine shield
tightening bolt

Tightening bolts

Chisel

Bolt x 2
Muffle
Tightening bolt x 2
5-4

CYLINDER HEAD INSPECTION
Use a straight edge and a feeler gauge to
measure the cylinder head for warp.
Service limit: 0.10 mm

CYLINDER HEAD INSTALLATION
Replace the cylinder head gasket with new one,
and place the cylinder head onto cylinder.
Tighten the 4 bolts with diagonal direction and by
2-3 sequences.
Install spark plug
Replace the exhaust pipe washer with new one
and then install exhaust pipe.
Tighten exhaust pipe connection nut.
Tighten exhaust pipe mounting bolt.
Install the removed parts in the reverse order of
removal procedures.
Inspect following item after installation.
compression pressure test
Check for engine noise.

Bolt

Bolts x 2
Muffle
Tightening bolts x 2
5-5

CYLINDER/PISTON
CYLINDER REMOVAL
Be careful to pull the cylinder up and prevent
piston from damage.
Caution

PISTON REMOVAL
Place a clean rag onto crankshaft to cover the
piston.
Remove piston pin clip (one piece) and then
push piston pin out the piston.
Caution

PISTON RING REMOVAL
Caution

Check if cylinder and piston are worn or
damaged, and then clean carbon deposit on
exhaust opening area as the diagram shown.
Caution

Do not have pry out operation between
cylinder and crankcase. Or let radiation
fan be knocked seriously.
Do not damage or scratch the piston.
Do not apply with lateral force to
connecting rod.
Do not let piston pin snap ring falling
into crankcase.
Pry out the opening end of each piston ring
and then remove the ring from piston.
Do not scratch both the cylinder and the
piston.

Piston pin clip
Piston pin
Piston

5-6

Use a straight edge and a feeler gauge to
measure the cylinder head for warp.

In X and Y direction, measure the cylinder for
worn out as the three levels shown in the figure.
With the max. value to decide cylinder wear out
condition.
Service limit: 39.05mm

Measure the OD of piston at the 7 mm from the
bottom of the piston.
Calculate the clearance between piston and
cylinder.

Measure the ID of piston pin hole.
Measure the OD of piston pin.

The ID of piston
pin hole
The OD of
piston pin

7mm
5-7

PISTON RING INSPECTION
Measure the end gap of each piston ring.
Caution

CONNECTING ROD INSPECTION
Install bearing and piston pin onto connecting rod
small end, and then check its clearance.
Measure the ID of connecting rod small end.

PISTON/CYLINDER INSTALLATION
Install the expanding ring into the groove of 2
nd

ring.
Align the ring end with the lock pin in the ring
groove.
Install the top ring and the 2
nd
ring onto the ring
groove respective.
Caution

Push the rings into ring groove and then check
rings mating condition.
If ring could not be push in the ring groove, it
means that ring groove is dirty or wrong ring
groove installation.
Caution

With the piston, push each piston ring into
cylinder correctly.
The top ring and the 2
nd
ring can not be
changeable each other.
All rings should be installed with the
marks facing up.
All ring should be replaced at same
time, and it can not be replaced one
ring only.
It should use same brand name piston
ring in an engine and can not mix with
other one.
Clearance
Top ring

2
nd
ring
Expanding
ring
Piston ring
mark
1T: top ring
2T: 2
nd
ring
5-8

Place a cleaning cloth onto the crankcase
opening to prevent the piston pin snap ring from
falling into the crankcase.
Apply with two-stroke engine oil onto needle
bearing and piston pin, and then install the piston
pin onto connecting rod. Install piston, and
place EX mark of the piston toward to exhaust
side.
Install new piston pin snap ring.

Clean all gaskets onto the interfaces of cylinder
and crankcase.
Place a new gasket onto the crankcase.
Make sure that the piston ring aligns with the lock
pin in piston ring groove.
Caution

Lubricate cylinder and piston with two-stroke
engine oil. Hold the piston and then install it
into cylinder.
Caution

Install the cylinder head.
Make sure that all rings in the piston ring
groove can not be rotated around the lock
pin to avoid to damaging the rings, piston
and cylinder.
To avoid to damaging the piston and the
cylinder sliding surface.
Piston pin snap
ring
Piston pin
Piston EX
Lock pin
6. ALTERNATOR
6-1
Mechanism Diagram 6-1
Alternator Removal 6-3
Alternator Installation 6-4
6
3.8 kg-m
HOME PAGE CONTENTS
6. ALTERNATOR
6-2
Precautions in Operation
The maintenance service of A.C. alternator can be carried out directly on the motorcycle.
Please refer to Chapter 15 for the relative alternator inspection.
Torque value:
Flywheel 3.8 kg-m
Tool
General tool
Rotor puller
Universal holder
Coil resistance value for the A.C. alternator
Y/L Y W R/B Earth
Earth
50
200
0.2
0.8
0.2
1.0
400
800
Alternator
6. ALTERNATOR
6-3
ALTERNATOR REMOVAL
Remove two bolts and then take out cooling fan
cover.
Remove four bolts, and then take out the cooling
fan.
Hold flywheel with universal holder.
Support the flywheel and the remove the 10 mm
nut on the flywheel.
Remove the flywheel with rotor puller.
Cooling fan
Universal
holder
10mm flanged nut
Rotor puller
Cooling fan
cover
Bolt
6. ALTERNATOR
6-4
Disconnect alternator wire connector and pulse
generator connector.
Remove the pulse generator and alternator four
(4) bolts, and then take out the alternator
assembly.
Caution
ALTERNATOR INSTALLATION
Install the alternator assembly.
Connect the alternator connector.
Caution
Install the woodruff key onto the crankshaft
groove.
Caution
Install the flywheel.
Tighten the flywheel 10 mm nut.
Torque value:
Install the removed parts in reverse order of
removal procedures.
Start engine and check its ignition timing.
Care to be taken for not damaging the
alternator coil.
Connect the alternator wire harness
properly and then clip the harness with
clipper.
Clean dirt and metal pieces inside the
flywheel.
Make sure that there is no foreign
material inside the flywheel.
Universal
holder
10mm flanged nut
Wire harness
connector
Pulse generator
Coil
7. V TYPE BELT DRIVING SYSTEM/KICK-STARTER
7-1
Mechanism Diagram 7-1 Kick-starter 7-3
Maintenance Information 7-2 Driving belt 7-5
Troubleshooting 7-2 Movable driven pulley 7-6
Left crankcase cover 7-3 Clutch/driven pulley 7-10
7
3.8 kg-m
3.8 kg-m
5.5 kg-m
HOME PAGE CONTENTS
7-2
Precautions In Operation
The surfaces of driving belt and driving pulley must be free of grease.
SPECIFICATION
Item Standard value(mm) Limit(mm)
Driving belt width 18.0 16.5
ID of movable driving pulley 20.035~20.085 20.120
OD of movable driving pulley boss 20.010~20.025 19.98
OD of weight roller 15.92~16.08 15.40
ID of clutch outer 107.0~107.2 107.5
Thickness of clutch weight 4.0~4.1 2.0
Free length of driven pulley spring 98.1 92.7
OD of driven pulley 33.965~33.985 33.94
ID of movable driven pulley 34.000~34.025 34.06
ID: Inner Diameter
OD: Outer diameter
Torque Values:
Movable driving pulley: 3.8 kg-m
Driven pulley: 5.5 kg-m
Clutch outer: 3.8 kg-m
Special Service Tools
Clutch spring compressor
Bearing driver
Clutch nut wrench 39x41 mm
Bearing driver accessory 39x41 mm
Universal holder
Driver
TROUBLESHOOTING
Engine can be started but motorcycle can
not be moved
1. Worn driving Belt
2. Worn ramp plate
3. Worn or damaged clutch weight
4. Broken driven pulley spring
Shudder or misfire when driving
1. Broken clutch weight
2. Worn clutch weight
Insufficient horsepower or poor high
speed performance
1. Worn driving belt
2. Insufficient spring capacity of driven pulley
3. Worn weight roller
4. Driven pulley operation un-smoothly
7-3
LEFT CRANKCASE COVER
Left crankcase cover removal
Remove body cover.
Remove air cleaner.
Remove kick starter.
Remove left crankcasecover.
Disassembly of Kick Starter
Remove snap ring and thrust washer from left
crankcase cover.
Install kick starter lever, rotate the lever slightly
and then remove driving gear and washer.
Remove the lever, kick starter, starter shaft, and
return spring as well as socket.
Inspection of kick Starter
Check if starter shaft, driving gear, socket and bearing hole for wear or damage.
Driving gear
Thrust washer
Friction spring
Return spring
Starter shaft
Snap ring
Kick starter lever
Bolt
Thrust washer
Socket
Driving gear
Starter shaft
Return spring
Left crankcase cover
Kick starter
7-4
Washer
Left crankcase cover
Lock pin
Mounting bolts
REASSEMBLY OF KICK STARTER
Install socket, return spring and starter shaft as
diagram shown.
Install thrust washer and snap ring onto starter
shaft.
Install Kick starter lever temporary.
Slightly rotate the lever and then align driving
gear with width-tooth on the starter shaft.
Install the friction spring of driving gear onto
convex part of the cover.
INSTALLATION OF THE LEFT CRANKCASE COVER
Install the left crankcase cover
Install kick starter lever
Starter
shaft
Return spring
Driving gear
Friction spring
Width-tooth
Convex part
7-5
DRIVING BELT
Removal
Hold clutch outer with universal holder, and
remove nut and clutch jacket.
Caution
Push the driving belt into belt groove as diagram
shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley/clutch. Do not remove
driving belt.
Remove the driving belt from the groove of driven
pulley.
INSPECTION
Check the driving belt for crack or wear.
Replace it if necessary.
Measure the width of driving belt as diagram
shown.
Service Limit: 16.5 mm
Replace the belt if exceeds the service limit.
Caution
Installation
Caution
Install driving belt onto driven pulley.
Install the driven pulley that has installed the belt
onto driving shaft.
Using special service tools for
tightening or loosening the nut.
Fixed rear wheel or rear brake will
damage reduction gear system.
Pull out driving pulley to avoid it closing.
Using the genuine parts for
replacement
The surfaces of driving belt or pulley
must be free of grease.
Clean up all grease or dirt before
installation.
Nut
Universal
holder

Clutch/driving belt
Width
Belt tooth
Movable
driven pulley
7-6
Install the clutch with universal holder, and then
tighten nut to specified torque value.
Torque value: 3.8 kg-m
MOVABLE DRIVEN PULLEY
REMOVAL
Hold generator flywheel with universal holder,
and then remove driving pulley nut.
Remove driving pulley.
Driving pulley
Clutch/driven pulley
Driving shaft
Driving belt
Clutch outer
Nut
Universal holder
Universal
holder
Flywheel
Nut
Driving pulley
7-7
REMOVAL
Remove movable driving pulley set and driving
belt from crankshaft.
Remove ramp plate.
Remove weight rollers from sliding pulley.
INSPECTION
The weight roller is to press sliding pulley by
means of centrifuge force. Thus, if weight rollers
are worn out or damage, the centrifuge force will
be effected.
Check if rollers are wear out or damage.
Measure each rollers outer diameter. Replace it if
exceed the service limit.
Crankshaft
Pulley boss
Movable driving
pulley
Ramp
plate
Movable driving
pulley
Weight roller
Weight roller
7-8
Check if driving pulley boss is worn or damage
and replace it if necessary.
Measure the outer diameter of pulley boss, and
replace it if it exceed service limit.
Measure the inner diameter of driving pulley, and
replace it if it exceed service limit.
REASSEMBLY/INSTALLATION
Install weight rollers.
Install ramp plate.
Apply with grease 4~5g to inside of driving pulley,
and install driving pulley boss.
Caution
The pulley surface has to be free of grease.
Clean it with cleaning solvent.
Weight roller
Ramp
plate
Pulley surface
Driving pulley
Pulley boss
7-9
Install movable driving pulley assembly onto
crankshaft.
DRIVING PULLEY INSTALLATION
Press driving belt into pulley groove, and then pull
the belt on to driving pulley shaft.
Install driving pulley, washer and nut.
Caution
Hold flywheel with universal holder.
Tighten nut to specified torque.
Torque value: 3.5-4.0 kg-m
Install left crankcase cover.
Make sure that two sides of pulley surfaces
have to be free of grease. Clean it with
cleaning solvent.
Crankshaft
Driving pulley
boss
Movable
driving pulley
Driving belt
Press down
Universal
holder
Flywheel
Nut
Driving pulley
7-10
CLUTCH/DRIVEN PULLEY
DISASSEMBLY
Remove driving belt and clutch/driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let nut
be installed more easily.
Caution
Hold the clutch spring compressor onto bench
vise, and then remove mounting nut with special
service tool.
Release the clutch spring compressor and
remove clutch and spring from driven pulley.
Remove socket from driven pulley.
Remove guide pin, guide pin roller, and driven
pulley, and then remove O-ring & oil seal seat
from driven pulley.
INSPECTION
Clutch jacket
Measure the inner diameter of clutch outer friction
face. Replace clutch outer if exceed service limit.
Do not press the compressor too much.
Clutch outer
Inner
diameter
O-ring
Guide pin
Guide pin
roller
Guide pin
Oil seal
Driven pulley
Or
Socket
Clutch nut wrench
7-11
Clutch weight
Measure each clutch weight thickness. Replace
it if exceeds service limit.
Driven pulley spring
Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Driven pulley
Check following items:
If both surfaces are damage or wear.
If guide pin groove is damage or wear.
Replace damaged or worn components.
Measure the outer diameter of driven surface and
the inner diameter of driven pulley. Replace it if
exceeds service limit.
Service limit: Outer diameter 33.94 mm
Inner diameter 34.06 mm
Driven Pulley Bearing Inspection
Check if the inner bearing oil seal is damage.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to
check if the bearing rotation is in smooth and
silent. Check if the bearing outer parts are
closed and fixed. Replace it if necessary.
Caution
Some of models are equipped with two ball
bearings.
Free length
Guide pin groove
Sliding disc
Driven pulley
Clutch
Clutch weight
Needle bearing
Outer ball bearing
7-12
Clutch Block Replacement
Remove clip and washer, and then remove clutch
weight and spring from drive plate.
Caution
Check if spring is damage or insufficient elasticity.
Check if shock absorption rubber is damage or
deformation. Replace it if necessary.
Apply with grease onto lock pins.
Install new clutch weight onto lock pin and then
push to specific location.
Apply with grease onto lock pins. But, the clutch
weight should not be greased. If so, replace it.
Caution
Install the spring into groove with pliers.
Some of models are equipped with one
mounting plate instead of 3 snap clips.
Grease or lubricant will damage the clutch
weight and effect the weights connection
capacity.
Shock absorption
rubber
Clutch block
Spring
Spring
Drive plate
Snap clip
Clutch weight
Shock absorption
rubber
Lock pin
7-13
Install snap clip and mounting plate onto lock pin.
Replacement of Driven Pulley Bearing
Remove inner bearing.
Caution

Remove snap ring and then push bearing forward
to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified oil.
Install new inner bearing.
Caution
Install snap ring into the groove of driving face.
Align oil seal lip with bearing, and then install the
new oil seal (if necessary).
Its sealing end should be forwarded to
outside as bearing installation.
Install needle bearing with hydraulic
presser. Install ball bearing by means
of hydraulic presser or driver.
If the inner bearing equipped with oil
seal on side in the driven pulley, then
remove the oil seal firstly.
If the pulley equipped with ball bearing,
it has to remove snap ring and then the
bearing.
Snap ring
Inner bearing
Sealing end
Clipper
Inner ball bearing
Inner needle bearing
Outer bearing
Snap ring
Snap ring
Outer bearing
Sealing end
Specified oil
7-14
Installation of Clutch/Driven Pulley
Assembly
Install new oil seal and O-ring onto driven pulley.
Apply with specified grease to lubricate the inside
of sliding disc.
Install sliding pulley onto driven pulley.
Install guide pin and guide pin roller.
Install socket.
Install driving belt, spring and clutch into clutch
spring compressor, and press down the assembly
by turning manual lever until mounting nut that
can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with special
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0 kg-m
Install clutch/driven pulley and driving belt onto
driving shaft.
Oil seal
O-ring
Specified grease
Or
Guide pin
Guide pin O-ring
Guide pin
roller
Oil seal
Driven pulley
Socket
Mounting
nut
Clutch nut wrench
8. FINAL DRIVING MECHANISM
8-1

Troubleshooting 8-2
Disassembly of Final Driving Mechanism 8-3
Inspection of Final Driving Mechanism 8-4
Re-assembly of Final Driving Mechanism 8-4

8

HOME PAGE CONTENTS
8-2

Limited usage of engine oil: 4-stroke lubricant
Recommended oil: King serial oil.
Oil quantity: 100 c.c. (90 c.c. as replacement)

Bearing puller set 12 mm
Bearing puller 15 mm

General tools:
Adapter 3235 mm
Adapter 3740 mm
Punch guide 12mm
Punch guide 15mm
Punch guide 17mm
Driver

TROUBLESHOOTING
Trouble Diagnosis
Engine can be started but motorcycle can not be moved.
1. Damaged driving gear
2. Burnt out or seized driving gear

Noise
1. Seized, worn or damage gear
2. Worn or loose bearing

Gear oil leaks
1. Excessive gear oil.
2. Worn or damage oil seal

8-3

DISASSEMBLY OF FINAL DRIVING
MECHANISM
Remove driven pulley
Drain gear oil out from gearbox.
Remove rear wheel.
Remove gearbox cover mounting bolts from the
clutch side and then remove the cover from the
rear wheel side.

Remove final driving gear and countershaft.

Remove the driving shaft from left crankcase
cover.
Caution

Remove driving shaft oil seal and bearing from
left crankcase cover.

The bearing must be replaced when
removing the driving shaft.

Final driving gear Counter
shaft
Thrust washer
Driving shaft
Gearbox cover
Bearing Oil seal
Oil filling
hole
Oil draining
hole
8-4

INSPECTION OF FINAL DRIVING
MECHANISM
Check if the driving shaft, countershaft and final
gear shaft are worn or damage.
Check if the gearbox cover bearing, oil seal and
the inner diameter of countershaft are worn or
damage.
Check if the left crankcase cover bearing, oil seal
and the inner diameter of countershaft are worn
or damage.

RE-ASSEMBLY OF FINAL DRIVING
MECHANISM
Re-assemble the gearbox cover and left
crankcase with following tools:
Gear Box Cover
Driving shaft bearing:
Driver
Adapter 37 x 40 mm
Punch guide, 17 mm

Final Driven Shaft Bearing:
Driver
Adapter 32 x 35 mm
Punch guide, 15 mm

Left Crankcase
Driving shaft bearing:
Driver
Adapter 32 x 35 mm
Punch guide, 12 mm

Final Driven Shaft Bearing:
Driver
Adapter 37 x 40 mm
Punch guide, 17 mm
With the special service tools to install driving
shaft by through the bearing.
Install a new driving shaft oil seal.
Install a new driven shaft oil seal.

Driving shaft
Countershaft
Final driven gear shaft

Adapter
Punch guide
Driver

8-5

Install countershaft, final driven gear and thrust
washer.

Install new washer and lock pin.

Install gearbox cover.
Install clutch/driven pulley assembly.
Install driven pulley, driving belt, and left
crankcase side cover.
Install body cover.
Install rear wheel.
Fill out specified oil quantity into gearbox.

Lock pin
Washer
Final driven gear
Counter
shaft Thrust washer
Oil filling
hole
Oil draining
hole
8-6

NOTES
9. CRANKCASE/CRANKSHAFT
9-1
Mechanism Diagram 9-1 Crankshaft removal 9-3
Maintenance Information 9-2 Crankshaft inspection 9-4
Troubleshooting 9-2 Crankshaft installation 9-5
Crankcase disassembly 9-3 Crankcase assembly 9-6
9
Apply liquid
gasket
1.0 kg-m
HOME PAGE CONTENTS
9-2
This chapter concerns disassembly of the crankcase for repair purpose.
Before disassembling crankcase, except removing engine firstly, following components must be
removed too.
Carburetor (page 10-3)
Oil pump (page 3-2)
Reed valve (page 10-6)
Driving belt (page 7-2, 7-4, & 7-5)
Alternator (page 6-2)
Cylinder head/cylinder/piston (page 5-2 & 5-4)
Except above components are needed be removed , when disassembling L crankcase, following
components must be removed too.
Final driving mechanism (page 9-2)
When assembling both crankcase and crankshaft, it has press the inner ring edge of the
crankshaft bearing to push the crankshaft into the crankcase hole by using the specified service
tools. The old bearing onto the crankshaft has to be removed. Then install a new bearing onto the
crankshaft on the crankcase side. Oil seal has to be replaced with new one after assembled the
crankcase.
Item Standard Limit (mm)
Lateral cearance of the big end of the connecting rod 0.60
Radial clearance of the big end of the connecting rod 0.04
Crankshaft run-out point A 0.10
Crankshaft run-out point B 0.10
Service Tools
Special Service Tools
Assembly shaft tube Driver
Assembly shaft Adapter 52 55 mm
Multi-purpose bearing puller Guide bar 17 mm
Crankcase puller
TROUBLESHOOTING
Engine noise
1. Worn bearing of connecting rod bog end
2. Bend connecting rod
3. Worn crankshaft bearing
9-3
CRANKCASE DISASSEMBLY
Remove the crankcase bolts.
Install the crankcase puller onto the right
crankcase with two (2) bolts, 6mm, as the
diagram shown.
Disassemble the right crankcase.
CRANKSHAFT REMOVAL
As the diagram show with 3 special bolts to install
the specified service tool onto the left crankcase.
Remove the crankcase.
Caution
Remove crankshaft bearing with bearing puller.
Remove the right and left side oil seals.
Caution
Do not use iron hammer to knock out the
crankshaft.
Replace the oil seal with new one as
removing the crankshaft.
Crankcase puller
Right crankcase
Multi-purpose
bearing puller
Shaft protector
Crankcase puller
Crankcase puller
9-4
CRANKSHAFT INSPECTION
Measure the clearance of connecting rod big end.
Measure the radial clearance of connecting rod
big end at X-Y directions as diagram show.
Place the crankshaft on a V-block, measure run-
out points A and B of the crankshaft with dial
gauge.
Service limit: A: 0.10 mm
B: 0.10 mm
Check the crankshaft bearing by means of turning
it with hand. If any noise and bigger clearance
are detected, replace the bearing with new one.
Clearance
Clearance
70mm
37mm
A B
Lateral Radial
9-5
CRANKSHAFT INSTALLATION
Clean the crankshaft with solvent and blow it with
compressed air. Then, check for damage or
other foreign materials attached.
Caution
Install new bearing into right crankcase.
Install new bearing into left crankcase.
Install crankshaft onto the left crankcase.
Install crankshaft assembly tool onto crankshaft.
Screw the bolt into crankshaft.
Turn the bolt in C.W. direction and then
completely screw the bolt to bottom.
Lubricate crankshaft bearing and bearing seat
with 2-stroke engine oil.
With the specified service tool to install a new oil
seal onto the left crankcase to the depth of 1 mm
as the diagram shown.
All rotation and sliding surfaces have to
be applied with clean engine oil.
Remove all gaskets onto the crankcase
interfaces and flat it with special tool.
Adapter
Assembly shaft tube (long
& middle size)
Assembly shaft
tube
Assembly shaft
Adapter
Driver
Pilot
Pilot
Assembly shaft
Oil seal
9-6
CRANKCASE ASSEMBLY
Install gasket and lock pin onto the interface of
crankcase.
Assemble the crankcase with assembly tools.
With same tools, install new oil seal into the right
crankcase. Its installation depth is 4 mm as the
diagram shown.
Install the bolts and tighten them.
Caution
Install the following components:
~ Final driving mechanism (page 8-3)
~ Alternator (page 6-2)
~ Piston/cylinder/cylinder head (page 7-4, 7-8)
~ Oil pump (page 3-2)
~ Reed valve and carburetor (page 10-3, 10-6)
~ Engine (page 4-3)
Make sure that the crankshaft can be
rotated freely after tightening the bolts.
Assembly shaft giude
Assembly shaft
Bolts
Assembly
shaft
Oil
seal
Oil seal
10. FUEL SYSTEM
10-1
Mechanism Diagram 10-1 Carburetor 10-4
Maintenance Information 10-2 Reed Valve 10-7
Troubleshooting 10-2 Fuel Pump 10-8
Throttle valve 10-3 Air Cleaner 10-9
10
Fuel tank
Fuel unit
Fuel filter
Vacuum tube
Fuel pump
Carburetor
Oil tube
Air hose
Vacuum hose
Throttle valve cable
HOME PAGE CONTENTS
10. FUEL SYSTEM
10-2
Precautions in Operations
Warning
Care must be taken when dealing with gasoline, and always work in a well-ventilated place and
strictly prohibit flame.
When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
It has to conduct air bleeding operation as removed the oil tube.
Idle speed adjustment.
Specification
Venturi diameter 14 mm
I.D. number PB2BE
Fuel level 8.6 mm (0.335 in)
Air screw opener 1 3/8
Idle speed 2000100 rpm
Throttle handle free play 2~6 mm
Main jet #82
Fuel pump output 20 c.c. minimum.
TROUBLESHOOTING
Engine can not be started
1. No fuel in fuel tank
2. Fuel can not reach to carburetor
3. Too much fuel in cylinder
4. Clogged air cleaner
Stall after started
1. Incorrect idle speed adjustment
2. No spark on the spark plug
3. Low compression pressure
4. Rich mixture
5. Lean mixture
6. Clogged air cleaner
7. Intake pipe leaking
8. Polluted fuel
Lean Mixture
1. Clogged carburetor jet
2. Clogged hose from carburetor to canister
3. Bend, squeezed or clogged fuel lines
4. Clogged fuel filter
5. Malfunction of float valve
6. Low fuel level in float chamber
7. Clogged vent pipe
8. Malfunction of fuel pump
Rich Mixture
1. Malfunction of float valve
2. Low fuel level in float chamber
3. Clogged carburetor air injector
Gasoline is a highly flammable material and may explosive under circumstance. Thus, always work
in a well-ventilated place and strictly prohibit flame when working with gasoline.
10. FUEL SYSTEM
10-3
THROTTLE VALVE
Removal
Remove the throttle valve cable from the throttle
valve.
Remove the throttle valve spring, carburetor
upper part and sealed cap.
Remove needle clamp and fuel needle.
Inspection
Installation
Place the fuel needle onto the throttle valve and clip it with needle clamp.
Install the sealed cap, carburetor upper part, and throttle valve spring.
Connect the throttle valve cable to the throttle valve.
Install the throttle valve into the carburetor body.
Caution
Tighten the carburetor upper part.
Install carburetor protector.
Adjust the free play of throttle valve cable.
Align the groove inside the throttle valve with the throttle stopper
screw of the carburetor body.
Carburetor
upper part
Vacuum hose
Needle clamp
Throttle valve
spring
Fuel needle
Throttle valve cable
Sealed cap
Carburetor upper part
Washer
Throttle valve
Fuel needle clip
10. FUEL SYSTEM
10-4
CARBURETOR
Remove the mounting bolts of carburetor cap and
cover.
Disconnect the auto by-starter connector.
Loosen draining screw and then drain out fuel
inside the carburetor.
Loosen connection screw and remove carburetor
upper part.
Remove fuel and vent hoses from carburetor.
Remove carburetor mounting bolt and carburetor.
AUTO BY-STARTER INSPECTION
Connect resistor meter to the terminals of auto
by-starter, and then measure its resistance.
If the resistance value exceeds specification too
much, it means that the PTC in the auto by-starter
is malfunction. Then, replace the auto by-
starter.
Resistance value: Max. 10 (at cold engine)
Caution
If the resistance value exceeds the
standard a little bit, the auto by-starter may
still in normal. However, it is necessary to
check other relative components for
damage.
Auto by-starter
Auto by-starter
Draining screw
Bolt
Fuel hose
Connection hose clamp
Carburetor
upper part
10. FUEL SYSTEM
10-5
Remove carburetor, and allow it to cool off for 30
minutes.
Connect fuel rich circuit with a hose and pump
compressed air to the hose.
Air should flow into fuel rich circuit.
Replace the auto by-starter if the circuit clogged.
Connect battery to starters connectors and wait
for several minutes.
Pump compressed air into the fuel rich circuit.
Air should not flow into the circuit.
If air flow through the circuit, then, replace the
starter.
Check resistor to make sure that the auto by-
starter is in normal. Engine is running.
If the resistor is in open-circuit, then current will
not flow into the PTC. Thus, the auto by-starter
is not operated.
However, if the resistor is in short-circuit, current
higher than specification will flow into the PTC.
Then, it will cause the fuel rich circuit close rapidly,
and difficult to start the motorcycle.
Resistance value: 10.2
AUTOMATCI BY-STARTER
Remove the cover of the by-starter.
Remove screw and mounting plate.
Remove the auto by-starter from carburetor.
Battery
Alternator
Resistor
Automatic by-starter
Screw
Mounting
plate
10. FUEL SYSTEM
10-6
FLOAT/FLOAT VALVE/JET
REMOVAL
Remove the float from carburetor body.
Remove the float pin and then remove float and
float valve.
Check the valve seat for worn out or damage.
Check float for bend and if fuel inside the float.
Before removing both the throttle valve stopper
and air screws, record their original turns for close
to their original set up position as installation.
Caution
Remove main jet, needle jet seat and idle jet and
clean them and each component with
compressed air.
FLOAT/FLOAT VALVE/JET
INSTALLATION
Install the idle jet, the needle jet seat and main jet.
Then install the throttle valve stopper and air
screws to their original position according to the
marks as removal. Adjust the screws if replace
with new ones.
Air inlet for
fuel rich
circuit
Air inlet for idle speed
Float cap
Air screw
Throttle valve
stopper screw
Needle jet
Needle jet seat
Main jet
Float pin
Float valve
Float
O-ring
Float cap
Screw
Draining screw
Idle jet
Do not tighten the screw forcedly to avoid to
damaging the valve seat.
10. FUEL SYSTEM
10-7
FLAOT LEVEL INSPECTION
Measure float fuel level to have the upper end of
float just contact with the float.
Float fuel level: 8.6 mm
Carefully bend the float arm for adjustment.
Check the float operation and the install it.
CARBURETOR INSTALLATION
Caution
Install the carburetor and insulator onto intake
pipe with bolts.
Install fuel and vent pipes onto carburetor.
Install the carburetor upper part.
Tighten the connection hose.
Tighten the draining screw.
Connect the automatic by-starter connector.
Install air cleaner cap.
Conduct following operations
Adjustment of throttle valve cable.
Adjustment of oil pump.
Adjustment of idle speed.
REED VALVE
REMOVAL
Remove the carburetor.
Remove engine shield.
Remove intake hose.
Remove the reed valve.
Do not let foreign materials into the
carburetor.
Draining screw
Bolt
Fuel hose
Connection
hose clamp
Intake hose
Reed valve
10. FUEL SYSTEM
10-8
INSPECTION
Check the reed valve for damage and its reed
strength.
Check the reed valve seat for crack, damage and
the clearance between the seat and the valve.
Replace reed valve if necessary.
Caution
INSTALLATION
Check for leaking after installed.
FUEL PUMP
INSPECTION
Warm up the engine and adjust idle speed.
Remove fuel hose from carburetor and then wait
for 5 minutes.
Measure the output of fuel pump. Its output time
is 10 seconds.
Output quantity: Min. 20 c.c.
If the output quantity is lower than 20 c.c., check
fuel hose, vacuum hose and fuel filter.
Remove floor plate.
Remove fuel inlet, outlet and vacuum hoses.
Remove 2 bolts and fuel pump.
Install the fuel pump in the reverse order of
removal procedures.
Do not bend the reed valve stopper.
Otherwise, it will cause its strength
insufficient and rough engine running. If
the reed valve or its seat is damaged,
replace with a set.
Reed stopper
Reed valve
Reed valve seat
Carburetor
Fuel hose
Fuel hose connector
Fuel inlet
hose
Fuel outlet
hose
Bolt
Vacuum
hose
10. FUEL SYSTEM
10-9
AIR CLEANER
Remove 5 bolts and then remove the carburetor
cap.
Remove the PCV hose from the air cleaner outer
case.
Loosen connection hose clamp.
Remove 2 bolts and then remove the air cleaner
outer case.
Install the air cleaner outer case.
Carburetor cap
PCV hose
Bolts
Seal gasket
Air cleaner element
10. FUEL SYSTEM
10-10
NOTES
11. BRAKE SYSTEM
11-1

Illustration - Front Disc Brake System 11-1 Troubleshooting 11-4
Illustration - Rear Drum Brake System 11-2 Hydraulic Disc brake 11-5
Maintenance Information 11-3 Drum brake 11-10

Front Disc Brake System

11
6.0 kg-m
4.5 kg-m
2.5 kg-m
1.0 kg-m
1.8 kg-m
0.55 kg-m
3.5 kg-m
HOME PAGE CONTENTS
11. BRAKE SYSTEM
11-2

Rear Drum Brake System

2.5 kg-m
11.0 kg-m
0.55 kg-m
11. BRAKE SYSTEM
11-3

Caution

The brake caliper can be removed without removing the hydraulic system.
After the hydraulic system is removed, or the brake system is felt to be too soft, bleed the
hydraulic system.
While refilling brake fluid, care should be taken not to let the foreign material entering into the
brake system.
Do not spill brake fluid on the painted surfaces, plastic or rubber parts to avoid damage.
Check the operation of the brake system before you go.

Specifications
Item Standard (mm) Limit (mm)
The thickness of front brake disc 3.5 2.0
Front brake disc run-out < 0.10 0.3
Master cylinder inner diameter 11.000 - 11.043 11.055
Master cylinder piston outer
diameter
10.957 - 10.984 10.945
ID of rear brake drum 95.0 95.5
Thickness of front brake lining 4.0 2.0
Thickness of rear brake lining 4.0 2.0

Torque values
Brake hose bolt 3.5 kg-m
Bolt for brake caliper 3.3 kg-m
Bolts for the lining guide pin 1.8 kg-m
Bolts for the lining guide pin cap 1.0 kg-m
Air-bleed valve 0.55 kg-m
Bolt for rear brake arm 0.55 kg-m

Inhaling brake lining ashes may cause disorders of respiration system, therefore, never use air
hose or dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.
11. BRAKE SYSTEM
11-4

TROUBLESHOOTING
DISC BRAKE
Soft brake lever
1. Air inside the hydraulic
system
2. Hydraulic system leaking
3. Worn master piston
4. Worn brake pad
5. Poor brake caliper
6. Worn brake lining/disc
7. Low brake fluid
8. Blocked brake pipe
9. Warp/bent brake disc
10. Bent brake lever

Hard operation of brake
lever
1. Blocked brake system
3. Blocked brake pipe
4. Seized/worn master
cylinder piston
5. Bent brake lever

Uneven brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Clogged brake hose
4. Deformed or warped
brake disc
5. Restricted brake hose and
fittings

Tight brake
1. Dirty brake lining/disc
2. Poor wheel alignment
3. Deformed or warped
brake disc

Brake noise
1. Dirty lining
2. Deformed brake disc
installation
4. Imbalance brake disc or
wheel

DRUM BRAKE
Poor brake performance
1. Improper brake
adjustment
2. Worn brake lining
3. Worn brake drum
4. Worn brake cam
5. Improper brake lining
installation
6. Seized brake cable
7. Dirty brake lining
8. Dirty brake drum
9. Brake pad worn in brake
cam area.
10. Poor contact between
brake arm and camshaft
indent
Tight operation or low
return speed of brake
lever
1. Worn/broken/crack return
spring
2. Worn drum
4. Brake seized caused from
dirty brake drum
5. Seized brake cable
6. Worn brake cam
7. Improper brake lining
installation

Brake noise
1. Worn brake lining
2. Worn drum
4. Dirty brake drum

11. BRAKE SYSTEM
11-5

HYDRAULIC DISC BRAKE
Close the drain valve of the hydraulic
disc brake.
Replace the brake fluid.
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, then remove the brake fluid
reservoir.
Cover the painted surfaces, plastic or rubber
components with a rag when servicing brake
system.
Caution

Remove the master cylinder cap and diaphragm.
Use brake fluid to clean the dirty brake disc.
Caution

Refill up same grade brake fluid into the
reservoir.
Caution

Connect drain hose to drain valve.
Open the drain valve on the caliper and operate
the brake lever until the old brake fluid is entirely
drained out. Close the drain valve and add
specified brake fluid into the brake master
cylinder.
Recommended brake fluid: WELLRUN DOT 3
brake fluid
Caution

Connect one end of transparent hose to the
drain valve, and put the other end into a
container.
Open the drain valve around 1/4 turns, and at
the same time hold the brake lever until the
there is no air bubble in the drain hose and also
feeling resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not. If brake is still soft,
please bleed the system as described below.

Spilled brake fluid on painted surfaces,
plastic or rubber components may result in
their damages.
The dirty brake lining or disc will reduce the
brake performance.
To reuse the spent brake fluid will effect
brake performance.
Drain hose
Air bubble
Drain
valve
Cap
Cap plate
Diaphragm
Lower level
Upper level
To mixed non-compatible brake fluid will
reduce brake performance. Foreign
materials will block the system causing
brake performance to be reduced or totally
lost.
11. BRAKE SYSTEM
11-6

Air Bleed
1. Tightly hold the brake lever and open the
drain valve around 1/4 turns, and then close
the valve.
Caution

2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER
level of the master cylinder, and refill the fluid
if necessary.
6. Cover the cap.

Brake Caliper Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove
the brake hoses.
Caution

Remove the bolt cap and loosen the lining guide
bolts.
Remove two caliper bolts and the caliper.
Brake Caliper Installation
Install the brake caliper and tighten the attaching
bolts securely.
Torque: 3.3 kg-m
Caution

Tighten the lining guide bolt.
Torque: 1.8 kg-m
Install bolt cap.
Torque: 1.0 kg-m
Use two seal washers and hose bolts to lock the
hose and brake caliper in place.
Torque: 3.5 kg-m
Refill up the brake fluid to the reservoir and
make necessary air bleeding.

Do not release the brake lever before
the drain valve is closed.
Always check the brake fluid level
when carrying out the air bleeding
procedure to avoid air enter into the
system.
Do not spill brake fluid on painted surfaces.
Drain hose
Air bubble
Drain valve

Brake hose
bolt
Caliper bolt
Collar bolt
Use M8 x 35 mm flange bolt only.
Long bolt will impair the operation of
brake disc.
11. BRAKE SYSTEM
11-7

Brake Disc Inspection
Visually check the brake disc for wear or break.
Measure the thickness of the disc at several
places. Replace the disc if it has exceeded the
service limit.
Allowable limit: 2.0 mm

Remove the brake disc from wheel.
Check the disc for deformation and bend.

Brake Master Cylinder Removal
Caution

Caution

Remove the front and rear handlebar guards.
Remove the leads of brake lamp switch.
Drain out the brake fluid.
Remove the brake lever from the brake master
cylinder.
Remove the brake hose.
Remove the master cylinder seat and the master
cylinder.
Remove the rubber pad.
Remove the circlip.
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Do not let foreign materials enter into the
cylinder.
The whole set of master cylinder, piston,
spring, diaphragm and circlip should be
replaced as a set.
Micrometer
Brake
disc
Master
cylinder
Brake hose
Rubber pad
Circlip
Piston
Spring
Master cylinder
11. BRAKE SYSTEM
11-8

Master Cylinder Inspection
Check the master cylinder for damage or scratch.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.

Measure the outer diameter of the piston.
Replace the piston if its measured value exceeds
allowable limit.

Master Cylinder Assembly
Caution

Apply clean brake fluid to the piston cup, and
then install the cup onto the piston.
Install the larger end of the spring onto the
master cylinder.
The master cups cavity should be face inside of
master cylinder when installing the master cup.
Install the circlip.
Caution

Install the rubber pad into groove properly.

It is necessary to replace the whole set
comprising piston, spring, piston cup,
and circlip.
Make sure there is no dust on all
components before assembling.
Never install cup lip in the opposite
direction.
Make sure the circlip is seated
securely in the groove.
Master
cylinder
Cylinder
gauge
Micrometer
Piston
Rubber
bush
Circlip
Piston
Spring
Master cylinder
Sub-cup
Sub-cup
11. BRAKE SYSTEM
11-9

Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the master cylinder seat and its bolts.
The UP mark on the seat should face upward.
Align the split ring on the master cylinder seat
with the alignment point on the handlebar.
Tighten the upper bolt of the seat to specified
torque value, and then tighten lower bolt to the
same specified torque value.
Install the brake lever, and connect leads to
brake lamp switch.
Connect brake hoses with 2 new washes.
Tighten the brake hose bolt to the specified
torque value.
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Caution

Caution

Add specified brake fluid and bleed the system.
Improper routing may damage leads,
hoses or pipes.
Kink of brake leads, hose or pipe may
reduce brake performance.
Washes
Hose bolt
Brake hose

Alignment
point
Master
cylinder
Split ring
UP Mark
Retaining Seat
11. BRAKE SYSTEM
11-10

DRUM BRAKE
To use vacuum cleaner or other alternatives to
avoid danger caused from dusts.
Caution

Remove wheel, and then remove brake disc from
front wheel hub.
Inspection
Check brake drum for damage or wear out, and
replace it if necessary.
Measure the inner diameter of brake drum and
record the max. value.
Allowable limit: rear (95.5mm)
Caution

Measure the thickness of brake lining at three
points (both ends and center).
If the thickness is less than specified value or if it
is contaminated by oil or grease, replace as a
set.
Service limit: Rear: 2.0 mm

REMOVAL
Caution

Remove the brake linings from brake panel.

Inhaling brake lining ashes may cause
disorders of respiration system,
therefore, never use compressed air or
dry brush to clean brake parts.
Brake performance will be reduced by
grease on brake lining.
Clean the rust onto the brake drum
with #120 sand-paper
Measure the inner diameter of brake
drum with micrometer.
Brake linings must be replaced as a
set.
Rear brake drum

Brake lining
Brake shoe spring
Brake shoes
11. BRAKE SYSTEM
11-11

INSTALLATION
Apply with a thin coat of grease to the brake cam
and the anchor pin.
Install brake cam.
Never allow brake linings to be contaminated by
oil or grease.
Wipe off the excessive grease from brake cam
and the anchor pin.
Caution

Install return spring of the brake cam onto front
brake disc.
Install the brake cam after aligning it with the
punched point.
Tighten the bolts and nuts to specified torque:
Torque value: Front: 0.8-1.2 kg-m
Rear: 0.4-0.7 kg-m

Reinstall return spring of the brake arm to the
rear brake.
Never allow brake linings to be contaminated by
oil or grease.
Use a brake cleaner to clean brake hub and
replace the two brake shoes if brake linings are
contaminated.
Caution

Install spring onto the brake shoes.
Install the brake shoes to the brake panel one
after one, and make sure the shoe springs are in
correct position.
Mount the brake panel onto the front hub.
Install the wheel.

Brake efficiency will be reduced if brake
linings is contaminated by oil or grease.
Brake efficiency will be reduced if brake
linings is contaminated by oil or grease.

Bolt
Brake arm
Rear

Wear indicator
plate
Brake arm
Brake arm
big indent
Bolt
Rear
Brake shoe
Brake shoe spring
Front

Brake shoe spring
Brake shoe
Rear
11. BRAKE SYSTEM
11-12

NOTES

12. BODY COVER
12-1

Body Overview 12-1 Front Guard 12-7
Maintenance Information 12-3 Front Lower Spoiler 12-8
Side Cover 12-4 Foot Rest 12-9
Luggage Box 12-5 Front Inner Box 12-10
Body Cover 12-6 Front Fender 12-11

Steering Handlebar Guard 12-12
Body Overview
FT05U SERIES
12
Luggage box
Battery
compartment cover
Steering handlebar
guard (rear)
Front guard
Steering handlebar
guard (front)
Front inner box cover
Lower cover, front
luggage carrier
Decoration, Front
guard
Lower spoiler
Front fender
Foot rest
Bottom cover
Rear fender
Tail lamps
Side cover (right)
Side cover
(left)
Body cover
Body series No.
plate and sight hole
HOME PAGE CONTENTS
12. BODY COVER
12-2

FT05T/V SERIES

Luggage box
Battery
compartment cover
Steering handlebar
guard (rear)
Front guard
Steering handlebar
guard (front)-disk type
Front inner box cover
Lower cover, front
luggage carrier
Decoration, Front
guard
Lower spoiler
Foot rest
Bottom cover
Rear fender
Tail lamps
Side cover (right)
Side cover
(left)
Body cover
Body series No.
plate and sight hole
Steering handlebar
guard (front)-drum type
12. BODY COVER
12-3

Body covers disassemble sequence:

Be careful not to damage various covers in disassembly or re-assembly operation.
Never injure hooks molded on the body covers in disassembly or re-assembly operation.
Align the buckles on the guards with slot on the covers.
Make sure that each hook is properly installed during the assembly.
Never compact forcefully or hammer the guard and the covers during assembly.

Left/right Cover
Front Guard
Front Spoiler
Luggage Box/Saddle
Body Cover
Front Fender
Bottom Cover
Front Luggage Carrier
Front Handlebar Guard
Rear Fender
Rear Handlebar Guard
Foot Rest
12. BODY COVER
12-4

SIDE COVERS
1. REMOVAL:
Remove 2 bolts (front/middle) from two side
covers.
Slide the side cover backward so that their
hooks are out of slots.
Take out the side cover end part and then
remove the cover.

2. INSTALLATION:
Install in reverse order of removal procedures.
Caution

The tail of each cover is held with buckles
and slot, never pull them with force, or it
would crack the buckles.

12. BODY COVER
12-5

LUGGAGE BOX
1. REMOVAL:
Lift up seat cushion.
Remove battery compartment screw and
cover.
Remove luggage box mounting screws (4
screws).
Remove oil box cover and gasket.
Hold the luggage box in both front and rear
sides by two hands, and then lift up the box
to remove it.

2. INSTALLATION:
Install in reverse order of removal
procedures.

Bolts

Oil tank

Luggage box bolts
12. BODY COVER
12-6

BODY COVER
1. REMOVAL:
Remove 3 bolts from rear carrier, and then
remove rear carrier.
Remove 5 screws from the front and both
sides.

2. INSTALLATION:
procedures.

Bolts

Bolts

Bolt

12. BODY COVER
12-7

FRONT GUARD
1. REMOVAL:
Remove 2 bolts from the front inner box and
front guard.
Remove 1 screw from the front side of front
guard.
Push the front guard up and then remove it.

2. INSTALLATION
procedures.

Screws
Screw
12. BODY COVER
12-8

FRONT LOWER SPOILER
1. REMOVAL:
Remove 4 screws from the front inner box.
Remove 2 mounting bolts from the front
upper part of the front spoiler and the front
inner box.
Remove 1 screw of front bracket.
Remove speedometer cable mounting
screw.
Remove front wheel bolt and wheel.
Remove 2 screws from the lower part of the
front spoiler.
Remove the front spoiler.

2. INSTALLATION:
procedures.

Caution

Bolt
Screws
Screws

Screws
2 screws
After front wheel removed, it has to place a
carton box board (cardboard) between
brake pads and do not operate the front
brake lever.
12. BODY COVER
12-9

FOOT REST
1. REMOVAL:
Remove 4 plugs of the foot rest.
Remove 4 bolts.
Remove the foot rest.

2. INSTALLATION:
procedures.

4 plugs and bolts

12. BODY COVER
12-10

FRONT INNER BOX
1. REMOVAL:
Remove hook and 1 screw.
Remove 5 screws of the fuel filling cap.
Remove the fuel filling cap.
Remove 1 screw from main switch cover.
Remove main switch cover.
Remove the front inner box.

Caution

2. INSTALLATION:
procedures.

While taking off the fuel filling cap, do
not let it fall to the ground that may
cause damage to the cap or personal
injury.
Cover the fuel filling hole with an
object to prevent screws from falling
into the fuel tank as removing the
Hook and screw
5 screws

Main switch cover screw

12. BODY COVER
12-11

FRONT FENDER

1. REMOVAL:
Remove odometer screw and cable.
Remove front wheel bolt and then remove
the wheel.
Remove 3 screws of front fender.
Remove the front fender.

2. INSTALLATION:
procedures.

3 screws
12. BODY COVER
12-12

STEERING HANDLEBAR GUARD
1. REMOVAL:
Remove 1 screw of front lamp.
Remove 3 screws from the rear handlebar
guard.
Remove front handlebar guard.
Remove 2 inner screws.
Disconnect each switch connectors.
Remove speedometer cable.
Remove rear handlebar guard.

2. INSTALLATION:
procedures.
Caution

Push the front connection part of rear
handle guard at first when removing
front guard so that the buckles are out
of the guard. Never push it forcefully
to cause buckles broken or guard
damaged.
Screw

3 screws

2 screws
Steering handlebar bolt
13. STEERING/FRONT WHEEL/SUSPENSION
13-1

Mechanism Diagram 13-1 Front wheel 13-4
Maintenance Information 13-2 Front shock absorber 13-8
Troubleshooting 13-2 Front Fork 13-9
Steering handlebar 13-3

13
5.0 kg-m
7.0 kg-m
2.7 kg-m
3.1 kg-m
6.0 kg-m
6.0 kg-m
HOME PAGE CONTENTS
13-2

MAINTANANCE INFORMATION
SPECIFICATION
Item Standard value (mm) Limit (mm)
Shaft bending 0.2 (0.01 in)
Radial 2.0 (0.08 in)
Rim wobbling
Axial 2.0 (0.08 in)

TORQUE VALUE
Steering column mounting nut 7.0 kg-m Handlebar mounting bolt 5.0 kg-m
Front shaft nut 6.0 kg-m Front wheel hub mounting nut 2.5 kg-m
Front shock absorber mounting nut 2.7 kg-m Front wheel hub mounting bolt 4.5 kg-m

TOOLS
General tool
Driver
Adapter 32 x 35 mm
Pilot 12 mm

TROUBLESHOOTING
Hard to steer
1. The steering shaft bolt is too tight.
2. The steering shaft bearing are damaged
3. The ball and the top cone of the steering
shaft are damaged.
4. Insufficient tire pressure.

The steering handlebar is tilted
1. Uneven arrangement of the front shock
absorbers.
2. The front fork is bent.
3. The front wheel axle is bent.

The front wheel wobbling
1. The rim is bent.
2. The wheel axle nut is not tightened
improperly
3. Bend wheel rim
4. Side-worn or poor tire.
5. The bearing play of the wheel axle is too
large.

Soft shock absorber
1. Weak front shock absorber spring

Noise in front shock absorber
1. Shock absorber outer tube noise
2. The joint of the shock absorber gets loose.

13-3

STEERING HANDLEBAR
REMOVAL
Remove handlebar guard and inner box.
Remove throttle grip after mounting screw
removed.
Remove master cylinder (disc brake) after 2
bolts removed.

Remove rear brake lever bracket after mounting
bolt removed.
Remove handlebar mounting bolt and nut, and
then remove the handlebar.

INSTALLATION
Install handlebar and align with bolt hole.
Install bolt and nut and then tighten it.
Apply with grease onto throttle cable and the
sliding surface of handlebar.
Align the lock pin of the handlebar outer tube
with the hole on the handlebar, and then install
the handlebar.
Tighten the bolt.

Align the lock pin with the hole on the
handlebar and also install brake lever seat.
Then, tighten the lever with clamp and bolt.

Rear brake lever seat
Master cylinder
Nut
Bolt
13-4

Place master cylinder onto handlebar and align
its connection surface with punch point on the
handlebar (disc brake).
Install the mounting seat, and let its UP mark
face up.
Tighten the upper part bolt, and then tighten
lower bolt.
Install all components in reverse order of removal
procedures.
Conduct following adjustment:
Oil pump control cable.
Throttle operation.
Brake lever free play

FRONT WHEEL
REMOVAL
Remove speedometer cable from speedometer
gear box.
Remove the guide pipe from brake arm.
Remove wheel shaft nut, and then pull out the
shaft and remove the wheel.
Remove brake disc.

Speedometer cable
Master cylinder
Punch point
UP mark
Mounting seat
Shaft nut
13-5

INSPECTION
Place the shaft onto a V-block to measure its
run-out with a dial gauge.
The dial gauge indicated 1/2 run-out.

Place the wheel on to a rotation seat, and turn
the wheel to check its bearing free play. If the
bearing is noisy or its free play is too much,
replace it.

Place the wheel on to a rotation seat to check its
rim wobbling. Turn the wheel with hand and
measure its rim wobbling value with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)

REMOVAL
Remove 3 socket head bolts and brake disc.

Socket head bolts
Brake disc

Wheel shaft

Free play
Free play
13-6

Remove dust seal, bearing and side collar.
Remove wheel hub from wheel rim after 4 nut
removed.

INSTALLATION
Install the wheel hub into the wheel rim and then
tighten the flange nut.
Fill out the block of bearing by grease.
Drive the left bearing and install the side collar.
Install the right bearing.
Caution

Adapter 32 35 mm
Pilot 12 mm
Driver

Install the brake disc and then tighten the socket
head bolts (disc brake).

INSTALLATION
Lubricate the speedometer gear with grease and
install the gear into the brake disc.

Carefully install the bearing in correct
and evenly.
Bearing outer face should be faced up
as bearing installation.

Socket head bolts
Brake disc
13-7

Align the flange part on the speedometer gear
with the slot of wheel hub, and then install the
brake disc.
Caution

Apply with grease onto the dust seal.
Install the dust seal and side collar.

Place the front wheel between the front shock
absorbers.
Caution

Insert the wheel shaft into the wheel and the
install the wheel shaft nut.
Tighten the nut to specified torque.
Connect the speedometer cable to the
speedometer gear.

Contaminated brake lining will reduce
brake performance so the brake lining,
brake drum and disc must be free of
grease.
Align the brake disc groove with the
stopper flange.

Stopper
Front fork groove
Brake disc groove
Speedometer cable
Shaft nut
13-8

FRONT SHOCK ABSORBER
REMOVAL
- front cover
- front lower spoiler
- front guard
- front wheel

Disc Brake
Remove the caliper mounting bolt and the
caliper.
Take out the hose from hose clamp.
Remove front guard mounting bolt and the guard.
Remove the front shock absorber upper bolt and
the shock absorber.

INSTALLATION
Align the cover flange with upper level of the
shock absorber clamp, and then tighten nut.
Install the removed components in reverse order
of removal procedures.

Bolts
Hose clamp
Brake caliper
Bolts
Shock absorbers

13-9

FRONT FORK
REMOVAL
- handlebar
- front wheel
- front shock absorber
Remove the steering stem mounting nut.
Remove top cone race and front fork.
Caution

Slightly tap the top and bottom ball bearing seats
with a plastic hammer to remove the seats.
Remove bottom cone race body with a punch.
Caution

INSTALLATION
Install a new bottom cone race onto the steering
stem.
Push the cone race until to mounted position.
Caution

Apply with grease onto the ball bearing seats,
and install steel balls onto the seats.
(Top: 26 balls, bottom: 29 balls)
Lubricate the top cone race seat with grease.
Screw the cone race in to top ball bearing seat till
touching, and then screw out the cane race 1/8
turns.
Caution

Install the steering stem mounting nut and tighten
the nut by means of holding the top cone race
body.

Place the steel ball onto a parts container
to prevent from missing.
Do not damage the steering stem.
Check the steering stem that should be
rotated freely and no clearance in vertical
direction.
Steering stem
mounting nut
Top cone race
Steering stem mounting nut
Top cone race
Top ball
bearing seat
Bottom ball
bearing seat
Bottom cone
race
Steel
balls
Steering stem
mounting nut
Cone race
Do not tilt the ball bearing seats as
installation.
13-10

NOTES
14. REAR WHEEL/SUSPENSION
14-1

Troubleshooting 14-2
Rear wheel 14-3
Rear shock absorber 14-4

14
2.7 kg-m
4.0 kg-m
2.5 kg-m
2.5 kg-m
HOME PAGE CONTENTS
14-2

SPECIFICATION
Item Standard value (mm) Limit (mm)
Rear wheel rim run out

2.0 (0.08 in)
Rear shock absorber spring free length 172 166.8

TORQUE VALUE
Rear shock absorber upper mounting bolt: 4.0 kg-m
Rear shock absorber lower mounting bolt: 2.7 kg-m
Rear wheel nut: 11.0 kg-m
Rear wheel hub: 2.5 kg-m

Tools
Rear shock absorber adapter
Spring adapter
Rear shock absorber compressor

TROUBLESHOOTING
Rear wheel wobbling
1. bend wheel rim
2. poor tire
3. loosen wheel shaft

Shock absorber too soft
1. insufficient shock absorber spring force

Poor brake performance
1. Poor brake adjustment
2. contaminated brake lining
3. worn brake lining cam
4. worn brake cam lever
5. worn brake drum
6. improper installation of brake arm gear set.

14-3

REAR WHEEL
Remove
body cover.
Remove exhaust pipe and muffler.

Remove rear wheel shaft nut and then remove
the rear wheel.

INSPECTION
As the diagram shown, measure wheel rim
wobbling with a dial gauge.
Service limit:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mm (0.08 in)

BRAKE HUB REPLACEMENT
Remove 4 nuts of cover and wheel rim, and then
remove the wheel hub.
Install the wheel hub and tighten the nuts.

Muffle
Connection
nuts
Bolts

Shaft nut
14-4

INSTALLATION
Install the rear wheel and tighten the nut.
Install exhaust pipe & muffler.

REAR SHOCK ABSORBER
REMOVAL
Remove body cover.
Remove rear shock absorber upper & lower
bolts.
Remove rear shock absorber.

DISASSEMBLY
Compress the shock absorber with compressor.

Hold the connector and then loosen mounting
nut.
Remove the connector, and then remove the
shock absorber spring.

Upper mounting
bolt
Lower mounting bolt
Connector
Mounting nut
Shock absorber
compressor
Shock absorber
adapter
Shock absorber
adapter

Shaft nut
14-5

SPRING FREE LENGTH
Measure the spring free length.
Service limit: 172 mm

RE-ASSEMBLY
Install the more intensive coils of the spring onto
upper side.
Compress the shock absorber with compressor.

Free length
Shock absorber
compressor
Shock absorber
adapter
Shock absorber
adapter
Stopper
Spring guide
Cushion bar
Plastic bushing
Spring
Connector
Shaft race
Mounting nut
14-6

Apply with locking sealant onto mounting nut,
and screw the mounting nut and connector into
the cushion stem.
Hold the connector and tighten the mounting nut.
Remove the compressor.

INSTALLATION
Install the rear shock absorber.
Tighten the upper & lower mounting bolts to
specified torque.
Torque value:
Upper mounting bolt: 4.0 kg-m
Lower mounting bolt: 2.7 kg-m
Press down the tail of the scooter for several
times to check shock absorber operation.
Installation all components in reverse order of
removal procedures.

Connector
Mounting nut

Upper mounting
bolt
Lower mounting bolt
15. ELECTRICAL EQUIPMENT
15-1

Mechanical Illustration 15-1 Starting System 15-10
Maintenance Information 15-2 Oil level switch 15-12
Troubleshooting 15-3 Fuel unit 15-13
Battery 15-4 Switch/Horn 15-14
Charging System 15-5 Bulb Replacement 15-16
Ignition System 15-8

15
Resistor
Horn
Voltage
regulator
Main switch
High/low beam
switch
Illumination
switch
Starter switch
AC
alternator
Spark plug
Ignition coil
Starter relay
C.D.I. unit
Oil level switch
Pusator
Starter motor
Fuel unit
HOME PAGE CONTENTS
15-2

When remove the battery, the disconnection sequence of cable terminals shall be strictly
observed. (First disconnect the negative cable terminal, next, the positive cable terminal.)
The model of the spark plug and the tightening torque.
The ignition timing.
Adjustment of headlamp.
Removal and installation of AC generator.
The maintenance-free battery requires no inspection of electrolyte level and refilling of distilled
water.
To recharge the battery, remove the battery from the motorcycle without removing ventilation
caps.
Unless in emergency, never rapid charge the battery.
The voltage must be checked with the voltmeter while charging the battery.
As C.D.I assembly does not require an ignition timing check. In case ignition timing is incorrect,
check C.D.I and AC generator. Verify with an ignition timing lamp after replacement if necessary.
The starter motor can be removed after the engine is removed.

Specification
Charging System
Item Specification
Capacity 12V3Ah
Battery
Charging rate 0.4A / 5 hours (standard), 4A / 0.5 hour (fast charging)
Leak current < 1 mA
Charging current 1.2 A / 5000 rpm
Control voltage in charging 14.0 - 15.0 V / 5000 rpm
Control voltage in headlamp 12.6 - 13.6 V / 5000 rpm

Ignition System
Item Specification
Model NGK BR8HSA (Recommended)
Spark plug
Gap 0.6 - 0.7 mm
Primary coil 0.19 0.23
Ignition coil and resistance
Secondary coil 2.8 3.4 K
Ignition timing F mark 17 BTDC / 1800 rpm

15-3

TROUBLESHOOTING
No voltage
Battery discharged
The cable disconnected
The fuse is blown
Improper operation of the main switch

Low voltage
The battery is not fully charged
Poor contact
Poor charging system
Poor voltage regulator

No spark produced by spark plug
The spark plug is out of work
The cable is poorly connected, open or
short-circuited
- Between AC.G. and C.D.I.
Poor connection between C.D.I. and
ignition coil
- Poor connection between C.D.I. and the
main switch
Poor main switch
Poor C.D.I.
AC.G. is out of work

Starter motor does not work
The fuse is blown
The battery is not fully charge
Poor main switch
Poor starter switch
The front and rear brake switches do not
operate correctly
Starter relay is out of work
The ignition coil is poorly connected, open
or short-circuited
The starter motor is out of work

Intermittent power supply
The connector of the charging system
becomes loose
Poor connection of the battery cable
Poor connection or short-circuit of the
discharging system
Poor connection or short-circuit of the
power generation system

Charging system does not operate
properly
Burnt fuse
Poor contact, open or short circuit
Poor regulator
Poor ACG

Engine does not crank smoothly
Primary coil circuit
- Poor ignition coil
- Poor connection of cable and
connectors
- Poor main switch
Secondary coil circuit
- Poor ignition coil
- Poor spark plug
- Poor ignition coil cable
- Current leakage in the spark plug cap
Incorrect ignition timing
- Poor AC.G.
- Improper installation of the pulse sensor
- Poor C.D.I.

Weak starter motor
Poor charging system
The battery is not fully charged
Poor connection in the windings
The motor gear is jammed by foreign
material

Starter motor is working, but engine
does not crank
Poor starter motor pinion
The starter motor run in reverse direction
Poor battery

15-4

Battery
Battery Removal/Installation
Turn off main switch.
Open seat and oil tank cap.
Remove screw and the open battery cap.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery from the motorcycle.
Install the battery in reverse order of removal.

Voltage Check
Open cushion seat and battery cap.
Remove wires from battery.
Check battery voltage.
Voltage:
Fully charged: 13.0 13.2V
Undercharged: 12 V

Charging
Remove the battery.
Connect the positive terminal (+) of the
charger to the battery positive terminal (+).
Connect the negative terminal (-) of the
charger to the battery negative terminal (-).
Standard charging current/time: 0.4A/5 hrs.
Fast charging current/hrs: 4A/0.5 hr.
Caution

Caution

Strictly keep flames and sparks away while
recharging to avoid to explosion causing by
hydrogen.
Stop charging battery when electrolyte
temperature is over 45(117).
Fast charging the battery is for in emergency
only. Battery should be charged in standard.
Battery cap
Negative terminal
Positive terminal
15-5

Charging System
Current Leakage Inspection
Turn the main switch to OFF position, and
remove the negative cable terminal (-) from the
battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal.
Caution

If the leaked current exceeds the specified value,
it may indicate a short circuit.
Allowable current leakage: Less than 1 mA
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.

CHARGING VOLTAGE INSPECTION
Caution

After the engine is warmed up, replace original
battery with a fully charged battery. Connect a
digital voltmeter to the battery terminals.
Connect an ammeter between both ends of the
main fuse.
Caution

Caution

Connect a tachometer.
Turn on the headlamp to high beam and start
the engine.
Accelerate the engine to the specified revolution
per minute and measure the charging voltage.
Specified Charging Current: 1.2 A / 5000 rpm
Control Charging Voltage: 14.0~15.0 V / 5000
rpm

In the current leakage test, set the
current range at larger scale, then
gradually decrease to the lower scale
as the test process goes to avoid
possible damage to the ammeter and
the fuse.
Do not turn the main switch to ON
position during test.

Battery (-) terminal
Ground circuit
Ammeter
Digital voltmeter
Ammeter
Fuse connector
Before conducting the inspection, be
sure that the battery is fully charged. If
undercharged, the current changes
dramatically.
Use a fully charged battery having a
voltage larger than 13.0 V
While starting the engine, the starter
motor draws large amount of current
from the battery.
When the probe is reversibly connected,
use an ammeter having an indication that
shows both positive and negative direction
current. The measurement would be at
zero, if the ammeter is one direction only.
Do not use short-circuit cable.
It is possible to measure the current by
connecting an ammeter between the
battery positive terminal and the + cable
position terminal, however, while the
starter motor is activated, the surge
current of the motor draws from the
battery may damage the ammeter. Use
the kick starter to start the engine.
The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the
cable while there is current flowing
through. It may damage the ammeter.
15-6

Caution

The following problems are related to the
charging system, follow the instructions provided
in the checking list to correct it if any one of the
problems takes place.
(1) The charging voltage can not exceed the
voltage between two battery terminals and
the charging current is in the discharging
direction.
(2) The charging voltage and current are too
much higher than the standard values.

The following problems are not related to the
charging system; correct it if any by following
steps indicate in the checking list.
(1) The standard charging voltage and current
can only reach when the revolution of the
engine exceeds the specified rpm.
- Bulbs used exceed their rate and
consume too much power.
- The replacement battery is aged and
does not have enough capacity.
(2) The charging voltage is normal, but the
current is not.
- The replacement battery is aged and
does not have enough capacity.
- Battery used do not have enough
electricity or is over charged.
- The fuse of the ammeter is blown.
- The ammeter is improperly connected.
(3) The charging current is normal, but the
voltage is not.
- The fuse of the voltmeter is blown.

HEADLAMP VOLTAGE INSPECTION
Connect a tachometer.
Do not disconnect the headlamp harness
connector after engine started.
Turn the headlamp ON and to high beam
position.
Measure the voltage between the blue wire (+)
and green wire (-) while the headlamp harness is
still in connection.
Gradually increase engine speed and read the
voltage in each specified rpm.
Control voltage: 12.0~14.0 V / 5000 rpm
Measure AC voltage with a voltmeter.
Needle type voltmeter: 12.0~14.0 V / 5000
rpm
Digital type voltmeter: 10.0~13.0 V / 5000
rpm
Resistance Measurement of Resistor
Resistance:
Resistor (5.9 30W) at 20.
One Body ground: 5.6 ~6.2
Resistor (10.2 5W) at 20.
Green/black Body ground: 9.0 ~10.0

To replace the old battery, use a new
battery with the same current and
voltage.
Headlamp
connector
Front
handlebar
guard
Resistor
15-7

VOLTAGE REGULATOR
INSPECTION
Check the each pins of connector on the voltage
regulator.

Inspection Probable cause
Check voltage between battery terminal (red) and ground
(green).
Blown fuse or poor main switch
contact
Check continuity between ground and frame. Open-circuit wire
Check charging coil (white to ground) if its resistance is
within 0.2~1.0
Check charging /illumination coil (yellow to ground) if its
resistance is within 0.2~0.8
Open-circuit in alternator charging
coil or in illumination switch.

If wire circuit check is in normal and there is no
loose in the pins of voltage regulator connector,
then measure the resistance among pins on the
connectors of voltage regulator.
Voltage Regulator
Multi-meter(+)
Multi-meter (-)
White
A
Yellow
L
Red
B
Green
E
White A 4~7
Yellow B 2.4~4.8
Red B 4~7
Green E 2.4~4.8
If the resistance values are abnormal among the
pins, replace the voltage regulator.
Caution

Voltage
regulator
connector
Voltage regulator
If the probe is touched by finger, then
the resistance values will be incorrect.
It contains semi-conductor in circuit so
the measured resistance value will be
in different if different testers are used.
Thus, these values cannot be judged
with standards.
Multi-meter type;
KOWA - digital type
SANWA - digital type
TH-5H - analog type
SANAWA tester: range x K
KOWA tester: range x 100
Red (B)
White (A)
Yellow (L)
Green (E)
15-8

AC Alternator Inspection
Remove body cover.
Disconnect the alternator harness connector.
Measure the resistance on both charging coil
(the white to ground) and illumination coil (the
yellow to ground).
Resistance Measurement: (20)
Charging coil (white - green): 0.2~1.0
Illumination coil (yellow - green): 0.1~0.8

IGNITION SYSTEM
Ignition Coil Inspection
Remove body cover.

Measure the primary coil resistance
Resistance :0.19~0.23K (A)(B)
Measure the secondary coil resistance
Resistance : 8.2~9.3K (A)(C)

Remove the high voltage coil cap, and measure
its negative (-) terminal for the secondary coil
resistance.
Resistance : 3.1~3.2K (A)(D)

AC alternator
harness connector

Ignition coil

(A)
(B)
(C)
(D)

(A)
(B)
(C)
(D)
15-9

Electrical System Circuit Inspection
Remove body cover.
Disconnect the CDI set connector, and check its
circuit to diagnosis related ignition components.

Pulse Generator/Exciting Coil
Remove body cover.
Disconnect alternator connector.
Resistance Measurement: (20)
Pulse generator coil (blue/yellow - ground):
50~200
Exciting (blue/yellow - ground): 400~800

CDI Electrical System Circuit Inspection
Remove body cover.
Disconnect the CDI set connector, and check its
circuit to diagnosis related ignition components.

CDI Electrical System Circuit Inspection
Inspection Item Diagnosis
Main switch harness Check continuity between body ground and black/white wire as the main switch in
ON position.
Exciting coil Check resistance between body ground and black/red wire for 400~800 (20)
Pulse generator coil Check resistance between body ground and blue/yellow wire for 50~200 (20)
Primary coil resistance Check resistance between body ground and black/yellow wire for 0.19~0.23 (20)
If above checks are in normal but spark plug is still no spark. Then it probable causes from CDI
set or high voltage coil. Test the CDI set and high voltage coil with CDI tester.
If abnormal circuits are found in above checks, at first check all items, and then check each item
one by one.

CDI Performance Test
Connect CDI to CDI tester with CDI adapter.
Conduct following connection and test according
to CDI tester instruction.
Switch Good condition Poor condition
OFF No spark
P No spark
EXT No spark Spark
ON1 Spark No spark
ON2 Spark No spark
If any abnormal condition is found, replace the
CDI set.

Black/red
Harness
connector

CDI set
CDI set
CDI tester
CDI adapter
15-10

STARTING SYSTEM
STARTER RELAY INSPECTION
Remove luggage box.

Connect both the green/yellow (-) and the
yellow/red (+) pins to battery posts directly.
If the red and red/white pins are also in continuity,
it means it is in normal.

STARTER MOTOR PINION
Remove starter motor pinion.
Install the starter motor pinion in reverse order of
removal.

STARTER MOTOR PINION INSPECTION
Pinion, reduction gear for wear out or
damage replace it with new one.
Gear journal for wear out or damage
replace it with new one.
Check the pinion for sliding in axial direction
smoothly.
The pinion sliding in axial direction not in
smooth replace it with new one.

Battery
Starter relay
Starter relay
Starter motor
pinion

15-11

STARTER MOTOR
REMOVAL/DISASSEMBLY
Remove body cover.
Remove bolt and oil pump control cable.
Disconnect starter motor harness connector.
Remove 2 bolts for separation starter motor and
gasket.
Remove 2 bolts for disassembly the starter
motor.

ARMATURE INSPECTION
Check the armature for discoloration or other
damage. It may be short-circuit if dark surface on
the shifter found.
Caution

Check continuity 1) both the shifter surface and
shaft, 2) among the shifter surfaces. It can be in
continuity among the shifter surfaces, but both
the shifter surface and the shaft can not be in
continuity.
STARTER MOTOR
RE-ASSEMBLY/INSTALLATION
Re-assemble and install the starter motor in
reverse order of removal procedures.
connector
Starter motor
Oil pump
Do not clean the shifter surface with
sandpaper.

O-ring
Motor housing
Armature
Carbon bracket
Spring
Front bracket
15-12

OIL LEVEL SWITCH
Troubleshooting
If the oil level in oil tank is in specified level,
but the oil level indicator still goes on.
1. Remove body cover.
2. Disconnect oil gauge wire, and turn the
main switch to ON position.

If there is no oil in oil tank or low oil level,
but the oil level indicator still not goes on.
1. Remove body cover.
2. Disconnect oil gauge wire and connect
a jump wire among connector, and then
turn the main switch to ON position.

3. Disconnect oil gauge connector, and
check voltage between wire and
ground.

Remove oil tank.
Remove oil level switch from the oil tank.
Install the oil level switch in reverse order of
removal procedures.

Indicator light up Indicator not light up
Short-circuit between
indicator and oil
gauge
Malfunction of oil
gauge
No voltage Voltage
Open-circuit between
oil gauge and
indicator.
Blown bulb
Indicator not light up Indicator light up
Poor wire connection Malfunction of oil
gauge
Malfunction of oil
gauge
Poor connection of oil
gauge
Main switch Fuse
Indicator Oil level switch
Main switch

Oil level
switch
15-13

FUEL UNIT
Remove 4 bolts and foot board.
Disconnect fuel unit connector.
Remove the fuel unit plastic cap.
Turn the snap ring in CCW direction and then
remove the fuel unit.
Caution

Remark: Aligning the slot of fuel unit with the ring
of oil tank as installation, and then turn the snap
ring in CW direction until matching to the arrow.

INSPECTION
1. Connect the fuel unit connector.
Turn the main switch ON.
Move the float in up and down, and make
sure that the fuel indicator can be reached to
F (Full) and E (Empty) positions.
Conduct the step 2 if the needle on the fuel
indicator is not moved.
2. Measure the connector resistance while the
float in up and down positions.
Float position Resistance value
Up (full) 3~10
Down (empty) 90~100
Check the fuel indicator if the resistance is in
normal.
Replace the fuel gauge if the resistance is
abnormal.

Do not bend the float arm.

Float
Fuel unit
Fuel unit plastic cap
15-14

SWITCH/HORN
Remove handlebar and front guards.
Remove handlebar lower guard and front inner
box.
Check continuity on each switch.
The connected circles with a line are that they
should be in continuity.

Main Switch
Wire
color
Black
Black /
White
Green Red
Mark BAT2 IG E BAT1
LOCK
OFF
ON

Turn signal lamp switch
Wire color Gray Light blue Orange
Mark WR R L
R
N
L

Horn Switch
Wire color Light green Black
Mark HO BAT2
FREE
PUSH

High/Low Beam switch
Wire color Brown White Blue
Mark HL LO HI
LO
(N)
HI

Main switch
Turn signal
lamp switch
High/low beam
switch
Horn switch
15-15

Illumination Switch
Wire color Brown Yellow Light red
Mark HL CI RE
OFF
ON

Starter Motor Switch
Wire color Yellow / Red Green
Mark ST E
FREE
PUSH

Front / Rear Brake Lamp Switch
If the switch is in continuity as braking, it is in
normal. The switch is non-adjustable.

Horn
If the horn give out sound as connecting to 12V
battery, it means that it is in normal.

Starter motor switch
Illumination
switch
Horn

15-16

BULB REPLACEMENT
Headlamp/Turn signal lamp
Remove front handlebar guard.
Remove bulb seat and replace the bulb.
Install the all removed parts.

Instrument panel
Remove handlebar guard.
Take out the bulb seat from the bottom of
instrument panel.

Tail lamp / Brake lamp / Rear winker lamp
Remove 2 screws and then remove outer cover.
Remove 2 screws and then remove inner cover.
Replace tail lamp or winker lamp bulb.

Lamp connector

Bulb
Bulb seat

16. ELECTRICAL DIAGRAM
16-1

16
R
E
A
R

B
R
A
K
E

L
A
M
P
(
L
E
D
)

W
i
r
i
n
g

D
i
a
g
r
a
m

B
l
a
c
k

Y
e
l
l
o
w

B
l
u
e

G
r
e
e
n

R
e
d

W
h
i
t
e

B
r
o
w
n

O
r
a
n
g
e

L
i
g
h
t

B
l
u
e

L
i
g
h
t

G
r
e
e
n

P
i
n
k

G
r
a
y

B

Y

L

G

R

W

B
R

O

L
B

L
G

P

G
R

HOME PAGE CONTENTS
16. ELECTRICAL DIAGRAM
16-2

NOTES

HOME PAGE CONTENTS

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SERVICE MANUAL

TO THIS CHAPTER CONTENTS

4. Oil pump linkage operation

25. Carbon cleaning for cylinder

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