Daelim S3 125cc Service Manual ENG PDF

SM63-1010-01E
SERVICE INFORMATION
GENERAL
INSPECTION / ADJUSTMENT
EXTERNAL PARTS
LUBRICATION SYSTEM
EMS
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
ENGINE LH. CRANK CASE COVER / CONTINOUSLYVARIABLE TRANSMISSION
AC GENERATOR / FLY WHEEL
CYLINDER HEAD / VALVE
CYLINDER / PISTON
CRANKCASE / TRANSMISSION/ CRANK SHAFT
FRONT WHEEL / FRONT FORK / STEERING

FRAME
REAR WHEEL / REAR CUSHION
BRAKES
CHARGING SYSTEM
ELECTRICAL SYSTEM
IGNITION SYSTEM
STARTER SYSTEM
LIGHTS / SWITCHES / HORN
TROUBLE SHOOTING
Copyright 2010. DAERIM MOTOR Co., LTD. WIRING DIAGRAM

All Rights Reserved
SERVICE INFORMATION
SERIAL NUMBER LOCATION 1-1 SYMBOLS / ABBREVIATIONS 1-12

SPECIFICATION 1-2 CAUTIONS AT WORK 1-13
TWIST TORQUE 1-4 CAUTIONS AT ASSEMBLY,
SPECIAL TOOL 1-6 DISASSEMBLY 1-13
PARTS COMPOSITION MAP 1-8 CAUTIONS AT WIRING 1-17
SERIAL NUMBER LOCATIONS

SERVICE INFORMATION
SPECIFICATION
OVERALLLENGTH 2,110 mm 2,140 mm

OVERALLWIDTH 750 mm 750 mm
OVERALLHEIGHT 1,200 mm 1,215 mm
WHEEL BASE 1,500 mm 1,500 mm
DIMENSIONS
SEAT HEIGHT 745 mm 762 mm
GROUND CLEARANCE 136 mm 143 mm
DRYWEIGHT 159 kgs 159 kgs
GROSS WEIGHT 170 kgs 170 kgs
TYPE Underbone Underbone

FRONT SUSPENSION/ STROKE Telescopic / 85mm Telescopic/ 85mm
REAR SUSPENSION/ STROKE Unit Swing Arm/ 80mm Unit Swing Arm/80mm
FRONT TIRE SIZE 120/70-13 (tubeless) 120/70-14(tubeless)
REAR TIRE SIZE 140/60-13 (tubeless) 140/60-13(tubeless)
TIRE PRESSURE 1 person FRONT 2.00kgf/cm2(200kpa) 2.00kgf/cm2(200 kpa)
REAR 2.40kgf/cm2(240kpa) 2.40kgf/cm2(200 kpa)
FRAME 2 persons FRONT 2.00kgf/cm2(200kpa) 2.00kgf/cm2(200 kpa)
REAR 2.50kgf/cm2(250kpa) 2.50kgf/cm2(200 kpa)
FRONT BRAKE Hydraulic Disk Hydraulic Disk
REAR BRAKE Hydraulic Disk Hydraulic Disk
FUELTANK CAPACITY Full capacity 11.5L 11.5L
Reserve capacity 1.9L 1.9L
CASTER ANGLE 27° 27°
TRAIL 94.5mm 94.5mm
TYPE Air cooled 4cycle DOHC engine (4 valves)

CYLINDERS, ARRANGEMENT 1(single cylinder), front angle 80°
BORE X STROKE 56.5mm×49.5mm
DISPLACEMENT 124cm3
COMPRESSION RATIO 11.8:1
COMPRESSION PRESSURE 13.0kg/cm2(600 rpm)
OIL CAPACITY FULL 1.30L(Full capacity)
REPLACEMENT 1.10L(at changing)
LUBRICATION 0.1L(Full capacity)
AIR CLEANER Forced pressure splash type
ENGINE VALVES Dry filter paper
VALVE SYSTEM DOHC chain operation
INTAKE VALVE IN VALVE OPEN DOHC 4 Valves
CLOSE 15°BTDC
EX VALVE OPEN 39°ABDC
CLOSE 57.4°BBDC
12.6°ATDC
VALVE CLEARANCE INTAKE 0.15±0.02mm
EXHAUST 0.23±0.02mm
ENGINE DRYWEIGHT 38kg
SERVICE INFORMATION
CLUTCH DRY PLATE SHOE TYPE

TRANSMISSION
Automatic Transmission(V-belt type)
TRANSMISSION TRANSMISSION PRIMARYREDUCTION RATIO
TRANSMISSION SECONDARYREDUCTION 2.786(39T/14T)
RATIO 3.462(45T/13T)
IGNITION SYSTEM TRANSISTOR

IGNITION TIMING IDLE 0°BTDC / 1,600(rpm)
AC GENERATOR 12V-17A/ 5,000(rpm)
BATTERY CAPACITY 12V 10AH
SPARK PLUG CR8EH - 9
SPARK PLUG GAP 0.8 - 0.9mm
FUSE CAPACITY 30A(main), 15AX 4
STARTING SYSTEM
CELL STARTING(STARTER MOTOR)
ELECTRICAL HEADLIGHT(HIGH / LOW)
60/55W
POSITION LAMP
5W
SYSTEM WINKERS
16W×2, 10W×2
TAIL/STOP LAMP
COMBI METER LAMP LED (8EA)
(SPEEDOMETER/TACHOMETER) LED
NEUTRAL INDICATOR LAMP LED x 1
HIGH BEAM INDICATOR LAMP LED
TURN SIGNALINDICATOR LAMP LED x 1
NUMBER PLATE POSITION LAMP LED
TACHOMETER LAMP LED x 1
SERVICE INFORMATION
TORQUES
STEERING STEM NUT

M26×1.0 6~8
STEERING TOPTHREAD
M26×1.0 0.2 ~ 0.3
BOTTOM BRIDGE(FORK PIPE) BOLT
M10×1.25 7.0 ~ 8.0
HANDLE POST NUT
M10×1.25 5.5 ~ 6.5 U-NUT
FRONT WHEELAXLE NUT
M12×1.25 5.0 ~ 7.0 U-NUT
REAR WHEELAXLE NUT
M16×1.5 12 ~ 13 U-NUT
BRAKE OIL BOLT(FRONT/REAR)
M10×1.25 3.0 ~ 4.0
CALIPER BRACKET BOLT(FRONT/REAR)
M8×1.25 2.8 ~ 3.4
MASTER CYLINDER HOLDER
M6×1.0 1.0 ~ 1.4
BOLT(FRONT/REAR)
M8×1.25 4.0 ~ 4.5
DISK PLATE BOLT(FRONT/REAR)
M5×0.8 0.35 ~ 0.5
SPEEDOMETER GEAR BOX SCREW
M8×1.25 1.5 ~ 2.5
FRONT FORK BOTTOM BOLT
M22×1.0 1.5 ~ 3.0
FORK BOLT
M10×1.25 3.5 ~ 4.5
REAR CUSHION UPPER BOLT
M10×1.25 3.5 ~ 4.5
REAR CUSHION UNDER BOLT
M10×1.25 3.0 ~ 4.0
REAR CUSHION ROAD LOCK NUT
M12×1.25 5.0 ~ 5.5
ENGINE HANGER UPPER BOLT
M10×1.25 4.0 ~ 5.0 U-NUT
ENGINE HANGER LOW NUT
M10×1.25 3.5 ~ 4.5
MAIN STAND BOLT
M10×1.25 1.0 ~ 2.0
SIDE STAND PIVOT SCREW
M10×1.25 4.0 ~ 5.0
SIDE STAND PIVOT NUT
SERVICE INFORMATION
CYLINDER HEAD COVER BOLT M6×1.0 1.0 ~ 1.2

CAP HOLER BOLT M6×1.0 1.0 ~ 1.2
CAM CHAIN GUIDE BOLT M6×1.0 1.0 ~ 1.2
CYLINDER HEAD SOCKET M10×1.25 3.5 ~ 4.5 Engine oil applied
CYLINDER BOLT M6×1.0 1.0 ~ 1.2
SPARK PLUG M10×1.0 1.5 ~ 1.7
ENGINE TEMPERATURE SENSOR M12×1.25 1.6 ~ 2.0
TENSIONER PIVOT BOLT M6×1.0 0.8 ~ 1.2
TENSIONER LIFT BOLT M6×1.0 1.0 ~ 1.4
TENSIONER LIFT SCREW M6×1.0 0.35 ~ 0.5
ACG FLYWHEEL NUT M16 1.0 6.0 ~ 6.7
STARTER CLUTCH OUTER SOCKET M8×1.25 3.0 ~ 3.4
OIL PUMPASS BOLT M6×1.0 1.0 ~ 1.2
OIL SEPERATOR M6×1.0 1.0 ~ 1.2
ACG STATOR COMPSCREW M5 0.35 ~ 0.5
TAPPETADJUST HOLE CAP M30×1.5 1.0 ~ 1.2
WATER PUMP IMPELLER M7×1.0 1.0 ~ 1.4
DRIVE FACE NUT M12×1.25 5.0 ~ 6.0
DRIVE PLATE NUT M28 5.0 ~ 6.0
CLUTCH OUTER NUT M12 1.25 5.0 ~ 6.0
MISSION COVER BOLT M8×1.25 3.0 ~ 4.0
MISSION CASE BOLT M8×1.25 3.0 ~ 4.0
MISSION COVER BOLT M8×1.25 1.6 ~ 2.0
MISSION COVER CHECK BOLT M8×1.25 1.6 ~ 2.0
STARTER MOTOR BOLT M6×1.0 1.0 ~ 1.4
※Torque values listed above ate for specific tightening points. Torque values for other items are listed in the following tables.
4㎜ BOLT, NUT 0.15 ~ 0.4 4㎜ SCREW 0.15 ~ 0.3

5㎜ BOLT, NUT 0.45 ~ 0.6 5㎜ SCREW 0.35 ~ 0.5
6㎜ BOLT, NUT 0.8 ~ 1.2 6㎜ SCREW 0.7 ~ 1.1
(SH Flange bolt included) (SH TYPE included)
8㎜ BOLT, NUT 1.8 ~ 2.5 6㎜ FLANGE BOLT,NUT 1.0 ~ 1.4
※ SH(Small Head) : presents 6mm bolt of 8mm flange head

SERVICE INFORMATION
TOOL
ACG ROTOR PULLER Used for disassembly ACG Rotor from Crank shaft 9
VALVE GUIDE DRIVER Used at the time of replacing valve guide
10
VALVE GUIDE RIMMER 〃
BEARING REMOVER SET Used at the time of disassembling bearings of crank case
THREAD ADAPTER Used at thetime of assembling crank shaft to crank case
12
ASSEMBLY SHAFT 〃
CRANK ASSEMBLY COLLAR 〃
BALL RACE DRIVER Used at the time of disassembling top blace and bottom ball race
STEERING STEM DRIVER Used at the time of pressing bottom cone race to steering stem
13
FORK SEALDRIVER Used at the time of inputting the oil seal of front fork
STEERING STEM SOCKET Used at the time of disassembling steering head top thread
SNAP RING PLIER Used at the time of disassembling the cir clip of master cylinder 15
COMPRESSION GAUGE Used at the time of measuring the compression power of cylinder 2
MULTI TESTER Used at measuring electrical parts 5,16,17,18,19
PVATESTER 〃 5,16,17,18,19
SCANNER Used at diagnosis of ECU and sensors 5
SERVICE INFORMATION
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions
SYMBOL MEANING SYMBOL MEANING
Indicates important work. Minor injury or vehicle part damage
Indicates dangerous areas. WARNING
mayresultifinstructionarenotfollowed
WARNING Serious accidents may result if instructions are not
Indicates general cautions. Provides safety and
followed. WARNING
appropriate handling procedures.
The following abbreviations are used in this manual.
ASS’Y Assembled part

LH. Left
RH. Right
Indicates oil applying. If there is no specific oil indicated, use the designated or recommended engine oil
Indicates molybdenum solution applying. Molybdenum solution is made by mixing engine oil and molybdenum
grease as 1:1 mixing ratio.
Indicates to apply grease(NLG 1#2)
Indicates to apply molybdenum grease(Containing more than 30% molydenum disulfide, NLG 1#2 or equivalent)
Indicates to apply molybdenum best(Containing more than 40% molydenum disulfide, NLG 1#2 or equivalent)
Indicates to apply silicone grease.
Indicates to apply ointment onto screw lock.

If not designated, use medium strength one.
Indicates to seal
Indicates the replacement part as new one whenever disassembly
Indicates to apply brake fluid. Use the recommended one(DOT3 or DOT4)
Indicates to apply the recommended oil
Indicates to use special tools
Indicates to use optional tools. Because this kind of tool is dealt as spare part, refer to the parts list to check the correct
tool number.
( 3-1) Indicates the reference. For left example, indicates the reference 3-1.
In case of special greases not written on above, they have not any specific symbols.
SERVICE INFORMATION
PARTS COMPOSITION MAP
TOP
STRAIGHT
RH. FRONT SIDE RH. CENTER SIDE RH. REAR SIDE

LH. FRONT SIDE LH. CENTER SIDE LH. REAR SIDE
TOTAL AREA DETAIL COMPOSITON MAP

SERVICE INFORMATION
COMBINATION METER ASS’

Y CODE
WINKER RELAY
DESS RECEIVER
FR. BRAKE HOSE
HAZARD / START SWITCH CODE
WATER PATH TUBE
HEAD LIGHT ASS’

Y CODE
COMBINATION SWITCH TUBE
DESS CORD COMP

FUEL PUMP RELAY
FUEL LEAD LOCK CABLE
LIGHT RELAY
SEAT OPEN SWITCH CODE STARTER CONTROL RELAY
SEAT OPEN RELAY
FRONT BRAKE HOSE
REAR BRAKE CODE
WIRE HARNESS
RH. FRONT SIDE
REAR BRAKE HOSE

WINKER SWITCH COUPLER
HAZARD / START SWITCH COUPLER

DESS COMBINATION / LOCK SWITCH
FRONT BRAKE HOSE
FUEL LID LOCK CABLE

COMBINATION METER ASS’
Y
SEAT LOCK CABLE
FUEL BREATHER TUBE

DESS RECEIVER CHARGING SOCKET COUPLER
SEAT OPEN RELAY
FUEL SPLY TUBE

VINYL TUBE
HEADLIGHT ASS’
Y COUPLER
FRONT BRAKE HOSE

RADIATOR HOSE
HORN CONNECTOR
LH. FRONT SIDE

SERVICE INFORMATION
BATTERY(12V 10AH)
FUEL BREATHER TUBE

FUEL SPLY TUBE
SEAT LOCK CABLE FUEL HOSE
CHARGING SOCKET WIRE
METER SOCKET WIRE INJECTOR
와이어 하네스 EMI ASS’
Y
INJECTOR CODE
HIGH TENSION CODE

EMI CODE
LF ANTENNA TRUNK LAMP CODE

STARTER MOTOR CABLE
LF ANTENNA CODE STARTER MOTOR CABLE
OXYGEN SENSOR COUPLER

FUEL PUMP CODE
SEAT LOCK CABLE

FUEL BREATHER TUBE
LH. CENTER SIDE
EMI ASS’
Y
REAR BRAKE HOSE
STARTER MAGNETIC(+) CABLE

BATTERY(-) CABLE EMI CODE
STARTER MOTOR CABLE REAR BRAKE PIPE

BATTERY(-) CODE LF ANTENNA
OXYGEN SENSOR CODE THROTTLE CABLE
START MAGNETIC(+) CABLE
STARTER MOTOR CABLE OXYGEN SENSOR CODE WATER PATH TUBE
FAN MOTOR CODE
START MAGNETIC SWITCH ASS’
Y
FUEL PUMP CODE
START MAGNETIC SWITCH CODE
FUEL HOSE RADIATOR HOSE B

RADIATOR HOSE A
OXYGEN SENSOR CODE
THROTTLE CABLE
WATER PATH TUBE
REAR BRAKE HOSE PIPE TUBE CLIP
REAR BRAKE HOSE PIPE
WATER PIPE HOSE
RH. CENTER SIDE

SERVICE INFORMATION
SEAT LOCK CABLE

WIRE HARNESS
SEAT OPEN SOLENOID
ECU COMP
SEAT OPEN SOLENOID CODE

ECU GROUND CONNECTION CODE
TOTAL SENSOR WIRE
WIRE HARNESS ENGINE BREATHE TUBE
SEAT LOCK CABLE
ENGINE BREATHER TUBE
BREATHER TUBE GUIDE
LH. REAR SIDE
WIRE CLIP
ACG CODE COMP
REGULATOR RECTIFIER
REGULATOR RECTIFIER CODE

FUEL HOSE
INJECTOR CODE
와이어 하네스
REAR BRAKE CODE
WATER HOSE B
WATER HOSE C
WATER HOSE A
RH. REAR SIDE

SERVICE INFORMATION
REAR BRAKE HOSE PIPE

WATER PATH TUBE HIGH TENSION CODE
ACG CODE THERMO SENSOR REGULATOR RECTIFIER CODE
START MAGNETIC(+) CABLE ACG CODE COMP
BATTERY(-) CABLE REAR BRAKE HOSE

FUEL HOSE CLIP ACG CODE COMP
THERMO SENSOR CODE
SCANNER COUPLER
INJECTOR COUPLER
TPS CODE
ISA CODE
BATTERY(+) CABLE
STARTER MOTOR CABLE
BATTERY(-) CABLE
IGNITION COIL PULLER
IGNITION COIL GROUND CONNECTION CODE
WIRE CLIP
MAPAT COUPLER SEAT OPEN SOLENOID

WIRE HARNESS HIGH TENSION CODE COMP WIRE HARNESS
SEAT OPEN SOLENOID CODE
TOP
SPEEDOMETER CABLE
DESS RECEIVER
FUEL BREATHER TUBE
FUEL SPLY TUBE
SPEEDOMETER CABLE
CABLE GUIDE
HORN COMP
BRAKE HOSE CLAMP
WATER PATH TUBE
RADIATOR HOSE FRONT BRAKE HOSE
STRAIGHT
SERVICE INFORMATION
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic sub-
stances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the
eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store
the battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right
after engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and alway have safety in
mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action
not to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated
area and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the
recommended parts. chasis.
3. Store the parts of each system discriminatively to 4. After removing gasket, O-ring, piston pin clip and cot-
install each part in the right place. ter pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
SERVICE INFORMATION
5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data dur-
remove the cleaning oil with compressed air. Apply oil ing installation. When installing, return to the state
to seal face during installation. before removing.
7. Align the bolts to uniform the tightening points before 8. Bolts, nuts and pieces must be tightened from the bigger
tightening them when you don’t know the bolt length. diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
9. Check to see if the rubber part is worn out when 10. Recommended grease must be applied to or filled in
removing it and replace it if necessary. Some rubber part the specified place.
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
performed with the right tool. applied pressure when removing press-fitted the bear-
ing.
SERVICE INFORMATION
13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the
ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open-
• Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way
longitudinal hanging. that the face marked with manufacturer and size
•Wipe the ball bearing likely to have hanging with should direct to the outer axle.
cleaning oil.(except double-sided sealed type ball bear- DOUBLE-SEALED TYPE
SINGLE-SEALED TYPE
ing)
• Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
OPEN TYPE MANUFACTURER’S NAME, BEARING No.

15. When blowing the ball bearing with compressed air 16. Install the snap ring so that chamfered side directs to
after cleaning, keep the race from rotating. High speed the load-applied side. After installation, check the
rotation of the race may damage the bearing. Prior to proper installation by rotating the snap ring.
installation, apply oil or grease to the bearing.
SNAP RING
CHAMFERED EDGE
17. Check each part for proper tightening and operation 18. The brake fluid and coolant can damage the painted
after installation. plastic or rubber parts. Keep these parts from contact-
ing with them and wash these parts with water in case
of contact.
19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
• Pay attention not to bend or damage the lip
• Apply the grease to the lip
CAVI-
MANUFACTURER’S NAME
CLIP
FITTING
SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of
interior from the infiltration of dust. each case of the engine while removing gasket materi-
al completely. Remove damaged contact surface by
wiping with the oil stone equally.
23. Pay attention not to bend the cable excessively. 24. Install the boots with the installing groove by inserting
Transformed or damaged cable may cause malfunction the boots into the groove.
or damage.
BOOTS
SERVICE INFORMATION
CAUTION WHEN WIRING

•Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord ter-
When connecting different cord, attach color tube minal using tester, contact the tester plug behind of the
around the connector. Connect the coupler to the con- coupler. Pay attention not to open the cord terminal
nector with same color and same pin number. and contact the tester plug from the front of the cou-
•Identify the two-colored cord by main color first and pler in case of water-proof coupler.
then striped color . TESTER PLUG RED STRIPE
WHITE WHITE
TUBE COUPLER.
BLACK TUBE
WHITE
•Recheck the condition of contact, securing and conti-
nuity of each part after maintenance.
BLACK CORD RED STRIPE •When connecting the battery, the plus terminal must
be connected first.
•After connecting the terminal, apply the grease to the
terminal.
WHITE / RED CORD
•When disconnecting the battery, the minus terminal •Connect covers to the terminal after maintenance.
must be disconnected first.
•Make sure that the tool such as spanner do not contact
with the frame.
•If the fuse is short-circuited, find out the cause and •If there is rust in the terminal, remove the rust with
repair. Replace with the fuse having the specified sand paper prior to connecting.
capacity.
VALIDATION REMOVE
OF CAPACITY! THE
RUST!
SERVICE INFORMATION
•Turn off the main switch before connecting/dis-con- •When disconnecting the coupler, disconnect it while
necting. holding the coupler body. Pull while holding the wire
•Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
•The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
•Insert the lock of the coupler until the lock is fully

secured.
•Release the lock by inserting the coupler slightly and •Pay attention not to damage the vinyl cover of the cou-
then narrowing connection to remove the coupler. pler.
•Check to see if there is bended terminal and secure it to •If the wire harness coating is damaged, repair by wind-
avoid disconnecting. ing vinyl tape or replace it.
•Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.
SERVICE INFORMATION
•Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start
inserted into the terminal. using the wiring driver and release the torque.
•The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then
direction but in case of the plain connector, the drain- insert until the groove is locked.
ing opening must face at the sky direction. •When removing T-start from the frame, replace it with
the new one.
DRAINING HOLE WIRING DRIVER GROOVE SIDE
•Wire band must be secured firmly in the specified •Secure the wire harness firmly using the clamp.
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.
•In case of the weld clamp, do not clamp in the welded •When clamping the wire harness, make sure that the
part. harness is not contacted with the shaft or rotating part.
•When clamping the wire, pay attention not to contact •The wire harness must be routed without contacting
with hot part. with the end of the lamp or any sharp edge.
•The wire harness must be routed without contacting
with the end of the bolt or the piece.
SERVICE INFORMATION
•In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively.
the sharp edge, protect both parts with tube or tape.
NOT TO
PULL!
•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness
is not pressed by the parts.
•Do not twist the wire harness. •Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left com-
pletely. Avoid excessive bending or chewing and inter-
ference with the engine.
•Prior to using the tester, please read the manual care- •Do not drop or throw the parts especially semiconduc-
fully and understand the contents. tor contained parts because these parts may be dam-
•When testing the resistance of the tester, the zero aged by the impact of the drop.
adjustment must be performed before testing.
Is this
measurement range or
configuration in accord
with the manual?
2. INSPECTIONS / ADJUSTMENTS
SERVICE INFORMATION 2-1 DRIVE BELT 2-9

SERVICE STANDARDS 2-1 COOLING WATER INSPECTION 2-9
SERVICE INSPECTION SCHEDULE 2-3 BRAKE FLUID 2-10
FUEL LINE(FUEL TUBE) 2-4 BRAKE PAD 2-10
THROTTLE GRIP OPERATION 2-4
BRAKE EQUIPMENT 2-10
AIR CLEANER 2-5
SIDE STAND 2-11
SPARK PLUG 2-5
VALVE GAP SUSPENSION 2-11
2-6
CYLINDER COMPRESSION PRESSURE 2-7 STEERING STEM 2-11
ENGINE OIL 2-8 WHEEL / TIRE 2-12
TRANSMISSION OIL 2-8 BOLT / NUT FASTENING 2-12
CVT DUST COVER ELEMENT 2-8 BATTERY 2-12
SERVICE INFORMATION
WARNING
● The exhaust gas contains poisonous substance. Do not keep engine idling in a closded or poorly ventilated Place for a long period of time
● Refer to the chapter 4-3 about the engine fluid
● Stand the main stand prior to the beginning wor
REPAIR STANDARDS
THROTTLE GRIPDIFFERENCE 2-6mm
SPARK PLUG CR8EH-9
SPARK PLUG GAP 0.8~0.9mm
VALVE GAP IN 0.15±0.02mm
EX 0.23±0.02mm
CYLINDER COMPRESSION RATIO 11.8:1
CYLINDER COMPRESSION PRESSURE 13.0kgf/cm2 (600rpm)
TIRES
FRONT 2.00 kgf・cm2
TIRE PRESSUR ATCOLD ONE PERSON
REAR 2.40 kgf・cm2
ROLLING
FRONT 2.00 kgf・cm2
TWO PERSONS
REAR 2.50 kgf・cm2
FRONT 120/70-13(TUBELESS )
TIRE SIZE
REAR 140/60-13(TUBELESS )
FRONT 0.5mm
MINIMUM HOME DEPTH
REAR 0.5mm
SERVICE INFORMATION
TORQUE
● SPARK PLUG 1.5~1.7 kgf-m
● CYLINDER HEAD COVER BOLT 1.0~1.2 kgf-m
● VALVE ADJUSTING NUT 1.0~1.2 kgf-m
● AIR CLEANER CASE COVER SCREW 0.7~1.0 kgf-m
TOOL
● COMPRESSION GAUGE
SERVICE INFORMATION
REGULAR INSPECTION SCHEDULE

According to each inspection schedule, please do preparatory inspection.
I : INSPECTAND CLEAN, ADJUST,LUBRICATE OR REPLACE IF NECESSARY
R : REPLACE L : LUBRICATE C: CLEAN A : ADJUST
ODOMETER READING(NOTE 1)
500 1,000km 1,500km 2,000km

REMARKS
(1 month) (6 months) (12 months) (18 months)
FULE LINE(FUEL TUBE) I I I I
THROTTLE GRIP OPERATION I I I
AIR CLEANER ELEMENT R R R
CVT DUST COVER ELEMENT I I I
SPARK PLUG I R I NOTE 2
VALVE GAP I I I I
ENGINE OIL R R R R
TRANSMISSION OIL R R R NOTE3
OIL FILTER SCREEN C C C C
BRAKE FLUID I I I
BRAKE PAD ABRASION I I I NOTE2
BRAKE EQUIPMENT I I I I
BRAKE STOP SWITCH I I I
HEAD LIGHT I I I
SIDE STAND I I I
SUSPENSION I I I
BOLT, NUT FASTENING I I
WHEEL/TIRE I I I
STEERING HEAD BEARING I I
RADIATOR COOLING WATER I I R I
WEIGHT ROLLER I I I
SLIDE PIECE I I I
DRIVE BELT I I I
If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology con-
tact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections.
To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops, dealers
or other designated repair shops.
After the odometer reading exceeds 12,000 km, repeat maintenance service at intervals indicated in the table.
After riding in areas with high humidity or pollution, carry out maintenance service more frequently.
Replace every years. Proper technology is required for this job.
INSPECTIONS / ADJUSTMENTS
THROTTLE BODY
THROTTLE
THROTTLE BODY
BODY INJECTOR
INJECTOR
INJECTOR FUEL LINE (FUEL TUBE)
● Check the connection status between injector and fuel
tube.
● Check fuel tube, replace whether it cracked, damaged
or oil leaked.
FUEL HOSE
THROTTLE GRIP THROTTLE GRIP OPERATION

● Check to see if the throttle grip operates smoothly in
any steering position.
● If the throttle grip does not operate properly, check
the throttle cable for aging, damage or kinking.
● Check the throttle grip free play.
FREE PLAY : 2~6mm
FREEPLAY
FREE
FREE PLAY
PLAY
● For main adjustment of the throttle grip freeplay,

adjust the nut on the carburetor side.
● Loosen the lock nut, turn the adjuster nut and adjust
of it.
● After adjusting, fasten lock nut.
ADJUSTOR
ADJUSTOR
ADJUSTOR
LOCKNUT
LOCK
LOCK NUT
NUT THROTTLECABLE
THROTTLE
THROTTLE CABLE
CABLE
● In case of main adjustment, do by the adjuster on the

side of throttle body.
● Untie lock nut and adjust freeplay by turning
adjuster.
● After completing adjustment, fasten lock nut and re-
check about operation of throttle grip.
● If necessary, replace the damaged parts.
THROTTLEBODY
THROTTLE
THROTTLE BODY
BODY THROTTLECABLE
THROTTLE
THROTTLE CABLE
CABLE
AIR CLEANER
● Loosen the 8 screws securing the air cleaner case
cover and remove it.
AIR CLEANER
AIR
AIR CLEANER
CLEANER
COVER
COVER
COVER
● Remove the air cleaner element.

● Whenever the filter gets seriously polluted or dam-
aged, replace it as always.
● The assmembly is done in the reverse order of disas-
sembly
CAUTION
•The air cleaner element is made from dry type
paper filter.
AIR
AIR CLEANER ELEMENT
•Do NOT reuse the air cleaner element by blowing
AIR CLEANER
CLEANER ELEMENT
ELEMENT and cleaning by compressed air.
CHECK THE GAP,

CONTAMINATION
SPARK PLUG
0.8~0.9㎜ ● Remove the center cover.
● Remove the spark plug.
● Check the damage, pollution, accumulated materials
in spark plug. If there is accumulated material, clean
it by plug cleaner or wire brush.
CHECK THE
DAMAGE OF
● Measure the spark plug gap by filler gauge and adjust
WASHER by bending the side pole.
CHECK THE
CRACK
● Rotate by the time plug washer meets to the cylinder

head by hand.
● At this moment, assemble by rotating 3/4 by plug
wrench.
● Assemble the spark plug cap.
Genuine plug: CR8EH-9
The gap of spark plug : 0.8~0.9mm
Torque : 1.5~1.7 kgf.m
CAUTION
•Assemble the spark plug by plug wrench after
semi-assembly by hand.
RH.
RH. CRANK
RH.CRANK CASE
CRANKCASE COVER
CASECOVER
COVER CHECK VALVE GAP
LH.
LH. CRANK
LH.CRANK CASE
CRANKCASE CPVER
CASECPVER
CPVER ● Loosen the ACG cap in RH CRANK CASE
COVER.
● Loosen the CVT dust cover in LH. Crank case cover,
rotate the drive face to the rotating way of crank and
fit the ‘ T ‘ mark of fly wheel and index mark of RH.
Crank case.
CAUTION
•Inspect and adjust the valve clearance when the
INDEX
INDEX ,MARK
INDEX,MARK
,MARK engine is cold(35℃)
DRIVE
DRIVE FACE
DRIVEFACE
FACE •Separate cylinder head cover. At this moment, fit it
to the top of compression stroke.
● Measure the valve gap by piller gauge

Valve gap : IN 0.15mm
EX 0.23mm
IN
IN VALVE
INVALVE
VALVE
EX.
EX. VALVE
EX.VALVE
VALVE
PILLAR GAUGE
IN VALVE LEAD METHOD TO ADJUST LEAD

● If the valve gap is over the standard limit, adjust it
according to designated method.
● Disassemble cam shaft
● Disassemble valve lift and lead
● Record valve lift and assembled position for lead,
keep them in order to be distinguished each other.
CAUTION
•Use the magnet when disassembly of valve lift
EX VALVE
EX
EX VALVE LEAD
VALVE LEAD
LEAD
•Be careful for the lead not to fall down inside the
cylinder on condition that the valve lift sticked to
valve lift.
•If the lead is difficult to be disassembled, use the
pin set or magnet.
● Disassemble valve lift and lead, then clean inside by

blowing the compressed air.
● Clean oil sticked to the lead, measure the thickness of
mirco meter, control it.
LEAD VALVE LIFT

CAUTION
LEAD
•There are various lead from 1.500mm to 2.300
mm, totally 33 leads.
Calculation for adjusting the valve gap lead : A=(B-C)=D

- Required lead thickness : A
- Recorded valve lifter gap : B
- Specified valve lifter gap : C(IN 0.15mm/EX 0.23mm)
- Disassembled lead thicknes : D
Calculation valve lead(example)

B : Recorded valve lifter lead : 0.06mm
D : Disassembled lead thickness : 1.875mm
C : Specified valve lifter gap : 0.15mm(IN)
A =(0.06-0.15)+1.875mm=1.785
New lead thickness : 1.775mm
Because there is only 1.785mm to meet the required lead thick-
ness from 1.500mm to 0.025mm, this lead will be choosed.
CAUTION
170
170 172
172 175
175 178
178
•Measure and check correctly new lead, disassem-
bled lead thickness by micrometer.
1.700mm
1.700mm 1.725mm
1.725mm 1.750mm
1.750mm 1.775mm
1.775mm •If the required lead thickness is over 2.300mm,
check the valve seat and remove carbon accumu-
lated material and adjust the valve seat.
● Assemble the selected lead to valve spring retainer

PILLAR GAUGE
PILLAR
PILLAR GAUGE
GAUGE
according to speficied sequence.
● Apply molybedenum fluid to sliding side of valve
lifter and assemble lifter
● Assemble cam shaft. Rotate crank shaft, make the
lead positioned, re-check valve gap.
COMPRESSION PRESSURE OF
CYLINDER
● Start the engine and heat it
● Turn off starting and disassemble spark plug cap and
sparkplug. Assemble compression gauge. Open com-
pletely throttle and idle the engine by starter motor by
the time when raising of gauge stops.
TOOL : Compression gauge
COMPRESSEDPRESSURE
COMPRESSED
COMPRESSED PRESSURE
PRESSURE
GAUGE
GAUGE
GAUGE
CAUTION
•Generally, from 4 to 7 seconds, it raises maxi-
mumly.
•Compressed pressure : 13.0 kgf/cm2
If the pressure is low, check the followings.

● Bad adjustment of valve gap
● Leaking of valve
● Leaking from cylinder head gasket
● Abrasion of piston and cylinder
If the pressure is high, check the followings.
● Carbon accumulation of head side of pistion, cylinder head.
OILLEVEL
OIL
OIL LEVELGAUGE
LEVEL GAUGE
GAUGE ENGINE OIL
INSPECTION
● Do warming up the engine and warm up the engine
oil enough.
● Stop the engine and loosen oil level gauge, clean oil
in gauge by cleaned towel. Rotate level gauge and
insert it to check the oil capacity.
● If the oil is between the upper and lower level, it is
UPPERLINE
UPPER
UPPER LINE
LINE OK. If the oil is close or below the lower level,
replenish it to the upper level.
LOWERLINE
LOWER
LOWER LINE
LINE
CAUTION
•Stand the vehicle by main stand and check
OILINLET
OIL
OIL INLET
INLET
TRANSMISSION OIL
● Stand the vehicle by main stand and check
● Stop the engine and separate oil check bolt.
● Check the oil level through the oil check hole.
● If the oil level is low, replenish oil(SAE90#)
● Assemble oil check bolt
CAUTION
•The sealing washer shall be good
DRAINBOLT
DRAIN
DRAIN BOLT
BOLT
OIL CHECK
OIL
OIL CHECKBOLT
CHECK BOLT
BOLT •Stand the vehicle by main stand and check
CVT DUST COVER ELEMENT

CHECK
● Untie 2 bolts in LH. Crank case cover and CVT Dust
cover ass’y.
CVT DUST COVER
● Disassemble CVT Dust upper cover and element,

check.
● If it gets dirty due to dust, other material, clean.
● The assembly is done in the reverse order of disas-
sembly.
˘˜¿„ ¿⁄‚fi‚˘fi •˛¿ ˜¿„

DRIVE BELT
● Disassemble LH. Crank case cover.
● Check whether drive belts is seriously damaged or
broken. According to regular inspection schedule,
check and if possible, replace with the new one.
DRIVEBOLT
DRIVE
DRIVE BOLT
BOLT
CHECK COOLING WATR

● Stand the vehicle by main stand and check
● Open RH. Inner box cover and check the cooling
water’s level in the reserve tank.
HIGH
HIGH
● The cooling water level shall be between high and
HIGH
low level line.
RESERVE TANK
RESERVE
RESERVE TANK
TANK ● If the cooling is not enough, replenish it to the high
LOWER
LOWER
LOWER level(H).
CAUTION
•If do not replace or replenish the cooling water, the
engine can be over heated or cooled, then replenish it
to the high level(H).
REPLACEMENT OF COOLING
WATER
● Untie the drain bolt and pull out the cooling
water(lean the vehicle to the right for cooling water
to easily come out.
● Disassemble the reserve tank cap
● Asssemble the drain bolt
COOLINGWATER
COOLING
COOLING WATER
WATER
DRAINBOLT
DRAIN
DRAIN BOLT
BOLT
● Replenish the cooling water to the reserve tank.
The capacity of cooling water : 1,500¡ 20cc
● Start the engine and remove air of cooling water,

check whether the level of cooling water is stable or
not.
● Close the reserve tank cap.
OIL CUP CAP BRAKE FLUID

● Check the oil level of front master cylinder.
● If the oil level is near the lower limit level , remove
the oil cup cap, diaphragm and fill DOT3 or DOT4
brake fluid to the top limit line.
● If the brake fluid reaches to the lower limit line,
check the leaking of the brake system entirely.
CAUTION
•If the brake pad is worn severely, brake fluid level
CHECK CAPACITY
CAPACITY OF
OF
can be down.
CHECK
CHECK CAPACITY OF
BRAKEFLUID
BRAKEFLUID
BRAKEFLUID
BRAKE PAD
BRAKE PAD REPLACEMENT
● Check the brake pads for wear.
● If the brake pad is worn under the abrasion limit of
pad, replace the brake pad with the new one.
● Refer to how to replace the brake pad( 15-5)
ABRASION LIMIT ABRASION LIMIT
CAUTION
•Replace with the brake pad as a set.
BRAKEPAD BRAKEPAD
BRAKE HOSE
BRAKE
BRAKE HOSE
HOSE BRAKE EQUIPMENT
● Check whether there is crack, damage in front/rear
brake hose, and if the brake fluid leaks, replace it
with the new one promptly.
FRONT CALIPER
FRONT
FRONT CALIPER
CALIPER REAR CALIPER
REAR
REAR CALIPER
CALIPER
REAR BRAKE
REAR
REAR BRAKE LEVER
BRAKE LEVER
LEVER
FREEPLAY OF BRAKE LEVER
10~20mm
10~20mm ● When pulling the lever, measure its freeplay
FRONT : 10~20mm
REAR : 10~20mm
SIDE STAND
● Stand the vehicle by main stand
● If pull the lower end of side stand by hand, check
whether it moves smoothly.
● If it doesn’t move freely, pour grease into its pivot
side.
● If it moves too freely, check the side stand spring.
● Check the axial movement of side stand.
SUSPENSION
CAUTION
•Do not ride motorcycle with an unsatisfactory sus-
pension. Loosen or worn suspension parts will lead
to deterioration in the vehicle’
s safety and opera-
tion efficiency.
FRONT WHEEL
● Hold the brake lever, and compress the front cushion
up and down several times to check the efficient
operation.
● Check the front fork for oil leakage, parts damage or
looseness.
REAR WHEEL
● Compress the near cushion up and down several
times to check the operating conditions.
● Check the front fork for oil leakage, parts or loose-
ness.
STEERING STEM
CAUTION
•Check the cable if it interferes with the handle
operation.
● Lift the front wheel and check if the handle moves

right and left smoothly.
● If the handle moves heavily, check if the cable or
electric codes interfere with the handle. If the handle
moves normally, remove the steering stem and check
the ball race for being worn or damaged.
WHEELS / TIRES
CAUTION
•Check the tire pressure when the tires have been
cooled off. Check the thread (the part making con-
tact with the road surface)and side for being worn,
cracked or damaged. Replace damaged tires.
STANDARD PRESSURE kgf/cm 2

front wheel front wheel
one person 2.00(28psi) 2.40(34psi)
two persons 2.00(28psi) 2.50(36psi)
FASTENING BOLTS, NUTS

● Meeting the schedule of regular inspection,
F ● Check whether the nuts, bolts of all vehicles are fas-
tened by specified torques.
● Check all pins, clips, hose clamp and cable stay
BATTERY
BATTERY
BATTERY BATTERY
● Remove the battery cover.
● Check the looseness of the terminals.
● If the terminals are loose, check and clean the con-
tacted area.
● Check the fuse
FUSE
FUSE
FUSE
● Measure the battery voltage

- COMPLETE CHARGING :12.6~13.0 V
- INCOMPLETE CHARGING : UNDER 12.4 V
§]POLE
POLE
§]POLE
§]POLE
§]POLE
§]POLE
§] POLE
§^POLE
§^
§^POLE ● If the terminal part get rusted, remove the battery and
pour the warm water then, clean it with a wire brush.
LUBRICATION POINTS
● Use the general grease unless specified here.
● Apply oil or grease to the other operating surfaces not shown
here.
CONTROL CABLE LUBRICATION

● Periodically disassemble the upper end of the throttle cable then
apply oil after cleaning. Change it when the cable lengthened.
THROTTLE GRIP
FRONT/REAR BRAKE LEVER PIVOT
STEERING HEAD BEARING
REAR BRAKE CALIPER BRACKET
WHEEL BEARING
FRONT BRAKE CALIPER BRACKET
MAIN/SIDE STAND PIVOT WHEEL BEARING / SPEEDOMETER GEAR
MEMO
3. EXTERNAL PARTS
SERVICE INFORMATION ···3-1 WIND SCREEN ASSEMBLY/DISASSEMBLY ·3-7

FLOW CHART OF ASSEMBLY/DISASSEMBLY 3-2 FRONT COVER ASSEMBLY/DISASSEMBLY ·3-7
SEAT DIASSEMBLY/ ASSEMBLY ·3-3 FRONT UNDER A COVER ASSEMBLY/
LUGGAGE BOX ASSEMBLY/ DISASSEMBLY ·3-3 DISASSEMBLY ········3-7
REAR CARRIER ASSEMBLY/DISASSEMBLY 3-3 FRONT UNDER B COVER ASSEMBLY/
CENTER COVER ASSEMBLY/DISASSEMBLY 3-4 DISASSEMBLY ········ 3-8
BODY COVER ASSEMBLY/DISASSEMBLY 3-4 SPEEDOMETER ASSEMBLY/DISASSEMBLY ·3-8
REAR FENDER ASSEMBLY/DISASSEMBLY 3-5 INNER BOX ASSEMBLY/DISASSEMBLY ·3-9
FLOOR SIDE COVER ASSEMBLY/DISASSEMBLY 3-5 FRONT FENDER ASSEMBLY/DISASSEMBLY ·3-10
FLOOR PANEL ASSEMBLY/DISASSEMBLY 3-5 REAR WHEEL MUD GUARD ASSEMBLY/
UNDER COVER ASSEMBLY/DISASSEMBLY 3-6 DISASSEMBLY ········3-10
HANDLE COVER ASSEMBLY/DISASSEMBLY 3-6 MUFFLER ASSEMBLY/DISASSEMBLY · 3-10
SERVICE INFORMATION
CAUTION
● This section describes external parts removal / installation

● Do not apply inreasonable force when disassmebling or assembling covers to prevent their possible damage.
● Because the muffler is hot, do not service it immediately after the engine is stopped.
EXTERNAL PARTS
MAINTENANCE PROCEDURE
NAME OF FRAME COVERS
FLOW CHART(ASSEMBLY/DISASSEMBLY)
● This chart shows arrows connected in the order of disassembling covers.
① SEAT ⑥ BODY COVER ⑪ HANDLE COVER ⑯ SPEEDOMETER COVER
② BATTERY COVER ⑦ REAR FENDER ⑫ WIND SCREEN ⑰ INNER BOX
③ LUGGAGE BOX ⑧ FLOOR SIDE COVER ⑬ FRONT COVER ASS’Y ⑱ FRONT FENDER
④ REAR CARRIER ⑨ FLOOR PANEL ⑭ FRONT UNDER COVER A ⑲ REAR WHEEL MUD GUARD
⑤ CENTER COVER ⑩ UNDER COVER ⑮ FRONT UNDER COVER B ⑳ MUFFLER
NOTE
•At disassembly of front wheel, be careful about turn over of the vehicle.
EXTERNAL PARTS
SEAT SEAT DISASSEMBLY/

ASSEMBLY
● Push the seat button and release seat lock
● Untie 2 flange nuts installed in seat guard spring
SEAT GUARD SPRING cylinder
CYLINDER ● Untie 2 flange nuts installed in seat, then remove the
seat
● Install in the reverse order of disassembly.
FLANGENUT
FLANGE
FLANGE NUT
NUT
LUGGAGE BOX DISASSEMBLY/

ASSEMBLY
● Untie 2 special screws installed at the battery cover
BATTERY
BATTERY
BATTERY
● Disassemble luggage box mat
COVER
COVER
COVER
LUGGAGE
LUGGAGE BOX
LUGGAGE BOX MAT
BOX MAT
MAT
WASHER BOLT
● Untie 2 washer bolts and 4 open stay nuts
OPEN STAY NUT
LUGGAGE BOX ● Lift up the luggage box and separate trunk lamp
wires
● Separate the luggage box
● Install in the reverse order of disassembly
TRUNK LAMP MAINTENANCE

MAINTENANCE
MAINTENANCE
COVER
COVER
COVER
REARCARRIER
REAR
REAR CARRIERCOVER
CARRIER COVER
COVER REAR CARRIER
REAR
REAR CARRIER
CARRIER REAR CARRIER
DIASSEMBLY / ASSEMBLY
● Disassemble rear carrier cover
● Untie 3 socket bolts
● Disassemble rear carrier
SOCKETBOLT
SOCKET
SOCKET BOLT
BOLT
EXTERNAL PARTS
CENTER COVER
REMOVAL/ ASSEMBLY
● Open the seat and erect
● Separate floor panel mat
● Untie 5 tapping screws installed at left and right of
center cover
CENTERCOVER
CENTER
CENTER COVER
COVER
● Put driver between center cover and floor panel,

then disassemble center cover by lifting up
● Assemble in the reverse order of removal
⊖DRIVER
⊖DRIVER
⊖DRIVER
BODY COVER BODY COVER REMOVAL/

ASSEMBLY
● Untie 2 flange bolts and 4 tapping screws installed at
left and right of body cover
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
● Untie 2 tapping screws installed at rear mud guard

● Disassemble rear combination light and winker wire
coupler
● Broaden gap the body cover to left and right side, lift
TAPPING SCREW
TAPPING
TAPPING SCREW
SCREW
up slightly and pull backward , disassemble it.
REARMUD
REAR
REAR MUDGUARD
MUD GUARD
GUARD
EXTERNAL PARTS
BODYCOVER
BODY
BODY COVER
COVER REAR FENDER REMOVAL
/ ASSEMBLY
● Disassemble luggage box
● Disassemble body cover
● Untie 6 tapping screws installed at body cover and
disassemble rear fender
REAR FENDER
REAR
REAR FENDER
FENDER
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW FLOOR SIDE COVER
REMOVAL / ASSEMBLY
● Disassemble floor mat
● Untie 4 tapping screws installed at floor panel
● Untie 2 washer screws installed at floor side cover,
disassemble
● floor side cover
FLOOR SIDE COVER WASHER SCREW
FLOOR PANEL FLOOR PANEL REMOVAL /

ASSEMBLY
● Disassemble center cover
● Disassemble floor side cover
● Disassemble 4 floor panel caps
FLOOR PANEL CAP WASHER BOLT
● Untie 4 washer bolts installed at floor panel

● Broaden wide pillion step bars and lift up slightly
floor panel,then pull backward and disassemble.
PILLIONSTEP
PILLION
PILLION STEPBAR
STEP BAR
BAR
EXTERNAL PARTS
FLANGE BOLT
UNDER COVER REMOVAL
/ ASSEMBLY
● Disassemble floor side cover
● Untie 4 flange bolts and disassemble under cover
UNDER COVER
UPPER HANDLE COVER HANDLE COVER

REMOVAL / ASSEMBLY
● Untie 4 tapping screws installed at RH / LH. Under
handle cover
TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW
TAPPING SCREW
TAPPING
TAPPING SCREW
SCREW
RH./LH.UNDER
RH./LH.
RH./LH. UNDERHANDLE
UNDER HANDLECOVER
HANDLE COVER
COVER
● Untie 2 tapping screws installed at upper handle

cover
● Disassemble RH / LH under handle cover
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
● Untie 2 tapping screws and 2 special screws

installed at left, right of upper handke cover
● Disassemble upper handle cover
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
SPECIAL SCREW
EXTERNAL PARTS
WIND SCREEN SPECIAL BOLT WIND SCREEN REMOVAL /

ASSEMBLY
● Untie 4 special bolts and disassemble wind screen
FRONT COVER FRONT COVER REMOVAL

/ ASSEMBLY
● Untie 7 tapping screws installed at front cover and
disassemble front cover.
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
FRONT UNDER
COVER A
FRONT UNDER COVER A
REMOVAL/ ASSEMBLY
● Disassemble front cover
● Untie 2 flange bolts
FRANGE BOLT
FRANGE
FRANGE BOLT
BOLT
FRONT UNDER ● Untie 2 tapping screws installed at front under cover

COVER A A
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
FRONT UNDER
FRONT
FRONT UNDER
UNDER
COVER BB
COVER
COVER B
EXTERNAL PARTS
● Untie 6 tapping screws installed at inner boc

INNER BOX
● Disassemble front under cover A
TAPPING
SCREWS
FRONT UNDER COVER B

REMOVAL / ASSEMBLY
● Diassemble floor side cover
● Untie 2 flange bolts installed at front under cover B
● Untie 2 tapping screws installed at inner box and
disassemble under cover
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
METERCOVER
METER
METER COVER
COVER ENGINECOOLANT
ENGINE
ENGINE COOLANT
COOLANT SPEEDOMETER REMOVAL
COVER
COVER
COVER
/ ASSEMBLY
● Disassemble body cover clip installed at meter cover
● Untie tapping screw installed at engine coolant cover
and disassemble cover
● Disassemble reserve tank cap
BODY COVER
BODY
BODY COVER CLIP
COVER CLIP
CLIP
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
SPEEDOMETER
SPEEDOMETER
SPEEDOMETER ● Untie 4 tapping screws installed at meter cover
CABLE
CABLE
CABLE ● Loosen the screw and bolt installed at reserve tank
1/2.
● Disassemble couplers of other wires
● Disassmble meter cover
RESERVETANK
RESERVE
RESERVE TANK
TANK TAPPING
TAPPING SCREW
TAPPING SCREW
SCREW
EXTERNAL PARTS
● Untie 4 tapping screws installed at meter cover,

TAPPING SCREW
disassemble speedometer.
SPEEDOMETER
METER COVER
CENTER INNER
INNER BOX REMOVAL/
BOX LID ASSEMBLY
● Disassemble the following parts
- luggage box
- center cover
- body cover
- floor panel
- wind screen
- front cover
- front under A, B cover
FLANGE BOLT
FLANGE
FLANGE BOLT
BOLT - speedometer
● Untie 2 flange bolts installed at inner box
● Untie 1 open stay nut after opening center inner box

OPENSTAY
OPEN
OPEN STAYNUT
STAY NUT
NUT lid
● Untie 2 screws installed at back holder and
disassemble back holder
BACKHOLDER
BACK
BACK HOLDER
HOLDER
INNER CENTER
INNER
INNER CENTER
CENTER
COVER
COVER
COVER
SEATLOCK
SEAT
SEAT LOCK
LOCK FUELLID
FUEL
FUEL LIDLOCK
LID LOCKCABLE
LOCK CABLE
CABLE ● Untie 4 tapping screws installed at fuel cap neck
CABLE AA
CABLE
CABLE A ass’y
TAPPINGSCREW
TAPPING
TAPPING SCREW
SCREW
● Disassemble fuel lid lock cable
● Disassemble seat lock cable
● Disassemble handle switch coupler
HANDLE SWITCH
HANDLE
HANDLE SWITCH COUPLER
SWITCH COUPLER
COUPLER FUELCAP
FUEL
FUEL CAPNECK
CAP NECK
NECK
ASS’Y
ASS’Y
ASS’Y
EXTERNAL PARTS
● Untie 3 tapping screws and 1 flange bolt installed at

reserve tank
TAPPING SCREW
TAPPING
TAPPING SCREW
SCREW
● Disassemble inner box
RESERVETANK
RESERVE
RESERVE TANK
TANK
WASHERBOLT
WASHER
WASHER BOLT
BOLT
FRONTFENDER
FRONT
FRONT FENDER
FENDER SPECIALSCREW
SPECIAL
SPECIAL SCREW
SCREW FRONT FENDER REMOVAL
/ ASSEMBLY
● Disassmeble wire grommet installed at RH.
● Untie 4 special screws installed at front fender
● Disassemble front fender
● Asssemble in the reverse order of removal
REAR WHEEL
REAR
REAR WHEELMUD
WHEEL MUDGUARD
MUD GUARD
GUARD REAR WHEEL MUD GUARD
REMOVAL / ASSEMBLY
● Untie 2 washer bolts installed at LH. Side of rear
wheel mud guard
● Disassemble air cleaner
● Untie 1 washer bolt installed at RH. Side and
disassemble rear wheel
WASHER
WASHER BOLT
WASHER BOLT
BOLT
EX
EX PIPE
EX PIPE COVER
PIPE COVER
COVER MUFFLER REMOVAL
/ ASSEMBLY
● Untie 3 washer screws installed at EX. Pipe cover
and disassemble the muffler
WASHER SCREW
EXTERNAL PARTS
● Untie 4 hex cap nuts installed at muffler comp
HEX CAP NUT

● Disassemble muffler
CAUTION
•Do not repair right now at stop becaue the muffler
is hot
SPECIALFLANGE
SPECIAL
SPECIAL FLANGEBOLT
FLANGE BOLT
BOLT
DISASSEMBLY OF EX. PIPE

● Disassemble oxygen sensor coupler
OXYGEN SENSOR
OXYGEN
OXYGEN SENSOR
SENSOR
COUPLER
COUPLER
COUPLER
HEX CAP NUT

● Untie 2 hex cap nuts installed with cylinder head
HEX
HEX CAP
CAP NUT
NUT
● Pulling under slightly EX. Pipe, disassemble it.
OXYGEN SENSOR
CAUTION
•Replace packing at disassembly-assembly of
muffler and EX. Pipe.
MEMO
4-1 LUBRICATION SYSTEM
SERVICE INFORMATION 4-1 REPLACEMENT OF ENGIEN OIL 4-3

TROUBLE SHOOTING 4-2 OIL FUMP 4-4
ENGINE OIL LEVEL CHECK 4-3 TRANSMISSION OIL 4-7
SERVICE INFORMATION
WARNING
•The exhaust gas contains poisonour substance. Do not keep engien idling in a closed or poorly ventilated place for
a long time.
•Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods.
It is desirable not to handle used oul frequently ; however, wash your hands thoroughly with soap and water
immediately after handling the used oil.
•The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
OIL CAPACITY 1.3L(full)

1.1L(replacement)
DAELIM Geguine oil

API Service classification SL grade
RECOMMENDED OIL Viscocity : 10W-40
(Use appropriate type of oil with viscocity satisfying the atmospheric temperature.
Temperature to the air
In your riding area based on the table shown on the right side) Temperature and viscocity
TRANSMISSION OIL
0.15L(Full capacity)
OIL CAPACITY
0.14L(at changing)
RECOMMENDED OIL DAELIM Geguine mission oil or SAE 80W/90
TORQUE VALUES
OIL PUMP BOLT 1.1kgf m
PAPPET ADJUSTING HOLE CAP 1.1kgf m
OIL DRAIN PLUG BOL 2.5kgf m
LUBRICATION SYSTEM
TROUBLE SHOOTING
Oil level low
●Natural oil consumption

●External oil leaking
●Worn piston ring or incorrect piston ring installation
●Valve guide or stem seal abrasion
Oil contamination
●Irregular engine oil replacement

●Damage of cylinder head gasket
●Piston ring abrasion
●Water inflows
Low or no oil pressure
●Clogged oil strainer

●Abrasion or damage of oil pump
●Oil leakage inside engine
●Improper viscosity oil
●Low capacity oil
●Non-fitting of oil pump drive gear or sprocket
LUBRICATION SYSTEM
OILLEVER
OIL
OIL LEVERGAUGE
LEVER GAUGE
GAUGE ENGINE OIL LEVEL
INSPECTION
● Erect the motorcycle on the main stand.
● Start the engine and let it be warm fully.
● Stop the engine, untie oil level gauge and clean oil
leaked near to gauge by clean towel. Without
fastening by turning level gauge, put oil into engine
UPPER
UPPER
UPPER
UPPER
UPPER
LOWER
LOWER
to check oil capacity.
LOWER
LOWER
LOWER
● If oil is between upper and lower line of level gauge,
it is ok.But if the oil capacity decreases close to or
under the lower line, replenish it to the upper line.
DRAIN PLUG BOLT ENGINE OIL CHANGE

● Untie oil drain plug bolt and pull out oil.
NOTE
•Make the engine warm and erect the motorcycle
with side stand in order to assure complete and
rapid draining.
● Disassemble tappet adjusting hole cap
● Clean filter screen by cleaned cleansing oil
● Check whether tappet adjusting hole cap o-ring is
TAPPET ADJUSTING good or not
HOLD CAP
CAUTION
•It is extremely important to replace oil filter or
clean the oil filter screen at the first maintenance
interval 500Km by loosen the tappet adjust hole
cap.
● Assemble tappet adjusting hole cap according

specified torque.
TORQUE : 1.5 kgf·m
FILTER SCREEN
● Fill the recommended engine oil with engine oil cap.

OIL CAPACITY : 1.3 L (FULL)
1.1 L(REPLACEMENT)
● Recommended engine oil : DAELIM genuine oil.
API service classification SL grade
Viscosity : 10W-40
● Start the engine and let it idle for a few minutes.
● Stop the engine and check the engine oil level. If the
oil level is low, add the recommended engine oil.
● Check to see if the oil is leak.
LUBRICATION SYSTEM
FLYWHEEL
FLY
FLY WHEELCOMP
WHEEL COMP
COMP
OIL PUMP
● Drain the engine oil.
● Drain cooling water
● Disassemble RH. Crank case cover( 9-2)
● Disassemble fly wheel comp( 9-2)
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
● Untie 2 flange bolts and separate oil separator
OILSEPERATOR
OIL
OIL SEPERATOR
SEPERATOR
OILPUMP
OIL
OIL PUMP CHAIN
● Disassemble cir clip
PUMPCHAIN
CHAIN
● Disassemble oil pump chain and driven sprocket
OILPUMP
OIL
OIL PUMPDRIVEN
PUMP DRIVEN
DRIVEN
SPROCKET CIRCLIP
CIR
CIR CLIP
CLIP
SPROCKET
SPROCKET
● Untie 2 flange bolts and disassemble oil pump

OILPUMP
OIL
OIL PUMP
PUMP
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
LUBRICATION SYSTEM
OIL PUMP BODY OUTER ROTOR INNER ROTOR PUMP PLATE

OIL PUMP DISASSEMBLY
● Loosen the screw securing the oil pump plate.
● Remove the oil pump body and oil pump plate.
● Clean the oil pump body, inner rotor, outer rotor with
fresh cleaning oil.
OIL PUMP SHAFT
OIL PUMP INSPECTION

FEELER GAUGE
● Measure the end clearance pump body.
OIL PUMP BODY
SERVICE LIMIT : 0.23 MM
TOOL : FEELER GAUGE
OUTER ROTOR
● Measure the end clearance between inner and outer

rotor.
INNER ROTOR
● Measure the twisteness of pump body by feeler

gauge and square.
OIL PUMP BODY

LUBRICATION SYSTEM
ASSEMBLY
OIL PUMP BODY PLATE
● Clean all parts with fresh cleaning oil.
● Install the inner and outer rotors into the oil pump
body.
● Install the oil pump plate into the pump body, then
OIL PUMP tighten the fan screw.
● Install pump shaft
PUMP SHAFT
● Assemble oil pump to RH. Crank case

OILPUMPCHAIN
OILPUMP
OILPUMP CHAIN
CHAIN ● Assemble oil pump chain and driven sprocket
● Assemble cir clip
CAUTION
•By rotating pump shaft, check whether it operates
well without hindrance.
● Assemble oil separator
DRIVENSPROCKET
DRIVEN
DRIVEN SPROCKET
SPROCKET
REDUCTIONGEAR
REDUCTION
REDUCTION GEAR
GEAR
● Assemble reduction gear and fly wheel
● Assemble new gasket and dowel pin
FLYWHEEL
FLY
FLY WHEEL
WHEEL ● Assemble RH. Crank case cover
● Replenish the genuine engine oil
● Replenish cooling water
LUBRICATION SYSTEM
ACGCAP
ACG
ACG CAP
CAP TRANSMISSION OIL
OILCHECK
OIL
OIL CHECKBOLT
CHECK BOLT
BOLT INSPECTION
● Check the connection part of case for any leak.
● Loosen the oil check bolt and check to see if the oil
overflows from the oil check hole.
CAUTION 4
•Oil level inspection must be performed in the flat
ground with the vehicle being straight by raising
the main stand.
DRAIN BOLT
DRAIN
DRAIN BOLT
BOLT
MISSION OIL
MISSION
MISSION OIL
OIL
● If oil is insufficient, loosen ACG cap and replenish
CHECK
CHECK HOLE
CHECK HOLE
HOLE slowly the genuine mission oil to inlet by the check
hole.
MISSION
MISSION OIL
MISSION OIL DRAIN
OIL DRAIN
DRAIN
HOLE
HOLE
HOLE
MISSIONOIL
MISSION
MISSION OILINLET
OIL INLET
INLET REPLACEMENT
● If the transmission oil is contaminated, loosen drain
bolt and pull out mission oil, then insert
recommended mission oil based on speficied
MISSION OIL
MISSION
MISSION OIL
OIL capacity.
CHECK HOLE
CHECK
CHECK HOLE
HOLE ● Oil capacity : 0.15L(full)
0.14L(replacement)
DRAIN
DRAIN BOLT
DRAIN BOLT
BOLT RECOMMENDED OIL : SAE 80W/90
MEMO
5.EMS(ENGINE MANAGEMENT SYSTEM)
1. CAUTION WHEN REPARING THE EMS PARTS 5-2

2. THE COMPONENT PARTS OF THE EMS 5-3
3. TERMINAL ARRANGEMENT OF THE ECU 5-4
4. WIRING DIAGRAM OF THE ECU 5-5
5. AN ERROR CHECK LIST FOR EACH TERMINAL OF ECU 5-5
6. SELF-DIAGNOSTIC FUNCTION BY MIL
(MALFUNCTION INDICATOR LAMP) 5-6
1) SELF DIAGNOSTIC FUNCTION 5-6
2) FAIL SAFE FUNCTION 5-7
3) HOW TO CHECK THE FAULTY CODE 5-8
4) HOW TO SHOW THE FAULTY CODE 5-9
5) HOW TO READ THE FAULTY CODE 5-9
6) FAULTY CODE TABLE 5-10
7) HOW TO REMOVE THE FAULTY CODE 5-11
8) EMS TROUBLE SHOOTING 5-11
7. ECU(ELECTRONIC CONTROL UNIT) 5-12
8. THROTTLE BODY ASSEMBLY/DISASSEMBLY 5-13
9. INJECTOR 5-17
10. MAPAT SENSOR(INLET PRESSURE+INLET TEMPERATURE) 5-19
11.TPS(THROTTLE POSITION SENSOR) 5-23
12. ETS(ENGINE TEMPERATURE SENSOR) 5-26
13. ISA(IDLE SPEED ACTUATOR) 5-29
14. O2 SENSOR(OXYGEN SENSOR) 5-32
15. CHECKING OF ESS CIRCIUT 5-35
16. CHECKING OF DIAGRAM OF ENGINE CHECK(CAUTION) LAMP 5-36
17. CKP(CRANK POSITION SENSOR) 5-37
18. FUEL PUMP 5-41
19. FUEL TANK 5-44
¡ EFI (ELECTRIC FUEL INJECTION)

EMS(Engine Management System)
1. CAUTION WHEN REPAIRING THE EMS PARTS.
●If the fuse is short-circuited, findout the cause and repair.

Replace with the fuse having the specified capacity.
●Do not use the electlic wires or others instead of the fuse.
●Do not drop or throw the EMS parts because these parts
may be damaged by the impact of the drop.
●Do not touch the ECU terminal, because it may be

damaged by the static.
●Be sure to key OFF when assembly / disassembly of the

coupler of ECU
●When assembly/disassembly at key ON, the ECU may be
damaged.
●Do not connect adversely the polarity of battery. otherwise,

It may be broken the EMS parts
●While engine operating, do not disassembly the battery

terminal.
otherwise, it might cause damaged the EMS parts.
●Use the specitied voltmeter and resistance meter.
2. STRUCTURE OF THE EMS

EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM.
1) INTAKE SYSTEM
As a system which controls and measures air to be necessary for combustion in engine, the intake system
is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air
cleaner and ISA(Idle Speed Actuator), etc.
In idling, because throttle value is almost closed, the idle status of engine shall be controlled by means
that idle speed control system is installed in order to control small of quantity of air being necessary for
combustion.
2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to
injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division
pipe and injector.
The fuel in tank, being high pressed by fuel pump, moves to the division pipe through fuel filter.
Next the fuel is supplied to injector being highly maintained as regulated pressure about the pressure of
intake system.
Injector sprays fuel into the intake system by injection signals of ECU.
3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to
control proper spark time in cylinder, high-voltage system, and so forth.
4) CONTROL SYSTEM
① Various sensors to move electric signals converted by checking the current engine status
② Input interface which works various processes like regulating voltage levels, removal of noise, A/D
conversion, amplifying of inputted signals from above sensors.
③ Micro-computer which decides output value through various calculating, arithmetic and logic
processing.
④ Output interface to amplify the above output signals.
⑤ Actuator being mechanically worked by receiving the amplified output signals.
(Intake pressure sensor+Intake

temperature)
3. TERMINAL ARRANGEMENT OF THE ECU
ECU PIN NO. and FUCTIONS

PIN NO. FUNCTION PIN NO. FUNCTION
ECU earth Frame earth
Oxygen Sensor earth Crank position signal B
Intake pressure sensor, Intake temperature sensor earth Communication LOW
Throttle position sensor, Engine temperature sensor earth Engine check lamp
Engine kill switch Battery power
- Supply of intake power sensor(5V)
- Signal of intake power sensor
- Signal of intake temperature sensor
ECU earth - -
After main key turns on, battery power Crank position signal A
- Communication HIGH
Oxygen sensor signal Engine speed signal
- Idle Speed Actuator
- Oxygen sensor heat
- Ignition coil earth
- -
Battery power Ignition signal
Supply of power(5V) of Throttle positon sensor Head lamp relay signal
Throttle position sensor signal Fuel pump relay signal
Engine temperature sensor signal Injector signal
Remarks
ECU PIN NO. 6,7,8,11,13,14,15,16,29,36 NOT available
Terminal arrangement is based on the ECU.
ECU Terminal Arrangement

- Earth wire : 1,2,3,4,9,21,35
- Power supply : 10,17,18,25,26
- Input signal to ECU :

5,12,19,20,22,27,28,30
- Output signal from ECU :

24,32,33,34,37,38,39,40
ECU WIRE DIAGRAM
AN ERROR CHECKLIST FOR EACH TERMINAL OF ECU

ERROR Checklist ERROR Checklist
PIN PIN
NO. Starting Idle RPM SCAN tool
Stability Driving Durability communication MIL NO. Starting Idle RPM SCAN tool
Stability Driving Durability communication MIL
SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp)

SELF-DIAGNOSTIC FUNCTION
The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation
normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL
(malfunction indicator lamp). It gives the rider that malfunction has occurred in the system.
However, the ECU takes fail-safe function, it enables to drive only temporary when that happen.
Normally, the MIL illuminates for 3 seconds, when the main key is turned on.
MIL(Malfuction Indicator Lamp)
when the ignition key ON.

MIL
OFF Able to engine start
Starting and driving are temporary

ON
Unable
Unable to engine start
* 시동키를 ON했을 경우임
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the
EMS’s fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen.
- Crankposition sensor
- Injector
- Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON MIL on continuously, when the engine operating
Blink MIL blinks, when the main key is turn on (engine is stop)
FAIL-SAFE FUNCTION
If the ECU checks something wrong , the vehicle can be driven by its fail safe function.
However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation
can be impossible.
MIL
on
INTAKE : MIL on/off
INTAKE
: MIL on
If there is something wrong in the EMS, it has fail safe function in order for engine to
work and to cover a minimum driving of vehicle.
intake
intake
The value of intake pressure is fixed as the

INTAKE
pressure just before when the intake pressure
sensor is out of order.
INTAKE The value of intake temperature is fixed as a
temperature just before when the intake
pressure sensor is out of order.
△
! CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe
function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case.
In this case, safe repairing of vehicle shall be required.
HOW TO CHECK THE FAULT CODE
There are two methods of checking the fault codes.
Use the MIL in the speedometer and the diagnostic tool.
First) Use the MIL in the Speedometer for checking.

• Turn off the ignition key
• The MIL blinks continuously
• Find the defects by checking the number of lighting, the fault code can be verified (refer to the fault code
table)
Second) The diagnostic tool (refer to scan user’s manual for checking.)
• Turn off the ignition key
• Aassemble the coupler of diagnostic tool with the coupler to check the malfunction of vehicle.
• Turn on the ignition key
• Press the power button of diagnostic tool
• Checks according to diagnostic procedure of diagnostic tool.
Coupler to check the malfunction diagnosis

Wire color to check the malfunction diagnosis
-P/W : PINK/WHITE : CAN_L
-P/Y : PINK/YELLOW : CAN_H
-B : BLACK : IGNITION KEY
-G : GREEN : GROUND
Third) Use the wireharness for checking

❶ Coupler for checking (ECU 1 - ECU 20 PIN)
❶
❷
❷ Coupler for checking (ECU 21 - ECU 40 PIN)
Measure the wire harness for checking by connecting the ECU with main wire harness to check the ECU.
It has two coupler to check the terminal.
The wireharness to check the ECU arrangement
❶ Coupler for checking : ECU PIN no. 1,2,3,4,5,9,10,12,17,18,19,20 were connected.

ECU PIN no. 6,7,8,11,13,14,15,16 is not connected.
❷ Coupler for checking : ECU PIN no. 21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,37,39,40 were connected.

ECU PIN no. 36 is not connected.
HOW TO SHOW THE FAULT CODE
There are two methods to show the Fault codes.
First) The methods to show in engine operation

In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the
light on/off function of MIL in order for driver to acknowledge defect. This time, so for checking the fault
code, stop the vehicle and engine, and in the ignition key on, by checking the number of lighting, the fault
code can be verified.(refer to the fault code table)
Second) The ways of indication only turn on the ignition key.

When only ignition key is on and if the defect of each part brings out, the MIL keeps showing
the Fault code of defect part repeatedly in order to give defect information to driver.
△
! CAUTION
If the MIL on when engine is working, engine is able to be operated by fail safe. However, in the event that
Injector, Fuel pump, Ignition coil has something wrong, vehicle may not been driven and engine not started.
HOW TO READ THE FAULT CODE

The fault codes are showed as 2 digits on the MIL of EMS.
Only one defect code is showed up to prior sequence of defects. This time, that fault code is repeatedly
showed.
E.g. ) The Fault code of ISA
ON
OFF
1.5 sec 3 sec
1 flashing cycle : 0.5 sec
If many problems will happened in the EMS parts at the same time, only one fault code is displayed by the
priority, however, the ECU remembers all the fault codes.
After revise the code, remove the memorized fault code by the method of warm up.(5-10)
(Refer to remove the fault codes)
When the vehicle is checked using the diagnosis tool.

- If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.
FAULT CODES TABLE
MIL INDICATION Fault Priority

code no. Description
(The number of blinks) order
No failure
Crank position sensor failure(CKP)
Injection valve failure(IV)
Idle speed actuator failure (ISA)
Electrical fuel pump failure (EFP)
Intake Manifold absolute pressure signal

failure (IMP)
Throttle position signal failure (TPS)
O2 sensor heater output failure (LSH)
Lambda signal failure (VLS)
Engine temperature signal failure (TENG)
Breathing air temperature signal failure

(TBA)
Engine speed signal output failure (ESS)
Headlamp relay failure
Malfunction indicate lamp failure (MIL)

HOW TO REMOVE THE FAULT CODE

Remove the fault codes in two ways;
First) Full warm up
1. Starting the engine.

- The MIL blinks continuously because the ECU memorized the fault code yet.
2. Full warm up the engine (keep idling five minutes)
3. Turn off the ignition key after full warm up the engine
4. Turn on the ignition key again, and check whether the fault code is disappeared or not.
After full warm up, it is possible to check the fault code is removed with the ignition key on/off.
If many problems happened in the EMS parts at the same time, only one defect code will is displayed
by the priority order.
Even thought repair a fault and remove the memorized fault code,
another fault code blinks.
at this time, revise the fault and remove the memorized fault code by
the warm up.
Second) Malfunction diagnosis tool

(refer to the scan user’s manual)
EMS TROUBLE SHOOTING

Inspection before diagnosis
Inspection the following before malfunction diagnosis.
Engine oil capacity and leakage
Condition of Spark plug
Cylinder compressed pressure
Fuel capacity and leakage
Air cleaner clogging
Condition of Battery
Remaining length of Throttle cable
Fuse cut or not
MIL’s blinking
Coming out of emission gas
Connection status of each coupler
ECU
ECU
ECU
ECU
ECU
●Press seat button and open seat.
●Diassemble luggage box
CAUTION
•The key shall be OFF before disassembly
● Disassemble based on sequence because coupler can

be broken if disassembling by force(1 2)
❷
❷
❶
❶
DISASSEMBLY
● Disassemble the coupler connected with ECU
● Untie 4 flange bolts installed at ECU
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
ASSEMBLY
● Assemble in the reverse order of disassembly
CAUTION
•At assembly, the ground wire(green colored) of
ECU shall be connected.
ECU
ECU
ECU
MAINTENANCE COVER
MAINTENANCE
MAINTENANCE COVER
COVER
SPECIALSCREW
SPECIAL
SPECIAL SCREW
SCREW THROTTLE BODY
DISASSEMBLY
● Open seat
● Untie 1 screw amd separate maintenance cover
● Untie the screw installed at air cleaner connecting

AIRCLEARNER
AIR
AIR CLEARNER
CLEARNER
tube band
● Untie the screw installed at connecting tube
THROTTLEBODY
THROTTLE
THROTTLE BODY
BODY
THROTTLECABLE
THROTTLE
THROTTLE CABLE
CABLE
● Separate throttle cable

● Disassemble fuel tube connected to injector cap
● Disassemble TPS, ISA, Map sensor, injector coupler
● Disassemble throttle body ass’y
THROTTLEBODY
THROTTLE
THROTTLE BODY
BODY
IDLE SPEED ACTUATOR DISCONNECT THE THROTTLE

THROTTLE BODY
BODY
● Remove the each component parts securing throttle
body and check.
CAUTION
THROTTLE POSITION SENSOR
Do not disconnect both the throttle adjust
MAP SENSOR
screw and adjust nut.
REMOVE
THROTTLE BODY ● Loosen the throttle body 2 bolts securing the
insulator.
● Disconnect the TPS (Throttle position sensor).
● Disconnect the ISA(Idle speed actuator).
● Disconnect the MAPAT.
CAUTION
IDLE SPEED ACTUATOR(ISA) Do not disconnect the throttle valve.
MAP SENSOR THROTTLE POSITION SENSOR
CHECKING THE THROTTLE BODY

● Check map sensor
● Check ISA
● Check TPS
● Check o-ring
● If there is abrasion or damage to the vehicle
MAP SENSOR THROTTLE POSITION SENSOR

IDLE SPEED ACTUATOR(ISA)
● Check throttle shaft

THROTTLE SHAFT ● Check throttle valve
CAUTION
Assemble in the reverse order of disassembly
VALVE
INJECTOR CAP THROTTLE BODY INLET PIPE DISASSEMBLY

INSULATOR ● Untie 2 flange bolts installed at cylinder head,
SCREW disassemble inlet pipe
● Untie throttle body insulator and screw installed at
inlet pipe
INLET PIPE
● Disassemble simultaneously injector and injector cap

from inlet pipe.
● Disassemble injector and iinjector cap
● Check injector
● Check injector o-ring
INJECTOR INJECTOR CAP
● Check inlet pipe and throttle body insulator.

● Check inlet pipe o-ring
● Check about abrasion, damage of throttle body
insulator
● Assembly of inlet pipe is in the reverse order of
disassembly
CAUTION
At assembly, replace with the new o-ring
INLET PIPE T-BODY INSULATOR
INJECTOR CAP T-BODY INSULATOR ● Assemble inlet pipe and throttle body
THROTTLE BODY Torque : 1.0kgf m
INLET PIPE ASS’Y
● Assemble installed inlet pipe and throttle body to
cylinder head.
● At assembly of inletpipe, check o-ring
Torque : 1.2 kgf m
CAUTION
Replace with the new o-ring
INJECTOR
● Assemble throttle body ass’y to air cleaner

connecting tube.
● Assemble throttle cable
● Adjust the freeplay of throttle grip
THROTTLEBODY
THROTTLE
THROTTLE BODY
BODY
INSPECTION OF SENSORS AND
ACTUATOR
MAPSENSOR
MAP
MAP SENSOR
SENSOR INJECTORCAP
INJECTOR
INJECTOR CAP
CAP
● Connect each sensor and actuator coupler
● Assemble fuel hose and injector cap
● Connect scanner(he diagnosis equipment ) and check
whether each sensor works regularly or not.
● Check idle speed actuator(ISA)
● Check throttle position sensor(TPS)
● Check MAPAT sensor
ISA
ISA
ISA
CAUTION
The checked value for TPS(throttle position sensor) after
TPS
TPS
TPS assembly shall be fit to the standard value.
ADJUSTMENT OF IDLE SPEED

ISA ADJUSTMENT
ISA
ISA ADJUSTMENT
ADJUSTMENT
SCREW
SCREW
SCREW ACUTATOR(ISA)
CAUTION
The ECU shall be always initialized before engine
starts.
● The vehicle is warmed up enough to adjusr the idling
speed.
● Connect scanner’s coupler to the coupler for
diagnosis of the vehicle.
● Check ISA value in the service data items by
pressing power button of scanner.
● If ISA value does not fit around 20%, adjust it using

the adjust screw to around 20% in 80~90°C of
engine temperature.
ISA ADJUSTMENT
ISA
ISA ADJUSTMENT
ADJUSTMENT
SCREW
SCREW
SCREW
INJECTOR CAP
INJECTOR
INJECTOR CAP
CAP INJECTORCOUPLER
INJECTOR
INJECTOR COUPLER
COUPLER
INJECTOR
DISASSEMBLY
● Open seat and disassemble maintenance cover
CAUTION
The key shall be OFF before disassembly.
FUELTUBE
FUEL
FUEL TUBE
TUBE
● After push injector coupler terminal and pull it

❷
❷ up, injector will be disassembled.
❶
❶
● Disassemble fuel hose

● Untie injector cap bolt
CAUTION
At disassembly, the engine shall be cooled.
- Be sure to check the engine is cooled because even a
little gasoline remains. If the engine is still hot, it
could cause fire or burnt.
If using the test of injector’s fuel spray, be sure to
disassemble the coupler of ignition coil.
- If the spark plug sparks, it could cause fire.
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
● Disassemble injector
● Check whether the fuel spray hole of injector is
cloggee or not.
INJECTOR
INJECTOR
INJECTOR
ASSEMBLY
● Assemble in the reverse order of disassembly.
CHECKING METHODS BY FAULT CODES

Checking of the Injector circuit
The fault code is displayed by MIL
Checking Circuit
40 : INJECTOR control
ECU 39 : FUEL PUMP control
INJECTOR FUEL PUMP RELAY
Coupler terminal is based on wire harness.

CHECKING PROCEDURE
1) Turn off the ignition key.
2) Check to see if the injector coupler has come loose or the wire is peeling off.
If there is no problem, measured the resistance of injector.
3)Disassemble the injector coupler and measure the resistance between injector terminals.
The resistance of injector : 14.5±0.7[ ], 20
Remarks : measuring unit for resistance : resistance ‘ R ‘ [ ]
4)If there is no problem, check the continuity between each terminal and ground.
The resistance between each terminal and ground : ∞[ ]
If resistance value is not normal, replace injector with the new one.
5)If the resistance is normal, turns on the ignition key
- If the fuel pump operated for 3 seconds, the power supply relay of injector is normal.
6) Measure between the voltage of coupler.
Measuring terminal : BLACK/RED electric wire ~ ground
Measuring voltage : battery voltage – 1.0[V]over
Remarks : Measuring unit of voltage : voltage [V]
7) If the measured voltage is normal,
Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited
or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40)
If there is no problem in the electric wires, ECU is broken
Replace the ECU with new one, it rechecks
8) If the measured voltage is not normal,
Check the Black/Red electric wire to see if they have been broken or have short-circuited.
Check the fuel pump relay.
9) After fault repaired, to erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
ISA
ISA
ISA MAPAT(Manifold Air pressure
sensor, Temperature sensor)
● MAPAT sensor is placed at the left side of throttle
body.
MAP SENSOR
MAP
MAP SENSOR
SENSOR TPS
TPS
TPS
TPS
DISASSEMBLY
● Disassemble MAPAT sensor coupler
CAUTION
The key shall be ‘OFF’ before disassembly.
❷
❷
❶
❶
● Untie 2 MAPAT sensor screws.
● Disassemble MAPAT sensor

● Check MAPAT sensor
DISASSEMBLY
● Install in the reverse order of disassembly.
MAP SENSOR
MAP
MAP SENSOR
SENSOR
Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit
Fault code number is displayed by MIL
The Fault code of intake pressure sensor The Fault code of intake temperature sensor
Checking circuit
MAPAT
33: Intake pressure sensor

: Inhalation pressureground
26 : 5V voltage
sensor GROUND
27
26 :IMP
: 5V voltage
ECU 28
27::TBA
IMP 28 : TBA
Coupler terminal is based on the side of wire-harness
CHECKING PROCEDURE
1) Turn off the ignition key .
2) Check to see if the MAPAT coupler has come loose or the wire is peeling off.
If there is normal, measured the input 5 voltage of MAPAT’s coupler.
3) Disassemble the coupler of MAPAT and turn on the ignition key
4) Measure the input voltage of MAPAT (intake pressure sensor + intake temperature sensor)’s coupler.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : MAPAT 3 terminal ~ MAPAT 1 terminal
Remarks : Measuring unit of voltage : voltage [V]
5) If voltage value is not normal,

Check to see if the ECU coupler is loose or if there is a bad contact.
Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ to see if they have been broken short-circuited
Remark : refer to (5-16) if the intake pressure sensor is broken
refer to (5-16) if the intake temperature sensor is broken
After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11).
CHECKING OF THE INTAKE PRESSURE

SENSOR
1) If voltage value is normal, turn off the ignition key.
Connect the MAPAT(intake pressure sensor + intake
temperature sensor) coupler
2) The wire-harness to check the ECU is connected with the

ECU with a wire-harness coupler.
Refer to how to assemble or disassemble the ECU ( 5-32 )
3) Turn on the ignition key. Start engine and operate idle.

4) Measure the voltage of intake pressure sensor for ECU Connect the wire harness to check
check.
Measuring the voltage of intake pressure sensor.
Measuring terminal : ECU No. 27(P/L:PINK/BLUE) ~ ¤¤¤
ECU No.3(P/G : PINK/GREEN)
Measuring voltage : 0.1[V] ~ 4.8[V] ¤Ł
¤Ł
Remarks : Measuring unit of voltage : Voltage [V]
The voltage of air pressure;
20[kPa]: 0.719 ~ 0.859[V]
107[kPa]: 4.154 ~ 4.294[V]

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’ ¤
electric wire to see if they have been broken or have
short- circuited.
¤Ł
Replace the MAPAT sensor with the new one and it
rechecks.
If measuring voltage is normal,

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P/L’ electric wire
to see if they have been broken or have short- circuited
if there is a bad contact.
badness of terminal No. 3, No. 26, No.27 of ECU coupler.
If the electric wire is no problem, ECU is broken.
Replace the ECU with the new one, it rechecks.
6) After repaired, refer to the fault code removal method to erase
the memorized fault code in the ECU.
CHECKING OF INTAKE TEMPERATURE SENSOR

1) If voltage value is normal, turn off ignition key.
2) Disassemble the MAPAT coupler and measure the resistance of
intake temperature sensor.
Resistance of intake pressure sensor : 2000±100[Ω], 25±1
Measuring terminal : ECU No. 28(P/B :PINK/BLUE) ~ ECU ¤¤
No. 3(P/G : PINK/GROUND)
Remarks : Measuring value for resistance : Resistance[ ]
The Voltage of air pressure; ¤Ł
¤Ł
24 ~ 26[ ] : 1800~2200[ ]
99 ~ 101[ ] : 161~206[ ]
3) If measuring resistance is not normal,
Replace the MAPAT sensor with new one and it rechecks.
¤
If the measured voltage is normal,
to see if they have been broken or have short- circuited ¤Ł
if there is a bad contact of terminal No. 3, No. 26, No. 27
of ECU coupler.
Replace the ECU with the new one, it rechecks.
4) Turn on the ignition key. Start the engine and idling.
5) Measure the voltage of intake pressure sensor for ECU check.
Measuring the voltage of intake pressure sensor ¤¤
- Measuring terminal: ECU No.28(TBA)
~ ECU No.3(IMP ground)
- Measuring voltage: 0.1[V] ~ 4.9[V] ¤Ł
¤Ł

Check the ‘P’ electric wire, ‘P/G’ electric wire, ‘P /L’
electric wire to see if they have been broken
or have short- circuited. ¤
Replace the MAPAT sensor with new one and it rechecks.
¤Ł
to see if they have been broken or have
short- circuited if there is a bad contact of terminal
No. 3, No. 26, No.28 of ECU coupler.
Replace ECU with the new one, it rechecks.
7) After fault repaired, To erase the memorized fault code in

the ECU is refer to how to remove the fault code(5-11).
ISA
ISA
ISA
ISA THROTTLE POSITION
SENSOR(TPS)
● TPS is placed at the left side of inside engine.
MAPSENSOR
MAP
MAP SENSOR
SENSOR THROTTLEPOSITION
THROTTLE
THROTTLE POSITION
POSITION
SENSOR
SENSOR
SENSOR
DISASSEMBLY
● Push and pull TPS coupler, disassemble
CAUTION
❷
❷ The key shall be ‘OFF’ before disassembly.
❶
❶
● Untie 2 TPS screws
● Disassemble TPS
● Check TPS
ASSEMBLY
THROTTLE
THROTTLE POSITION
THROTTLE POSITION
POSITION
SENSOR
SENSOR
SENSOR
CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM

Checking circuit
The coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off ignition key .
2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of TPS.
3) Disassemble the TPS coupler
4) Turn on the ignition key.
Input voltage : 4.5 ~ 5.5[V]
Measuring terminal : ECU NO.18(Gr/B : GRAY/BLACK) ~ ECU NO.4 (W/R : WHITE/RED)
Measure the terminal voltage of TPS’s coupler.
Measuring voltage : 4.5[V] ~ 5.5[V]
If voltage value is not normal,

Check to see if the ECU coupler is loose if there is bad contact.
Check the ‘GR/B’’ electric wire, ‘W/R’ electric wire, ‘GR /L’ electric wire to see if they have been
broken or have short- circuited.
5) If the value of voltage is normal, turn off the ignition key.

Checking Procedure
6) Check continuty between the Sensor Ground Terminal of
TPS and Earth.
The continuty TPS : 0~1.0[ ], 20±1

Measuring Terminal : ECU No. 4 (W/R : WHITE/RED)
~ EARTH
Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ ]
7) If not problem, measure the resistance of TPS.

By turning round throttle Lever, measure the resistance.
The resistance of TPS
If the throttle is totally closed : 0.9~1.6[k ], 20±1
If the throttle is totally opened : 2.3~2.6[k ], 20±1
Measuring Terminal : ECU No. 19 (Gr/L:
GRAY/BLUE) ~
ECU No.4 (W/R : WHITE/RED)
Remarks : Measuring value of resistance : Resistance[k ]
8) If resistance and the continuty are not abnormal.

Adjust correctly the position of TPS
Replace the TPS with the new one and re-check.
9) If resistance and continuty are normal, connect the

coupler of TPS.
11) Measure the TPS voltage of the wire-harness to check the
ECU.
Rotate the throttle lever, measure the voltage
Measuring terminal: ECU No. 19 (Gr/L:
GRAY/BLUE) ~
ECU No.4 (W/R : WHITE/RED)
Output voltage of TPS
-If the throttle is totally closed : 4.0~5.5 [V]
-If the throttle is totally opened : 0.1~0.6 [V]
Remarks : Measuring unit for voltage : Voltage [V]
12) If the measured voltage is abnormal,

Replace the TPS with the new one, and re-check.
Check the ‘GR/B’ electric wire, ‘GR/L’ electric wire, ‘W/R’
electric wire to see if they have been broken or have
short- circuited if there is a bad contact of terminal
No. 4, No. 18, No. 19 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, and recheck.
13) After fault repaired, To erase the memorized fault code in the
ECU is refer to how to remove the fault code (5-11).
TEMPERATURESENSOR
TEMPERATURE
TEMPERATURE SENSOR
SENSOR
E N G I N E T E M P E R AT U R E
SENSOR(ETS)
● Engine Temperature Sensor(ETS) is
positioned at cylinder.
DISASSEMBLY
● Press the coupler of Engine Temperature
Sensor(ETS) and pull it.
❷
❷
CAUTION
Before disassembling, the ignition key shall be
‘OFF’
❶
❶
● Disassemble ETS coupler

● Disassemble ETS
● Check ETS
ASSEMBLY
1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor)

CHECKING CIRCUIT
ETS
ECU 4 : SENSOR GROUND

50V SUPPLY VOLTAGE
20 : ETS
Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key .
2) Check to see if the ETS(Throttle Position Sensor) coupler is loose, or bad.
If there is no defect, measure the input voltage of ETS.
3) Disassemble the coupler of ETS
4) Turn on ignition key.
Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE)
~ ECU No.4 (W/R : WHITE/RED)
Measure the terminal voltage of ETS’s coupler.

Measuring voltage : 4.5[V] ~ 5.5[V]
Remarks : Measuring unit for voltage : voltage [V]
If the voltage value is not normal,

Check to see if the ECU coupler is loose, or bad contact.
Check the ‘G/L’’ electric wire, ‘W/R’ electric wire,
‘W/R’ electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.
6) Disassemble the coupler of ETS, and measure the resistance of ETS.
Resistance of ETS : 1.6[k ] ~ 10.6[k ], 20 ~ 80
Measuring terminal : Each terminal of ETS
Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [k ]
6-1) If the measured value is not normal,

Replace the ETS with the new one, recheck.
If the measured value is normal,

Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if
the ECU coupler is a bad contact ( No.4, No. 20.)
Replace ECU with the new one, recheck.
6-2) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code (5-11).
Checking Procedure-2
1) Disassembly
Disassemble the ETS(Engine Temperature Sensor) : (Refer to 5-27)
2) Check the ETS(Engine Temperature Sensor)
Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil.
Read the temperature of thermometer depending upon oil temperature’s change and tester’s value.
Characters of ETS
Temperature Resistance value

20℃ 10.6 kΩ~14.4 kΩ
80℃ 1.35 kΩ~1.65 kΩ
110℃ 0.57 kΩ~0.69 kΩ
Measuring unit of resistance : Resistance ‘ R ‘[k ]
If the value of resistance is high or out of the standard value, replace the ETS with the new one.
△
! CAUTION
1)Be careful do not fell down the ETS, because its weakness.
2)Be careful the ETS and the Thermometer do not to touched to oil bowl.
3)Be careful oil temperature will not raised more than measurement temperature.
3) Install
Install in the reverse order of removal with standard torque.
ETS torque : 3.0[kgf m]

ISA
ISA
ISA
ISA(IDLE SPEED ACTUATOR)
● ISA is located at the upper side of throttle body
DISASSEMBLY
● Push ISA coupler and disassemble it.
❷
❷ ❶
❶
CAUTION
Before disassembly, the key shall be “OFF”.
● Untie 2 ISA screws
● Disassemble ISA
ISA
ISA
ISA
ISA ● Inspect ISA
ASSEMBLY
CHECK THE ISA(Idle Speed Actuactor)

Showing of defects codes by MIL
CHECKING CIRCUIT
ECU
39::ISA
33 FUEL PUMP CONTROL
CONTROL
39:FUEL PUMP
40 : INJECTOR CONTROL
40 39
ISA FUEL PUMP RELAY

Coupler terminal is based on the side of the wire-harness
CHECK PROCEDURE
1) Turn off ignition key .
2) Check to see if the ISA(Throttle Position Sensor) coupler is loose,
or bad.If there is no defect, measure the input voltage of ISA
3) Disassemble the coupler of ISA, measure the resistance
between ISA terminals.
ISA resistance : 31.5~ 38.5[ ], 20
remarks : Measuring unit of resistance : Resistance ‘R’[ ]
4) If there is no problem, check about the level of electricity flow
ISA
ISA
ISA
ISA
between each terminal,
and between each ground.
Resistance between each terminal , and between each ground : ∞[ ]
If measure resistance value is not normal, replace with the new one
Disassembly and Assembly : refer to ( 5-29 )
remarks : Measuring unit for resistance : Resistance ‘R’[ ]
5) If the measured resistance and continuity are abnormal,
* Replace with new ISA and recheck.
6) If the resistance and continuity are normal, connect ISA coupler.
7) Turn on ignition key

8) Measure ISA voltage of wire-harness to check ECU.
Measuring terminal : B/R electric wire ~ EARTH
Output voltage of ISA : BATTERY VOLTAGE[V]
Remarks : Voltage measuring unit : Voltage [V]

Check the ‘B/R’ electric wire, ‘L/G’ electric wire, ‘W/R’ electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 33, No. 39 of ECU coupler.
If there is no problem in wires, ECU has broken down.
Replace ECU with the new one, recheck.
If the measured voltage is abnormal,

Check the ‘B/R’’ electric wire, ‘L/G’ electric wire, ‘W/B’ electric wire to see if they have been
9) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-11)
※Remove the faulty code of scanner

OXYGENSENSOR
OXYGEN
OXYGEN SENSORCOUPLER
SENSOR COUPLER
COUPLER
O2(Oxygen) SENSOR
● Assemble O2 Sensor to the muffler exhaust pipe.
● The coupler is located at the upper side of fuel
tank.
DISASSEMBLY
● Disassemble O2 sensor coupler.
CAUTION
The key shall be ‘OFF’ before disassembly.
OXYGENSENSOR
OXYGEN
OXYGEN SENSOR
SENSOR ● Disassemble O2 sensor installed at the muffler
exhaust pipe.
● Check O2 sensor
CAUTION
Handle with care because O2 sensor is fragile.
ASSEMBLY
OXYGENSENSOR
OXYGEN
OXYGEN SENSOR
SENSOR ● Install in the reverse order of disassembly.
1) CHECKING OF OXYGEN(O2) SENSOR CIRCUIT

Fault code number is displayed by MIL of the oxygen(O2)sensor lambda signal.
CHECKING CIRCUIT
OXYGEN SENSOR
2 : LAMBDA SENSOR GROUND

ECU 12 : OXYGEN SENSOR SIGNAL
34 : OXYGEN SENSOR HEATER
Coupler terminal is based on the side of Wire-Harness.
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

1) Turn off the ignition key.
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) Disassemble the coupler of oxygen(O2)sensor and turn on ignition key
4) Measure input voltage of oxygen(O2)sensor coupler
Input voltage : Battery voltage[V]
Measuring terminal (side of Wire-harness) : oxygen(O2)3 terminal of sensor coupler
(B/BR : BLACK/BROWN) ~ EARTH
Remarks : Measuring unit of voltage : Voltage[V]
CHECKING FOR A FAULT CODE BY OXYGEN(O2)SENSOR HEATER

If the voltage value is abnormal,
Check to see if the ECU coupler is loose or if there is bad contact.
Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been
5) If the voltage value is normal, turn off the ignition key.

Measure the Resistance of oxygen (O2) Sensor heater : about 9[ ], about 22
Measuring terminal (side of wire-harness) : oxygen(O2)3 terminal of sensor coupler
(B/BR : BLACK/BROWN) ~ ECU No.4(G/W :GREEN/WHITE)
Remarks : Measuring unit of Resistance : Resistance ‘R’[ ]
6) If the measured resistance is abnormal,

Replace the oxygen(O2)sensor with new one and recheck it.
If the measured resistance is normal,

Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if
they have been
If the electric wire is no problem, the ECU is broken.
Replace the ECU with new one, and recheck it.
CHECKING FOR A FAULT CODE

BY OXYGEN(O2)SENSOR LAMBDA SIGNAL
1) Turn off the ignition key
2) Check the O2(oxygen) coupler is loose, or bad.
If there is no defect, measure the input voltage of O2(oxygen)
3) The wire-harness to checck the ECU is connected to the ECU
with a coupler. refer to the ECU assembly/disassembly.
4) Turn on the ignition key

5) Measure the oxygen(O2)sensor voltage of wire harness to check ECU.
Measuring terminal: ECU No.12(V :VIOLET)
~ ECU No.2(V/B:VIOLET/BLACK)
Output voltage of oxygen(O2) sensor : 0.1~0.8[V]
Remark : Measuring unit of voltage : Voltage[V]
Assembly of oxygen(O2)sensor : 4.08 ~ 6.12[kgf

Check the ‘B/R’ electric wire, ‘V’ electric wire, ‘V/B’ electric wire to see if they have been broken or
have short- circuited if there is a bad contact of terminal No. 2, No. 12 of ECU coupler.
If there is no problem in wires, ECU is broken.

Check the ‘V’ electric wire, ‘V/B’ electric wire, ‘W/B’ electric wire to see if they have been
CHECKING OF ENGINE SPEED SIGNAL(ESS)CIRCUIT

CHECKING CIRCUIT
TACHOMETER
ECU
32 : ESS(ENGINE SPEED SIGNAL)
CHECK PROCEDURE
1) Turn off the ignition key
2) Check the ESS coupler is loose or bad.
If there is no problem, check the resistance of tachometer
3) If the resistance and continuity is normal, connect the tachometer coupler.
4) Turn on the ignition key
5) Measure the voltage of tachometer of wireharness for checking ECU.
Measuring terminal: B electric wire ~ G electric wire =>
Output Voltage: battery voltage
Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G electric
wire =>Output voltage: 9[V]~15[V]
Measuring terminal: ECU No. 32(B/Y: BLACK/YELLOW) ~ G
Measuring the output voltage of electric wire, using the PVA(peak
voltage adapter) multi-tester tool.
Remark : Measuring unit of voltage : Voltage[V]

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric wire to see
if they have been broken or have short- circuited if there is a bad
contact of terminal No. 32 of ECU coupler.
If there is no problem in wires, ECU has is broken.

Check the ‘B/Y’ electric wire, ‘B’ electric wire, ‘G’ electric
wire to see if they have been broken or have short- circuited.
6) After repairing fault, to erase the memorized fault code in the ECU, refer to how to remove the
fault codes(5-11)
CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT

CHECKING CIRCUIT ECU

24 : MALFUNCTION INDICATOR LAMP OUTPUT
MALFUNCTION INDICATOR LAMP(MIL)
CHECK PROCEDURE
1) Turn off ignition key.
2) Check the ESS coupler is loose, or bad.
If there is no problem.
4) Check the MIL on for 3 seconds when turn on the ignition key at the same time.
If there is no lighting, check the Lamp.
But If the Lamp is working for 3 second,
5) Measure the MIL voltage of wire harness to check ECU.
Measuring terminal : B electric wire ~ EARTH => Output
Voltage: battery voltage
Measuring terminal : ECU No.24(L/B :BLUE /BLACK) ~
EARTH => Output voltage:
battery voltage
Remarks : Measuring unit of voltage : Voltage[V]

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric wire to
see if they have been broken or have short- circuited if there
is a bad contact of terminal No. 24 of ECU coupler.
If there is no problem in wires, ECU has is broken.
Replace the ECU with new one, and rechecks it.

Check the ‘L/B’ electric wire, ‘B’ electric wire, ‘Br/L’ electric
wire to see if they have been broken or have short- circuited.
CKP(CRANK POSITION SENSOR)

● Remove the luggage box
● Remove ACG(crank position sensor) coupler
CAUTION
The ignition key shall be ‘OFF’ before disassembly
ACG COUPLER
ACG
ACG COUPLER
COUPLER
RH.CRANK
RH.
RH. CRANKCASE
CRANK CASECOVER
CASE COVER
COVER DISASSEMBLY
● Drain the cooling water and engine oil
● Disassemble RH. Crank case cover
● Untie 3 stator screws

CRANK POSITION SENSOR
● Untie 2 CKP(Crank position sensor) screws
AAACCCGGG
● Check ACG stator and crank position sesnsor

AAACCCGGG
CAUTION
Take precaution not to use the stator comp(18
terminals) like the carburetor type stator.
● Check the fly wheel.

● Fly wheel for the EMS system have 10 spots on
the fly wheel protrusion. It is different with
carburetor type.
● Check the mark or contamination on the
protrusion.
CAUTION
When replace the fly wheel, check the 10 spots of
protrusion part.
PROJECTED AREA
ASSEMBLY
● Assembly is the reverse order of removal.
MEASUREMENT RESISTANCE
CRANKPOSITION
CRANK
CRANK POSITIONSENSOR
POSITION SENSOR
SENSOR
● Disassemble AC. Generator coupler
● Measure the resistance between G and L.
STANDARD : 80~150Ω(20℃)
MEASUREMENT PVA
● Disconnect the ACG (L/G) connector.
● Connect the (+)cord of PVA tester to the green
terminal or ground wire.
● Connect the (-)cord of PVA tester to the blue
terminal.
● Crank the engine with the starter motor and
measure the peak voltage of crank position sensor
coil.
● HIGHEST VOLTAGE : 1.5V Over.
TOOL : PVA Multy tester.
● Assembly is the reverse order of removal.

CHECK THE CIRCUIT OF CKP

●Fault code number is displayed by MIL
CHECKING CIRCUIT
GREEN BLUE
녹색 청색
청색
BLUE 적색
RED
ECU PIN NUMBER

ECU 핀 번호
30 : CRANK SIGNAL-A 22 30
30 : 크랭크 신호 _ A
22 : 크랭크
22 : CRANK 신호 _ B
SIGNAL-B
CHECK PROCEDURE
1) Turn ON ignition key.
Before starting
2) Check to see if the ENGINE SINK ON is ON or OFF with
diagnosis tool.
When start up the ENGINE SINK ON change “OFF’ to “ON”,
it’s okay.
Check if ENGINE SINK ON is OFF while start up.
- Remove the A.C. generator.
- If there are over 10 spots on the flywheel protrusion, replace it.
- Check the CKP is working or NOT (metal residue)
3) Turn OFF ignition key, check the breaking of A.C GEN CKP.
Check the A.C. GEN CKP resistance. After starting
- measuring resistance : 80 ~ 150[Ω]
4) Check if crank signal A,B wires is breaks or not.

Remove the ECU, connect wire harness for inspection to wire
harness of vehicle.
Check the wiring of crank signal A
¤Ł
¤Ł
- Measure terminal : No. 30 pin of wire harness for inspection - ¤¤¤
Red wire of coupler of CKP.
- Measuring resistance : 0 ~ 1[Ω]
Check the wiring of crank signal B ¤

- Measure terminal : No. 22 pin of wire harness for inspection -
Blue wire of coupler of CKP. RED
- Measuring resistance : 0 ~ 1[Ω] ¤Ł
5) After fault repaired, to erase the memorized fault code in the ¤Ł

¤Ł
ECU is refer to how to remove the fault code.(5-11) ¤¤
BLUE
¤Ł
FUEL PUMP
● The fuel pump is located inside fuel tank
CAUTION
The ignition key shall be ‘OFF’ before disassembly.
DISASSEMBLY
FUELHOSE
FUEL
FUEL HOSE
HOSE ● Disassemble fuel tube
● Disassemble fuel pump coupler
FUELPUMP
FUEL
FUEL PUMPCOUPLER
PUMP COUPLER
COUPLER
● Untie 7 flange nuts and disassemble fuel pump
● Disassemble fuel pump

FUELPUMP
FUEL
FUEL PUMP
PUMP ● Check fuel pump
CHECK FUEL PUMP
The terminal arrangement of the fuel pump

(The following color chart is the internal color of the fuel pump)
Measure the resistance between terminals.
Float position Resistance between terminals [Ω]
F : 128.5[mm] 40 ± 5[Ω]
1/2 : 83.5[mm] 220 ± 5[Ω]
E : 28.5[mm] 400 ± 3[Ω]
The float position is based on tank bottom plate.

Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND)
wire of fuel unit terminal
※ Remark : measuring unit of resistance : resistance[Ω]

If the measured resistance value is out of standard at float position, replace the fuel unit.

CHECK THE BLOW PRESSURE OF FUEL PUMP

- Blow pressure : 3.8 Bar
- After remove fuel tube from the injector, turn the ignition key ON/OFF 3 times, when the fuel come
out about 130cc over, it’s Okay.
If under 130cc, check the fuel pump. Replace it if necessary.
(Be sure to the resistance of battery is over 12.6V)
ASSEMBLY
Assembly is the reverse order of removal.
FUEL TANK
DISASSEMBLY
CAUTION
Gasoline is very volatile, then during repairing,
caution inflammables or use of fire strictly
prohibited. Also, evaporated gasoline may cause
explosion then repairing shall be recommendable in
the place having good air circulation.
● Disassemble the following parts

- luggage box
- body cover
- floor panel
- inner box
● Untie 4 flange nuts installed at fuel tank
● Disassemble the fuel pump coupler

● Disassemble fuel hose and breather tube.
FUELPUMP
FUEL
FUEL PUMP
PUMP
● Disassemble fuel tank
● Diassemble tube clip in fuel supply tube and
separate it from fuel tank
● Check fuel tank. If it damaged, replace with the
new one.
Capacity of fuel tank : 11.5 L
BREATHER TUBE
BREATHER
BREATHER TUBE
TUBE Reserve capacity(capacity of caution lamp) :
1.9 L
ASSEMBLY
FUEL SUPPLY
FUEL
FUEL SUPPLY TUBE
SUPPLYTUBE
TUBE
● Asssemble in the reverse order of disassembly
● After assembly, check whether gasoline leaks out
or not.
TUBECLIP
TUBE
TUBE CLIP
CLIP
MEMO
COOLING SYSTEM
6. COOLING SYSTEM
SERVICE INFORMATION 6-1 WATER PUMP 6-7
TROUBLE SHOOTING 6-2 WATER DAMPER GAUGE 6-11
COOLANT 6-3 THERMOSTAT ASS’Y 6-12
RADIATOR 6-4
SERVICE INFORMATION
CAUTION
•Do not remove radiator cap if the temperature of coolant may over 100°C, it is very dangerous removing the cap
while the eninge is hot and the coolant is under pressure may cause serious scalding. Then if the temperature
decrease, open with care by wrapping it with piece of cloth.
•The repairing of cooling system shall be done at cooling time.
•Cooling liquid is toxic, keep it away from skin, eyes and cloths.
- If any coolant gets on your skins or cloths, rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them with water and consults a doctor immediately
- If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately.
- Especially pay attention to reserve the coolant. Keep out of reach of children.
•Do not remove the radiator cap, except to refill or drain the cooling system after servicing the cooling system.
•Avoid spilling coolant on painted surfaces, if contaminated, do wash in water immediately.
•After disassembling or servicing the cooling system, check for leaks with a radiator cap tester(saleat a market)
SPECIFICATIONS
ITEM STANDARD VALUES REMARKS
RADIATOR CA[ RELIEF PRESSURE 0.9±0.15kg/cm2
BEGIN TO OPEN 80±2° C
THERMOSTAT
FULLY OPENED 90±3° C
TEMPERATURE
VALVE LIFT 3.5~4.5mm
COOLANT CAPACITY Full : 1,500cc
TORQUE
WATER PUMP IMPELLER : 1.0~1.4 kgf m
WATER PUMP COVER BOLT : 1.0~1.2kgf m
COOLING SYSTEM
TROUBLESHOOTING
Engine temperature too high
Faulty temperature gauge or thermo sensor

Air in cooling system
Faulty thermostat stuck (Thermostat stuck closed)
Passages blocked in radiator, hoses or water jacket
Faulty fan motor switch
Faulty water pump
Engine temperature too low or unstable
Faulty temperature gauge or thermo sensor

Faulty thermostat stuck (Thermostat stuck open)
Faulty fan motor switch
Coolant leaks
Faulty water pump mechanical seal

Damaged or deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated gasket
Loose hose connection or clamp
COOLING SYSTEM
COOLANT
COOLANT INSPECTION RADIATOR
Radiator coolant mixes the distilled water. WATER
Standard consistenly : 30~50%
Coolant mixes the light water and radiator liquid

COOLANT
about 5°C of tolerance inrespect to the minimum
temperature.
RADIATOR COOLANT MIXTURE CHART
(ANTICORROSIVE AND ANTIFREEZE)
Radiator coolant is toxic. Keep it away from When the whole capacity of coolant is 2000cc
(Unit:cc)
skin, eyes and clothes. Minimum temperature Mixture Ratio Distilled water
- If any coolant gets on your skin or clothes,
-9°C 20% 400 1,600
rinse thoroughly with soap and water.
- If any coolant gets in your eyes, rinse them -16°C 30% 600 1,400
with water and consults a doctor immediately. -25°C 40% 800 1,200
- If any coolant is swallowed, induce vomiting, -37°C 50% 1,000 1,000
gargle and consult a physician immediately. -44.5°C 60% 1,100 900
- Especially pay attention to reserve the coolant.
Keep out of reach of children.
HYDROMETER
(Sale at a market)
COOLING SYSTEM INSPECTION
SPECIFIC GRAVITY TEST OF COOLANT
Follow the hydrometer manufacturer’s instructions.
Check the coolant specific gravity using a hydrometer.

Check the contamination of the coolant.
COOLANT GRAVITY CHART
5 1.009 1.009 1.008 1.009 1.007 1.006 1.005 1.003 1.001 0.999 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.049 0.047 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
COOLING SYSTEM
RADIATOR
CHECKING RADIATOR
●Disassemble front under cover A
●Disassemble front under cover B
FRONT
FRONT UNDER
FRONT UNDER
UNDER
COVER BBB
COVER
COVER
●Check leakage from the depths and welding points of

radiator.
RADIATOR
COOLING WATER DISASSEMBLY

DRAIN BOLT ●Drain cooling water
●Disassemble reserve tank cap

RESERVETANK
RESERVE
RESERVE TANK
TANK
COOLING SYSTEM
●Untie 3 flange bolts installed at radiator
FLANGE BOLT
FLANGE
FLANGE BOLT
BOLT
●Disassemble inner box

RADIATORFAN
RADIATOR
RADIATOR FANTHERMO
FAN THERMO
THERMO
SWITCH
SWITCH
SWITCH
●Disassemble fan motor coupler
●Disassemble radiator fan thermo switch coupler
●Disassemble water hose B,C
●Diassemble water path tube ass’y and water path tube
B
FAN
FAN MOTOR
FAN MOTOR
MOTOR
●Disassemble radiator comp
●Disassemble fan motor

●Check whether fan motor rotates or not by connecting
with battery
COOLING SYSTEM
RADIATOR FAN
RADIATOR
RADIATOR FAN THERMO
FAN THERMO
THERMO
CHECK RADIATOR FAN THERMO
SWITCH
SWITCH
SWITCH SWITCH
●Check radiator fan thermo switch.
●If the temperature of cooling water is over 87°C,
Resistance value : 0~1 (open)
ASSEMBLY OF RADIATOR
●Assemble 3 flange bolts
●Assemble radiator B,C

●Assemble radiator fan thermo switch and fan motor
coupler
●Assemble water path tube
●Put ino colling water
CAUTION
•Replenish fully cooling water to the entrance of inlet.
●Do snapping 3~4 times by idling the engine for a few

minutes and pull out air in cooling system
●By checking the capacity of cooling water in reserve
UPPER
UPPER
UPPER
UPPER tank, if insufficient, replenish cooling water to the
LOWER
LOWER
upper limit.
LOWER
LOWER
COOLING SYSTEM
●Disassemble inner box

●Assemble front under cover A,B
WATER PUMP
WATERLEAKAGE
WATER
WATER LEAKAGE
LEAKAGE CHECK WATER SEAL
CHECKING HOLE
CHECKING
CHECKING HOLE
HOLE ●Check at checking hole whether cooling water leaks
or not from mechanical seal
●If cooling water leaks from mechanical seal,
diassemble water pump body and check mechanical
seal, replace.
WATER PUMP / IMPELLER DISASSEM-

BLE
●Pull out cooling water
●Untie 3 flange bolts installed at water pump cover
●Diassemble radiator hose
WATERPUMP
WATER
WATER PUMPCOVER
PUMP COVER
COVER
●Disassemble water pump impeller

GASKET
CAUTION
•Because impeller is left-handed screw, untie to the
reverse way of clockwise rotation
IMPELLER
COOLING SYSTEM
●Disassemble IN, EX cir clips

WATER PUMP SHAFT ●Disassemble water pump shaft
EXCIRCLIP
EX
EX CIRCLIP
CIRCLIP IN CIRCLIP
●Diassemble mechanical seal

RH. CRANK CASE COVER
MECHANICAL SEAL
●Check about the abrasion and damage of mechanical

WATER PUMP seal
IMPELLER ●Inspect shaft, bearing
WASHER CAUTION
MECHANICAL SEAL •Assemble mechanical seal
•Assemble bearing and shaft and IN, EX circlips
WATER PUMP
SHAFT EX CIRCLIP(12mm)
BEARING IN CIRCLIP(28mm)
●Assemble mechanical seal

●Assemble bearing and shaft and IN, EX circlips
COOLING SYSTEM
●Assemble impeller
●Assemble new gasket and dowel pins
DOWELPIN
DOWEL
DOWEL PIN
PIN
●Assemble water pump cover

●Replenish cooling water
●Check whether cooling water leaks or not

COOLING SYSTEM
WATERDAMPER
WATER
WATER DAMPER
DAMPER
WATER TEMPERATURE
GAUGETERMINAL
GAUGE
GAUGE TERMINAL
TERMINAL GAUGE
●Disassemble terminal of water temperature gauge
●Disassenble water temperature gauge
WATER DAMPER
GAUGE
TEMPERATURE CHECK WATER TEMPERATURE

GAUGE GAUGE
●Pull water temperature gauge into water, heat water
and measure the resistance
TEMERATURE( ) 50 80 100 120
RESISTANCE( ) 154 52 27 16
●Apply waterproof agent and assemble water tempera-

ture gaue.
●Connect the terminal of water temperature gauge
COOLING SYSTEM
WATER DAMPER
WATER
WATER DAMPER GAUGE
DAMPER GAUGE
GAUGE THERMO STAT
DISASSEMBLY OF THERMO STAT
●Disassemble thermo stat and water hose
●Untie 2 bolts and disassemble thermo stat cap
THERMOSTAT
THERMO
THERMO STATCAP
STAT CAP
CAP
●Disassemble thermostat from thermostat cap

THERMO STAT CAP
CHECK THERMOSTAT
THERMO STAT ASS’Y
●Put thermostat into water of test vessel and increase
water temperature, check the temperature at the time
of opening of thermostat.
TEMPERATURE GAUGE
OPEN(TO BEGIN) 80±2°C
FULLY OPENED 90±3°C
VALVE LIFT 3.5~4.5mm
CAUTION
•Replace thermostat when it opens even a little at high
temperature
•Because the size of thermostat is small then its open-
ing may take late, check changing lift by obtaining 5
minutes before or after at opening temperature
•Be careful the thermostat, temperature gauge not to
THERMO STAT ASS’Y
be touched to the bottom of vessel
ASSEMBLY OF THERMOSTAT
●Assemble in the reverse order of disassembly
CAUTION
•At assembly, assemble for hole position of airvent is
upward.
ENGINE DISASSEMBLY / ASSEMBLY
7. ENGINE DISASSEMBLY / ASSEMBLY
SERVICE INFORMATION 7-1 ENGINE ASSEMBLY 7-3

ENGINE DISASSEMBLY 7-2
SERVICE INFORMATION
CAUTION
•Use a jack to remove or install the engine. Support the scooter with a jack firmly, taking precautions not to damage
the frame, engine, cable or harness.
•Attach the tape to the frame to protect it during the engine removal or installation.
•The following works can be done without disassembly of the engine.
- TRANSMISSION( chapter 12)
- OIL PUMP( chapter 4)
- AC. GENERATOR( chapter 9)
- CVT( chapter 8)
- CYLINDER HEAD, CYLINDER, PISTON( chapter 10,11)
- EX. MUFFLER( chapter 3)
- THROTTLE BODY( chapter 5)
- REAR SWING ARM( chapter 13)
•The following works is done after disassembly of the engine.
- CRANKSHAFT, CRANKSHAFT BEARING, CRANK CASE BEARING
•The capacity of engine oil : 1.3L(at disassembly)
TORQUE VALUES :
TORQUE(upper) 5.0~5.5kgf m
(lower) 4.0~5.0kgf m
RADIATOR HOSE
RADIATOR
RADIATOR HOSE
HOSE ENGINE DIASSEMBLY
●Pull out the cooling water
●Disassemble the following parts
- LUGGAGE BOX( 3-3)
- CENTER COVER( 3-4)
●Diassemble the coupler connected to the wire harness
of AC generator and the cable of starter motor.
MUFFLER ●Disassemble the muffler( 3-10)
REARWHEEL
REAR
REAR WHEELMUD
WHEEL MUDGUARD
MUD GUARD
GUARD
SWING ARM
SWING
SWING ARM
ARM ●Disassemble rear brake caliper( 15-8)
●Untie the under bolt installed at RH. Rear cushion.
REAR BRAKE
REAR
REAR BRAKECALIPER
BRAKE CALIPER
CALIPER
●Disassemble rear swing arm

●Disassemble rear wheel mud guard.
REARCUSHION
REAR
REAR CUSHION
CUSHION
●Disassemble TPS, ISA, Map sensor coupler

●Disassemble throttle body
●Disassemble air cleaner
ENGINEHANGER
ENGINE
ENGINE HANGERLINK
HANGER LINKASS’Y
LINK ASS’Y
ASS’Y ●Untie LH. Rear cushion under bolt.
ENGINEHANGER
ENGINE
ENGINE HANGER
HANGER
●Lift up slight,ly the rear part of frame, then pull out the
BOLT
BOLT
BOLT flange bolt after assembling the engine hanger,
disassemble the frame and engine.
REAR CUSHION
ASSEMBLY OF ENGINE
CAUTION
•Be careful for wires, calbes not to be damaged.
•Be careful for the screws of bolts not to be damaged
•Cables, tube and wires shall be placed at right
positions.
TORQUE : Engine hanger bolt : 4.5 §‚f¡⁄m
●Check the followings after assembly of engine

- ENGINE OIL, COOLING WATER
- Checking the electrical parts
LH. CRANK CASE COVER /BELT TYPE CONTINUOUSLY TRANSMISSION
8. LH. CRANK CASE COVER /BELT TYPE CONTINUOUSLY TRANSMISSION
SERVICE INFORMATION 8-1 DRIVE BELT 8-2

TROUBLE SHOOTING 8-1 DRIVEN PULLEY ASS’Y 8-4
LH. CRANK CASE COVER 8-2 MOVABLE DRIVE FACE 8-9
SERVICE INFORMATION
CAUTION
•Take precautions not to apply grease or oil to drive belt or the surface of pulley.
•Take precautions not to apply oil to the movable drive face, weight roller.
SPECIFICATIONS
UNIT : mm
ITEM STANDARDS SERVICE LIMIT
MOVABLE DRIVE FACE BUSHING INNER DIAMETER 24.000-24.013mm 24.05mm
DRIVE FACE BOSS OUTER DIAMETER 23.980-23.993mm 23.960mm
DRIVE BELT WIDTH 22mm 20.5mm
WEIGHT ROLLER OUTER DIAMETER 19.95-20.02mm 19.5mm
CLUTCH OUTER INNER DIAMETER 120.0-120.2mm 120.5mm
DRIVEN FACE SPRING FREE PLAY 97.85mm 90.00mm
DRIVEN FACE OUTER DIAMETER 37.965-37.985mm 37.94mm
MOVABLE DRIVEN FACE INNER DIAMETER 38.0-38.025mm 38.060mm
TROUBLE SHOOTING
Engine starts but scooter does not work

•Drive belt worn
•Ramp plate damaged
•Clutch weight shoe worn or damaged
•Driven face spring cut
Engine stops or the vehicle suddenly runs after starting

•Clutch weight shoe spring cut
Vehcile unable to run at the maximum speed or lack of output power

•Drive belt worn
•Defect of driven face spring
•Weight roller worn
•Contamination of the face of pulley.
LH. CRANK
LH.
LH. CRANK CASE
CRANK CASE
CASE
LH. CRANK CASE
COVER
COVER
COVER COVER
● Untie flange bolt installed at LH. Crank case cover
●Disassemble LH. Crank case cover

CAUTION
•Fasten alternately and obliquely at assemblying bolts.
DRIVE FACE DRIVENPULLEY

DRIVEN
DRIVEN PULLEY
PULLEY
CLUTCH
CLUTCH OUTER
CLUTCH OUTER
OUTER DRIVE BELT
DISASSEMBLY
●Untie driven pulley flange nut by using of universal
holder
TOOL : Universal holder
DRIVE BELT
●Like the left photo, hang drive belt and disassembke

belt from drive face.
●Disassemble belt from driveb pulley.
INSPECTION
●Check crack, aging, abnormal abrasion of drive belt,
and if necessary, replace it.
COCK ●Measure the width of drive belt
SERVICE LIMIT : 20.5mm
WIDTH
CAUTION
•At replacing, use the genuine parts.
•Take precautions not to apply greases on the contact
position of pulley of belt.
ASSEMBLY
DRIVEN
●Like left photo, rotate the driven pulley sub ass’y to
PULLEY the right way, widen inside touching place and
assemble drive belt to driven pulley sub ass’y.
●Assemble driven belt to the assemble area of

movable drive face.
●Assemble driven pulley ass’y to drive shaft.
●Assemble temporarily flange nut to driven pulley.

●Fix the universal holder to clutch outer hole and
assemble flange nut by designated torque.
TORQUE : 5.0~6.0 kgf¡⁄m
CAUTION
•Take precaution for the movable drive face not to be
rotated by original position until driven pulley sub
ass’y is assembled completely to drive shaft.
DRIVEN PULLEY ASS’Y

DIASSEMBLY
●Disassemble driven pulley ass’y
●Disassemble drive belt
SPECIAL NUT CLUTCH SPRING COMPRESSOR DISASSEMBLY

●Untie 26mm special nut
TOOL : CLUTCH SPRING COMPRESSOR
LOCK NUT WRENCH
DRIVE PLATE ASS’Y ●Disassemble drive plate ass’y
DRIVEN FACE ASS’Y
DRIVEN FACE SPRING SPRING COLLAR ●Disassemble driven face spring

SEAL COLLAR
●Disassemble spring collar
DRIVEN FACE ASS’Y

DRIVE PLATE ASS’Y CLUTCH OUTER
●Diassemble seal collar.

SEAL COLLAR
DRIVEN FACE ASS’Y
GUIDE PIN
GUIDE ROLLER PIN ●Disassemble roller guide pin
GUIDE PIN
GUIDE ROLLER
DRIVEN FACE
●Disassemble movable driven face

ROLLER GUIDE PIN
●Disassemble O-ring from movable driven face.

OIL SEAL O-RING
●Diassemble oil seal from movable driven face.
MOVABLE DRIVEN FACE

CHECKING DRIVEN FACE

NEEDLEBEARING
NEEDLE
NEEDLE BEARING
BEARING
●Check whether there is clattering or damage in
needle bearing. Also, check whether there is
abnormal sound or clattering between outer race and
shaft, by turning the inner race of ball bearing(outer
side with hand.
●Check free elasticity of driven face spring

DRIVEN FACE SPRING
TOOL : VERNIER CAPLIERS
FREE PLAY
●Check whether ther is damage or abrasion of clutch

CLUTCH OUTER outer.
●Measure the inside diameter of outer clutch.
●Check on the damage or abrasion of clutch shoe.

●Meause the thickness of each shoe.
CLUTCH SHOE
●Check damage or abrasion of movable driven face

●Check on abrasion of the end-plate of guide home of
movable driven face.
●Measure inside diameter of movable driven face.
MOVABLE DRIVEN
FACE
●Check on damage or abrasion of driven face.

●Measure outer diameter of driven face
SERVOCE LIMIT : 33.94mm
DRIVEN FACE
ASSEMBLY
GUIDE PIN ●Assemble oil seal, O-ring to movable driven face
●Assemble movable driven face to driven face
●Assemble guide roller and roller pin
●Assemble seal collar
ASSEMBLY OF DRIVEN PULLEY SUB

ASS’Y
●Assemble spring guide and driven face, drive plate
ass’y.
LOCK NUT WRENCH

●Compress the length of special nut to 28mm by
clutch spring compressor.
LOCK NUT ●Fix the clutch spring compressor by vice like the left
picture, assemble lock nut as the designated torque
by using lock nut wrench.
●Remove spring compressor
TORQUE : 5.0~6.0kgf m
TOOL : LOCK NUT WRENCH, CLUTCH SPRING
COMPRESSOR.
CLUTCH SPRING
COMPRESSOR
ASSEMBLY OF DRIVEN PULLEY

ASS’Y
●Assemble driven pulley to drive shaft
●Assemble temporarily flange nut.
●Assemble temporarily flange nut to driven pulley

●Fix to cultch outer hole by universal holder,
assemble flange nut as designared torque.
●Assemble LH. Crank case cover.
CAUTION
•Take precaution for drive face not to return to its
original position by the time that driven pulley sub
ass’y will be assemble completely to drive shaft.
DRIVE FACE
DRIVE
DRIVE FACE
FACE MOVABLE DRIVE FACE
DIASSEMBLY
●Disassemble LH. Crank case cover( 8-2)
●Fix drive face holder to drive face.
TOOL : DRIVE FACE HOLDER
●Disassemble drive face nut, rear axle collar, drive

DRIVE FACE
DRIVE
DRIVE FACE BOSS
FACE BOSS
BOSS face
●Disassemble movable drive face from drive face
boss.
MOVABLEDRIVE
MOVABLE
MOVABLE DRIVEFACE
DRIVE FACE
FACE
●Disassemble lamp plate, weight roller, oil seals from

SLIDE PIECE WEIGHT ROLLER FACE BOSS movable drive face.
LAMP PLATE
INSPECT
●Check abrasion and damage of weight roller.
●Measure outer diameter of weight roller.
●Measure side worn.
SERVICE LIMIT : within 2mm
●Check damage and worn oil seal of movable drive

DRIVE FACE BOSS
face boss.
●Measure the outer diameter of movable drive face
boss.
●Measure the inner diameter of movable drive dace
bushing.
MOVABLE DRIVE FACE
ASSEMBLY
LAMP PLATE ●Assemble weight roller to movable drive face.
●Assemble movable drive face boss.
CAUTION
•Do not apply grease to the pulley side of movable
drive face.
OIL SEAL •Remove grease if aplplying.
WEIGHT ROLLER
●Assemble movable drive face boss and movable

drive face to LH. Crank case shaft.
●Assemble drive face to LH. Crank shaft.
DRIVE FACE
●Assemble rear axle collar

REARAXLE
REAR
REAR AXLECOLLAR
AXLE COLLAR
COLLAR
●Assemble temporarily flange nut to drive face.
●Fasten it as the designated torque by using drive face

holder.
TOOL : Drive face holder
CAUTION
•Assemble by the designated torque
●Assemble LH. Crank case cover( 8-2)

AC. GENERATOR /FLY WHEEL
9. AC. GENERATOR /FLY WHEEL
SERVICE INFORMATION 9-1 AC. GENERATOR 9-2

SERVICE STANDARDS 9-1 FLY WHEEL 9-3
SERVICE INFORMATION
This section describes the removal and assembling of the A.C. generator
For the information of A.C. generator inspection, refer to the section 16.
The charging systme can be maintained without removing the engine.
SERVICE STANDARDS
ITEM STANDARDS USAGE LIMIT
OUTER DIAMETER 39.622 ~ 39.635 39.607
STARTER DRIVEN GEAR
INNER DIAMETER 22.010 ~ 22.022 22.100
REDUCTION GEAR INNER DIAMETER 10.013 ~ 10.045 10.100
REDUCTION GEAR SHAFT OUTER DIAMETER 9.991 ~ 10.000 9.97
TORQUE
FLY WHEEL NUT 6.0~6.7kgf m
RH. CRANK CASE COVER BOLT 1.0~1.2kgf m
TOOL
A.C.G. ROTOR PULLER
RH.CRANK
RH.
RH. CRANKCASE
CRANK CASECOVER
CASE COVER
COVER AC. GENERATOR
DISASSEMBLY
●Disassemble EX. Pipe cover
●Untie flange bolt installed at RH. Crank case cover.
●Drain engine oil and cooling water
●Disassemble the connection of AC. Generator coupler

ACG COUPLER
ACG
ACG COUPLER
COUPLER and RH. Crank case cover.
●Untie the screw installed at ACG. Stator.

●Disassemble ACG. Stator comp
●Check the damage or broken of wires by checking

ACG. stator.
●Assemble stator
REDUCTION GEAR
REDUCTION
REDUCTION GEAR
GEAR FLY WHEEL
●Disassemble RH. Crank case
●Disassemble dowel pin and gasket
FLYWHEEL
FLY
FLY WHEEL
WHEEL
●Disassemble fly wheel lock nut
●Disassemble fly wheel from crank shaft by using of

ACG. Rotor puller.
TOOL : ACG. ROTOR PULLER
●Disassemble fly wheel and starter driven gear collar
STARTER DRIVEN
STARTER
STARTER DRIVEN
DRIVEN
GEAR COLLAR
GEAR
GEAR COLLAR
COLLAR
●Disassemble reduction gear and shaft
CHECKING REDUCTION GEAR

●Check on abrasion and damage of reduction gear
●Measure inner diameter of reduction gear
●Measure the outer diameter of reduction gear shaft

REDUCTION GEAR REDUCTION SHAFT
DISASSEMBLY
SOCKET BOLT
●Disassemble fly wheel
●Untie 3 socket bolts and disassemble starter
clutch(one way clutch) from fly wheel.
STARTER DRIVEN
GEAR
FLY WHEEL COMP
●Measure on damage and abrasion of starter driven

gear
●Measure inner and outer diameters of driven gear
INNER
INNER
INNER
DIAMETER
DIAMETER
DIAMETER
SERVICE LIMIT
Outer diameter : 39.607 mm
Inner diameter : 22.100 mm
OUTER
OUTER
OUTER
DIAMETER
DIAMETER
DIAMETER STARTER DRIVEN GEAR
STARTER ONEWAY ASSEMBLY

CLUTCH ASS’Y
●Check on abrasion and damage of one way clutch
●Asssmble one-way clutch to fit to fly wheel
●Apply screw locking adhesive to starter clutch socket
bolt.
●Assemble starter driven gear
TORQUE : 3.2kgf m
FLY WHEEL
●Grasp fly wheel and rotate starter driven gear so that it

rotates well like the left picture.
REDUCTIONGEAR
GEAR
●Assemble reduction gear
REDUCTION
REDUCTION GEAR
●Assemble fly wheel

LOCKNUT
LOCK
LOCK NUT
NUT
FLY
FLY WHEEL
FLY WHEEL
WHEEL ●Assemble temporarily lock nut
●Assemble lock nut

●Assemble RH. Crank case
CAUTION
•Fix completetly to the home position of grommet
●Assemble ACG. Coupler

●Put into engine oil and cooling water.
MEMO
CYLINDER HEAD / VALVES
10. CYLINDER HEAD / VALVES
SERVICE INFORMATION 10-1 DISASSEMBLY OF CYLINDER HEAD 10-5

SERVICE STANDARDS 10-1 REPLACEMENT OF VALVE GUIDE 10-6
TROUBLE SHOOTING 10-2 CHECK AND ADJUSTMENT OF VALVE SEAT 10-7
DISASSEMBLY OF CAM SHAFT 10-3 ASSEMBLY OF CYLINDER HEAD 10-8
DISASSEMBLY OF CYLINDER HEAD 10-4 INSTALLATION OF CYLINDER HEAD 10-9
SERVICE INFORMATION
CAUTION
The rocker arm and the camshaft can be served without removing the engine. If cylinder head was repaired already, the
engine shall be taken out from the frame.
The oil of camshaft oil is supplied through the cylinder head oil hole. Then, clean th oil hole prior to assembling the
cylinder head.
SPECIFICATIONS
UNIT: mm
IN. 31.6±0.08 (32.02~32.18) 31.40

CAM HEIGHT
EX. 31.8±0.08 (31.72~31.88) 31.60
VALVE SPRING FREE LENGTH IN., EX. 41.4 40.0
VALVE STEM OUTER IN. 4.975~4.990 4.925
DIAMETER EX. 4.955~4.970 4.905
VALVE GUIDE INNER DIAMETER IN., EX. 5.000~5.012 5.03
CLEARANCE BETWEEN IN. 0.010~0.037 0.08
STEM AND GUIDE EX. 0.030~0.057 0.10
VALVE SEAT WIDTH 0.7~0.9 1.3
TIGHTENING TORQUE
SPARK PLUG 1.6 kgf-m
CYLINDER HEAD SPECIAL SOCKET NUT 4.0 kgf-m
CAM CHAIN TENSIONER PIVOT BOLT 1.0 kgf-m
CAM CHAIN TENSIONER LIFTER BOLT 1.2 kgf-m
CAM CHAIN TENSIONER LIFTER SCREW 0.4 kgf-m
CYLINDER HEAD COVER BOLT 1.1 kgf-m
AC GENERATOR CAP 0.6 kgf-m
TOOL
SPECIAL TOOL
- VALVE GUIDE REAMER
- VALVE GUIDE DRIVER
COMMON TOOL
- VALVE SPRING COMPRESSOR
- VALVE SEAT CUTTER
TROUBLE SHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down
test or by tracing noises to the top-end with a sounding rod or stethoscope.
Low compression
Valves
- Incorrect valve gap adjustment
- Valve spring damaged
- Incorrect valve timing
- Uneven valve seating
Excessive white smoke

Worn valve guide or valve stem
Damaged valve stem seal
Worn or damaged piston ring
Rough idle
Low cylinder compression
Bad fuel system(chapter 5)
Compression too high

Excessive carbon build-up on piston or combustion chamber
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
DIASSEMBLY OF CAM
SHAFT
●Untie 4 cylinder head cover special bolts and disas-
semble cover.
●Untie cam chain tesnsioner screw, tensioner flange
bolt and disassemble tensioner
CYLINDER HEAD COVER
●Disassemble ACG cap from RH. Crank case cover.

DRIVEN FACE
DRIVEN
DRIVEN FACE
FACE ACG CAP ●Disassemble CVT dust cover of LH. Crank case
cover.
●Rotate crank shaft and square “T” mark of fly wheel

with the index mark of RH. Crank case cover.
●Check whether piston is positioned in the compressed
upper line.
●If the teeth of cam is not toward outside, rotate crank
shaft and fit it with “T” mark.
INDEX MARK
●Disassemble cam chain guide B.

CAM SHAFT
CAM
CAM SHAFT HOLDER
SHAFT HOLDER
HOLDER ●Untie 8 flange bo of cam shaft holder, disassemble
cam shaft holder from cylinder head.
CAM CHAIN
CAM
CAM CHAIN GUIDE
CHAIN GUIDE BB
GUIDE B
●Take out cam chain from cam shaft

CAM CHAIN
●In order for cam chain not to be taken off from crank
case, tie it with thread or string.
●Disassemble cam shaft.
CAM
CAM SHAFT
CAM SHAFT
SHAFT
●Check on abnormal abrasion or damage of cam of

cam shaft.
●Measure the height of cam .
SERVICE LIMIT IN : 31.4mm
EX : 31.6mm
BEARING
●Rotate with hand the outer race of cam shaft bearing,

check whether it rotates well or not. Then check on
damage of bearing.
BEARING
SPECIAL NUT(10mm) DISASSEMBLY OF

CYLINDER HEAD
●Disassemble inlet pipe
●Disassemble cylinder head cover
●Disassemble cam chaft
●Untie cylinder head special nut(10mm)
●Disassemble after marking the position of valve.
●Diassemble cylinder head from cylinder
●Disassemble cylinder head gasket, dowel pin and cam

chain guide.
DISASSEMBLY OF
CYLINDER HEAD
●By using valve spring compressor, disassemble valve
spring cotter, retainer, spring and valve.
TOOL : VALVE SPRING COMPRESSOR
CAUTION
•Do not compress valve spring more than necessary to
prevent the damage of spring tension
IN VALVE CAUTION
VALVE SPRING •Mark in order forr disassemble parts to be able to be
assembled in their original positions.
VALVE
COTTER ●Disassemble valve spring seat and vale stem seal.
Remove the carbons in cylinder.
EX VALVE
VALVE SPRING RETAINER
CHECKING
CYLINDER HEAD
●Remove the trace of gasket on the gasket side of
cylinder head.
●Check on crack in the nearby valve seat and hole of
spark plug.
CAUTION
•Take precaution for the gasket side of cylinder head
to be damaged.
VALVE SPRING
VALVE SPRING
●Measure the free length of valve spring.
CAUTION
•If even one unit of valve spring is shorter than SER-
VICE LIMIT, replace them with the set.
GAP BETWEEN VALVE STEM AND

GUIDE
●Check on abnormal abrasion of stem, twist, stick,
damage of valve.
●Check on operation of valve by puttiing it into valve
guide.
●Record by measuring outer diameter of valve stem.
SERVICE LIMIT IN : 4.925mm
EX : 4.905mm
VALVE
●Insert valve guide reamer and remove carbon deposit.
CAUTION
•The entering of reamer shall be done by rotating it to
the right way as always. If rotating to the left or not
rotating then entering reamer, the inside of guide can
be damaged.
TOOL : VALVE GUIDE REAMER.
●Record by measuring inner diameter of valve guide.

●Calculate the gap between valve stem and guide.
SERVICE LIMIT : IN : 0.08mm
EX : 0.10mm
●Measure inner diameter of new valve guide, then
replace
Valve too not to be in the service limit.
REPLACEMENT OF
VALVE GUIDE
CAUTION
•If replacing valve guide, the valve seat shall be cor-
rected.
•Get warm cylinder head totally at 130~140°C and be
careful the temperature not to be over 150°C.
•Because of getting burnt, unskillful working shall not
be done.
•When cylinder head gets warm, do not heat it sec-
tionally by using like gas burner that may cause twist
of cylinder head.
●Pull out the valve guide from cylinder, supporting
cylinder head.
TOOL : VALVE GUIDE DRIVER.
CAUTION
•Take precaution that cylinder head is not damaged.
●Insert valve guide tto the upper side of cylinder head.

●Assemble new O-ring to the new valve guide.
TOOL : VALVE GUIDE DRIVER
●After inserting valve guide, insert valve guide reamer

to the cylinder and make valve guide finished by
inserting valve guide reamer.
TOOL : VALVE GUIDE REAMER
CAUTION
•Make reamer finished for it not to be leaned.
•If cutting on condition that reamer leaned, the hole of
valve guide leans that makes stem seal leaked and
widen the surrounding of valve seat, then fixation
and adjustment seat can not be done.
•Going in and out of reamer shall be done by rotating
it to the right. If it rotates to the left or doe not rotate,
flaw can occur inside guide.
CHECKING AND ADJUST-

MENT OF VALVE SEAT
●Remove carbon deposit of valve
●Apply slightly and equally red lead to the valve seat
of cylinder head.
●Do not rotate valve by using valve guide reamer,
knock slightly for fixation to be correctly placed.
●If there is any flaw on valve seat, adjust valve seat. If
valve leans, check the gap between valve guide and
stem. If not normal gap, replace valve guide.
VALVE ASSEMBLY OF CYLIN-

DER HEAD
●Assemble valve spring seat and new stem seal.
●Apply molybdenum to valve stem. In order not to
damage stem seal, rotate slowly valve and assemble it
to guide.
●Check whether valve moves smoothly up and down.
●Assemble so that narrow pitch of valve spring is

toward cylinder head.
●Assemble spring retainer.

●Assemble valve cotter by compressing valve spring.
TOOL : VALVE SPRING COMPRESSOR
CAUTION
•Do not compress valve spring more than necessary
●Knock 2~3 times slightly the end of valve stem so

that valve and cotter are placed safely.
CAUTION
•Take precaution for valve not to be damaged.
INSTALLATION OF
CYLINDER HEA
●Assemble cam chain guide to cylinder
●Assemble dowel pin and new cylinder head gasket
●Assemble cylinder head
●Assemble special nut

※CAUTION : cylinder head special socket nut(M8 X 1.25)
At assembly, assemble as following picture sequence by
¤¤ ¤Œ
¤Œ dividiing two times.
Half assembling → 2) assemble by correct torque → 3)
assemble by correct torque →4) assemble by correct
torque → 1) assemble by correct torque
TORQUE : 4.0kgf-m
¤Ø
¤Ø ¤Ł
¤Ł ●Assemble the valve lead diassembled to fit to its posi-
tion.
●After checking on something wrong of cam shaft

comp, assemble it to the back of cylinder head.
●Rotate slowly crank shaft and fit the T mark of fly
wheel to RH. Crank case cover.
CAUTION
•When rotating crank shaft, take precautions so that
cam chain does not come from timing gear of crank
shaft.
CAMCHAIN
CAM
CAM CHAIN
CHAIN
●Hang cam shaft sprocket to cam chain and assemble it

to cylinder head.
●By squaring timing mark of cam sprocket to the upper
side of cylinder head, fit to the upper level.
●Apply engine oil to cam shaft.
FITTING MARK
FITTING
FITTING MARK
MARK
MATCHED
MATCHED
MATCHED
●Assemble dowel pin to cylinder head.

CAM
CAM CHAIN
CAM CHAIN HOLDER
CHAIN HOLDER
HOLDER ●Assemble cam shaft holder, then install flange bolt.
●Assemble cam chain guide B.
●Rotating tensioner shaft by small driver to the right,

fix shaft by putting it completely into lifter body.
CAM CHAIN
CAM
CAM CHAIN GUIDE
CHAIN GUIDE BB
GUIDE B
●Assemble new gasket to the cylinder.
●Assemble tensioner lifter bolt
O-RING
TORQUE : 1.2 kgf m
●Insert O-ring to the home of lifter body and install
screw.
TORQUE : 0.4kgf m
CAUTION
•If falling tensioner shaft, the shaft goes forward due
to spring power.
●Check valve gap

●If valve gap does not fit, adjust valve lead.
IN VALVE GAP : 0.15mm
EX VALVE GAP : 0.25mm
CYLINDER
CYLINDER HEAD
CYLINDER HEAD COVER
HEAD COVER
COVER ●After removing oil in , assemble correctly the gas-
ket of cylinder head cover to cover.
●Assemble cylinder head cover
●Install cylinder head cover.
TORQUE : 1.0kgf m
MEMO
CYLINDER / PISTON
11. CYLINDER / PISTON
SERVICE INFORMATION 11-1 CYLINDER 11-2

SERVICE STANDARDS 11-1 PISTON 11-3
TROUBLE SHOOTING 11-1 PISTON / ASSEMBLY OF CYLINDER 11-5
SERVICE INFORMATION
GENERAL SAFETY
Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike
the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to
the cylinder pins.
Take precautions not to damage the cylinder wall and piston
SPECIFICATIONS
unit : mm
ITEM STANDARDS SERVICE LIMIT
INNER DIAMETER 56.505 ~ 56.565 56.6
TAPER - 0.1
CYLINDER
OUT-OF-ROUND - 0.05
HEAD CONTACT WARPAGE - 0.1
PISTON SKIRT OUTER DIAMETER 56.450 ~ 56.470 56.35
PISTON PIN HOLE INNER DIAMETER 15.002 ~ 15.008 15.04
PISTON, PISTON PIN OUTER DIAMETER 14.994 ~ 15.000 14.96
PISTON PIN, PISTON-TO-PISTON PIN CLEARANCE 0.002~0.014 0.02
PISTON PISTON RING TO TOP 0.015~0.050 0.09
RINGS GROOVE CLEARANCE SECOND 0.015~0.045 0.09
PISTON RING TOP/SECOND 0.35~0.45 0.5
JOINT GAP OIL(SIDE RAIL) 0.2~0.7 1.1
CYLINDER-TO-PISTON CLEARANCE 0.035 ~ 0.065 0.30
CONNECTING ROD SMALL END INNER DIAMETER 15.010~15.028 15.06
GAP BETWEEN CONNECTING ROD SMALL END AND PISTON PIN 0.010~0.034 0.04
TROUBLE SHOOTING
Compression pressure too low Over heated
Piston worn Excessive carbon built up on top of piston
Piston ring worn or damaged
Cylinder worn
Abnormal engine noise
Emission of white gas from muffler Cylinder, piston worn
Cylinder, piston, piston rings worn Worn connecting rod small end bearing or piston pins
Bad adjustment of piston rings Damaged piston rings
Piston, cylinder worn Excessive carbon built up on top of piston
CYLINDER / PISTON
CYLINDERHEAD
CYLINDER
CYLINDER HEADGASKET
HEAD GASKET
GASKET
CYLINDER
DISASSEMBLY
●Diassemble cylinder head(ßú10-4)
●Disasemble cylinder head gasket
●Disassemble cam chain guide from cylinder
CAMCHAIN
CAM
CAM CHAINGUIDE
CHAIN GUIDE
GUIDE
●Disassemble cylinder
●Remove gasket from cylinder
CAUTION
•Take precaution for touched area of gasket of cylin-
der not to be damaged.
CYLINDER INSPECTION
GAUGE
●Measure the inner diameter of cylinder from 6 posi-
tion of top, middle, bottom by the direction of piston
pin and by the rectangular direction(X-Y direction).
●Be the maximum measured value to that of inner
diameter of cylinder.
●Measure the outer diameter of piston.
●Minusing the value of outer diameter of piston from
that of inner diameter of cylinder, measure the gap
between cylinder and piston.
●By each measured values, calculate the out-of-round-
ness(X and Y direction) and cylindricity(the value of
inner diameter of top, middle, bottom by the direction
of X or Y).
●By choosing the maximum values among the values,
they are out-of-roundness and cylindricity.
상 SERVICE LIMIT : OUT-OF-ROUNDNESS : 0.05mm
CYLINDRICITY : 0.1mm
●Boring processing of cylinder shall be done till the
중 gap between cylinder and piston will be standard
value by measuing the outer diameter of over-sized
piston.
하 OVER SIZE : 0.25mm, 0.50mm
0.75mm, 1.00mm
STANDARD GAP : 0.020~0.050mm
CYLINDER / PISTON
●Check the twistness of the touched area of cylinder

head gasket.
CYLINDER
CYLINDER
CYLINDER PISTON
DISASSEMBLY
●Pull out piston pin clip.
CAUTION
•Be careful for the piston pin clip in crank case not to
be fall down.
PIN CLIP
PIN
PIN CLIP
CLIP •Disassemble piston by pulling out piston pins.
●Disassemble piston top ring

TOP RING ●Disassemble piston second ring
CAUTION
•At disassembly, do not hurt the piston by piston ring
SECOND RING
●Measure the gap between piston ring and home

SERVICE LIMIT : TOP/SECOND : 0.09mm
O-RING : 0.09mm
●Measure the abrasion and damage of piston.
RING
CYLINDER
CYLINDER
CYLINDER
PISTON
PISTON RING
PISTON RING
RING
SIDEWORN
PISTON SIDE
SIDE WORN
WORN
CYLINDER / PISTON
●Check the gap of piston ring by inserting it to the

PILLAR GAUGE
inside of cylinder.
SERVICE : TOP/SECOND : 0.5mm
OIL : 1.1mm
CAUTION
•Insert piston ring by using piston head so that the pis-
PISTONRING
PISTON
PISTON RING
RING ton ring will be flat.
●Measure the outer diameter of piston at 10mm from

the bottom side of piston to the 90° direction against
°
90°
°
°
90°
90° piston pin.
MICRO METER
●Measure the inner diameter of the hole of piston pin.

●Measure the outer diameter of piston pin.

●Measure the gap between piston and piston pin

●Measure the inner diameter of small side of connect-

ing rod.
SERVICE LIMIT : 15.06 mm
●Measure the gap between small side of connecting

rod and piston pin.
CYLINDER GAUGE
CYLINDER / PISTON
ASSEMBLY OF PISTON /
TOP RING
CYLINDER
SECOND RING ASSEMBLY OF PISTON RING
●Clean of piston ring by oil and fit piston ring into
MARK piston.
WHITE PAINTED
CAUTION
•Because ring can be easily cut, then take precaution
that it is not cut and for piston not to be damaged dur-
TOP RING ing assembling.
•Assemble so that the mark side of ring shall be
SECOND RING upward
•Be careful not to be confused in distinguishing top
ring and second ring.
SIDE RAIL
•Be sure for the end gap of each ring to be 120°.
SPACER OIL RING
●Check about smooth operation of ring after assem-
SIDE RAIL bling.
ASSEMBLY OF PISTON AND CYLIN-

DER
●Clean completely gasket attached to the surface of
crank case and replace with new gasket.
CAUTION
•Take precaution for contact side of gasket not to be
damaged.
•By using cloth, protect for alien material like piece of
gasket not to fall into crank case.
●Insert piston, piston ring to cone rod.

●Assemble with the new piston pin clip.
CAUTION
•The “IN” mark shall be toward to the in valve.
•By using of cloth, protect for piston pin clip not to
fall into crank case.
•Be sure that piston pin clip and piston home are not
fit each other.
CYLINDER / PISTON
●Apply the engine oil to the inside of cylinder and pis-

CYLINDER
CYLINDER
ton ring, assemble piston to cylinder.
CYLINDER
●Combine cam chain guide.
- Insert the bottom side to of crank case and
assemble the upper swelling of guide to of cylin-
der.
CAUTION
•Take precautions for piston ring not to be damaged.
•Take precautions for cam chain not to fall into crank
case.
●Assemble with the new cylinder head gasket.
●Assemble cylinder head( 10-9)
●Assemble in the reverse order of disassembly.

MEMO
TRANSMISSION/CRANKSHAFT/CRANKCASE
12. TRANSMISSION / CRANKSHAFT / CRANKCASE
SERVICE INFORMATION 12-1 CRANK SHAFT REMOVAL 12-7

TROUBLE SHOOTING 12-2 TRANSMISSION BEARING 12-8
TRANSMISSION 12-3 CRANK SHAFT ASSEMBLY 12-9
CRANK CASE REMOVAL 12-7 CRANK CASE ASSEMBLY 12-10
SERVICE INFORMATION
GENERAL SAFETY
● This section describes how to remove the crank case and to maintain the transmission and the crankshaft.
● Service transmission without removing the engine from the vehicle. However, to prevent damage to the LH. Crank
case, remove the engine and disassemble the rear brake prior to changing the LH. Crank case bearing
● Always use special tools to change the drive shaft. Fix the bearing inner race, and install the shaft
● The following parts must be removed prior to removing the crank case. Follow the removal procedure specified in
each section.
- Disassembly of oil pump( chapter 4)
- Disassembly of engine( chapter 7)
- Disassembly of cylinder head, cylinder, piston( chapter 10,11)
- Disassembly of AC. Generator( chapter 9)
- Disassembly of driven pulley( chapter 8)
● When replacing the LH crank case, follow the below procedure specified in each section.
- Disassemble the transmission( chapter 12)
SPECIFICATIONS UNIT : mm
ITEM STANDARD VALUE SERVICE LIMIT
CONNECTING ROD 0.15~0.60 0.6
GAP OF BIG END SIDE 0.1~0.35
CRANK
CONNECTING ROD BIG END 0-0.008 0.05
SHAFT
CRANKSHAFT RIGHT - 0.1
SHAKING LEFT - 0.1
SPECIFICATIONS
OIL CAPACITY 0.15L(Full capacity) 0.14L(After oil change)
RECOMMENDED OIL DAELIM genuine mission oil or SAE 80W/90
TORQUE
CRANK CASE BOLT 1.0kgf·m
TOOL
- UNIVERSAL BEARING PULLER
- BEARING REMOVER SET
- REMOVER ASS’Y
- REMOVER SHAFT
- REMOVER HEAD
- SLIDIING WEIGHT
- ASSEMBLY SHAFT
TROUBLE SHOOTING
Engine Noise
● Connecting rod big and small ends loose
● Crank pin bearing loose free play
Engine started but unable to move out

● Transmission damage
● Transmission seized
Noise during operation

● Gear worn, overheated, cracked
● Bearing worn
Oil leaks
● Excessive oil level
● Oil seal worn, damaged
TRANSMISSION
DIASSEMBY
● Loosen the drain bolt, drain the mission oil.
● Disassemble the LH. crankcase cover.
● Disassemble the driven pulley, drive belt.
● Disassemble 5 flange bolts installed at LH. Crank
case.
FLANGE BOLTS
● Disassemble EX. Muffler.

TRANSMISSIONCOVER
TRANSMISSION
TRANSMISSION COVER
COVER
● Disassemble rear cushion
● Disassemble rear swing arm
● Disassemble rear brake caliper
● Disassemble rear wheel
● Untie 2 flange bolts(85mm) installed at misson
FLANGE
FLANGE
FLANGE cover ass’y.
BOLTS
BOLTS
BOLTS
● Disassemble transmission ass’y
CAUTION
•Take precautions for the assemble position of cover
not to be damaged.
TRANSMISSION ASS’Y
TRANSMISSIONCASE
TRANSMISSION
TRANSMISSION CASE
CASE ● Untie 3 flange bolts installed at transmission ass’y.
DRIVE SHAFT
● Disassemble transmission cover and case comp
● Disassemble final shaft, counter gear, counter shaft.
COUNTER GEAR
FINAL SHAFT
TRANSMISSION
COVER
● Disassemble drive shaft pressed to the transmission

cover by the press.
DRIVE SHAFT
TRANSMISSION
TRANSMISSION
TRANSMISSION
COVER
COVER
COVER
CHECK
● Check the final shaft
FINAL SHAFT
● Check the counter shaft and gear
COUNTER GEAR COUNTER SHAFT
● Check the driver shaft
DRIVER SHAFT
CHECKING BEARING
● Check whether the inner race of bearing pressed to
mission cover and case rotates smoothly or not by
turning fingers.
● Check whether the outer race assembled pressed
correctly to the case.
● Replace the bearing if necessary
TRANSMISSION COVER TRANSMISSION CASE
● Disassemble bearing by using of special tool
● Press the bearing into case by using of special tool

TOOL : DRIVER HANDLE A
OUTER DRIVER
DRIVER PILOT
ASSSEMBLY
DRIVER SHAFT ● Assemble the drive shaft to transmission case
● Assemble the new drive shaft oil seal.
TOOL : CRANK ASSEMBLY SHAFT
CRANK ASSEMBLY COLLAR
TRANSMISSION CASE
● Assemble the new gasket and dowel pin

● Assemble the final shaft, counter shaft.
● Assemble bolts after doing mission cover and cover
LH. CRANK
LH.
LH. CRANK CASE
CRANK CASE
CASE ● Assemble transmission ass’y to LH. Crank case,
then install bolts.
● Assemble the following parts
- rear wheel assembly( 14-4)
-rear swing arm assembly( 14-5)
-rear brake caliper assembly( 16-8)
-assembly belt typed continuously variable
transmission( 8)
● Assemble rear cushion upper bolt
● By disassembling AC Generator cap, inject the
mission oil( 4-8)
DOWELPIN
DOWEL
DOWEL PIN
PIN TRANSMISSION ASS’Y
TRANSMISSION ASS’Y
ASS’Y
TRANSMISSION
DIASSEMBLY OF CRANK
CASE
●Unload the engine from frame( 7-2)
●Disassemble RH/LH Crank case cover( 8-2,9-2)
●Disassemble transmission cover( 12-3)
●Disassemble the parts to be necessary for
disassmebling of crank case
LH. CRANK
LH.
LH. CRANK CASE
CRANK CASE
CASE ●Untie 1 flange bolt installed at LH. Crank case
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
● Untie 4 flange bolts installed at RH. Crank case.

LH. CRANK CASE
CAUTION
•Do not disassemble twistedly the fixing positin of
crank case.
● Beat slightly by plastic hammer the LH. Crank case

downward and disassemble RH. Crank case from
LH. Crank case.
DISASSEMBLY OF
CRANK SHAFT CRANK SHAFT
●Because crank shaft is installed to RH/LH Crank
case, lift up crank chast slightly upward and
diassemble it.
CAM CHAIN
GASKET
DIALGAUGE
DIAL
DIAL GAUGE
GAUGE CHECK
● Install crank shaft to the stand or V block, measure
and vibratioon of the journal position.
SERVICE LIMIT : RIGHT 0.1mm
LEFT 0.1mm
MEASURED POSITION
● Measure the gap between the big end of connecting

PILLAR GAUGE rod and crank weight.
TOOL : PILLAR GAUGE
● Measure on movement of axle verical way of the

DIAL GAUGE
DIAL
DIAL GAUGE
GAUGE big end of connecting rod by X and Y directions.
CRANK CASE BEARING

CHECKING
● Check by rotating the inner race of bearing with
fingers on whether bearing rotates smoothly.,
● Also, check whether the outer race correctly pressed
into the case or not.
● If the free play is big and the status of case pressing
is loose, disassemble and replace.
DISASSEMBLY
● Disassemble bearing by using of special tool.
● Apply clean engine oil to the new RH. Crank shaft
bearing and press to RH. Crank case.
TOOL : DRIVER HANDLE A
DRIVER PILOT
OUTER DRIVER
CAM CHAIN
ASSEMBLY OF CRANK
CASE
● Assemble cam chain to LH. Crank case.
● Assemble crankshaft to the inside of cam chain

CRANK SHAFT
assembled at LH. Crank case.
● Check whether cam chain assembled exactly to
crank shaft
● Assemble dowel pin and new gasket
CAUTION
•Check whether the gasket completely attached
without any gap.
● Assemble RH. Crank case to LH. Crank case.
● Assemble flange bolt to RH. Crank case.

● Assemble required parts for assembling the engine.
● Assemble the engine to the frame( 7-3)
FRONT WHEEL / FRONT FORK / STEERING STEM
13. FRONT WHEEL / FRONT FORK / STEERING STEM
SERVICE INFORMATION 13-1

SPEEDOMETER GEAR BOX 13-6
TROUBLE SHOOTING 13-2
FRONT WHEEL ASSEMBLY 13-7
STEERING HANDLE 13-3
FRONT FORK 13-7
FRONT WHEEL 13-4
STEERING STEM 13-11
FRONT WHEEL BEARING 13-5
SERVICE INFORMATION
CAUTION
● Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged
● Place a jack underneath the engine to support the 2-wheeled vehicle
ITEM STANDARD VALUE(mm) SERVICE LIMIT(mm)
AXLE SHAFT RUN OUT - 0.2
RADICAL - 2.0
FRONT WHEEL RIM RUN OUT
AXIAL - 2.0
FRONT CUSHION SPRING FREE LENGTH 281
TORQUE VALUES
STEERING STEM LOCK NUT 6.0~8.0kgf m

STEERING TOP CON RACE 0.2~0.3kgf m
FRONT CUSHION BOLT 1.5~3.0kgf m
FRONT AXLE NUT 5.0~7.0kgf m
BRAKE CALIPER BOLT 2.8~3.4kgf m
TROUBLE SHOOTING
Hard steering
● Steering top cone race excessvely tightened
● Steering stem steel ball damaged
● Steering ball race, cone race damaged
● Insufficient tire pressure
● Tire worn
Steer to one side or does not track straight

● Bent fork
● Bent front axle
● Bent frame
● Worn or deformed tire
● Worn wheel bearing
Front wheel wobbling

● Rim deformed
● Bad wheel bearing
Wheel turning heavy

● Bad wheel bearing
Weak Front suspension

● Weak spring
Front cushion noise

● Looseness of front cushion assembled position
HANDLE UPPER COVER STEERING HANDLE

DISASSEMBLY
● Disassemble upper handle cover and under handle
cover.
MASTER CYLINDER ●Untie front, rear brake master cylinder holder bolts.
MASTER CYLINDER HOLDER
HAZARD / STARTER
SWITCH ASS’Y
THROTTLE CABLE
WINKER SWITCH ASS’Y ●Disassemble hazard starter switch ass’

y.
●Disassemble throttle cable
●Disassemble winker switch ass’ y
SCREWS
STEERING HANDLE ●Untie steering handle U nut and disassemble steering

handle.
U-NUT
ASSEMBLY
● Assemble steering handle to steering stem.
● Fit the flange bolt and assemble lock nut.
CAUTION
•Adjust the free play of throttle grip to 2~6mmm
AXLE
AXLE NUT
AXLE NUT
NUT FRONT WHEEL
DISASSEMBLY
● Fix the front wheel not to be taken out from the
ground by bridging.
● Untie axle nut and speedometer cable fixing screw,
disassemble the wheel.
FRONT WHEEL
FRONT
FRONT WHEEL
WHEEL
DIAL GAUGE FRONT AXLE CHECK

● Check on bent of front axle. Install the front axle on
the V block and measure it by dial gauge.
● Install the front wheel to stand. Turn slowly the

ROTATE wheel and check on the rim trembling by dial gauge.
SERVICE LIMIT : longitudinal 2.0 mm
Lateral 2.0 mm
DIAL GAUGE
FRONT WHEEL BEARING

CHECK
● Turn the inner race of bearing by fingers, replace it
if it makes noise or is worn.
● Check whether the outer race of bearing assembled
exactly to the wheel hub and if it is worn, replace it.
REPLACEMENT
● Install bearing remover head, remover shaft to
wheel and disassemble bearing and distance collar.
TOOL : BEARING REMOVER HEAD

BEARING REMOVER
BEARING BEARING
REMOVER REMOVER HEAD
● Apply grease enough to bearing

● Press to assemble seal position of bearing from the
right.
● Assemble distance collar and press to install bearing
on condition that its seal position is external side.
TOOL : DRIVER HANLDE A
DRIVER PILOT
OUTER DRIVER
CAUTION
•At assembly of bearing, assemble correctly for it not
to be inserted obliquely.
SPEEDOMETER GEAR BOX

● Disassemble the speedometer gear from
speedometer gear box.
CHECK
● Check the speedometer gear.
● Check the speedometer gear box
SPEEDOMETER SPEEDOMETER GEAR

GEAR BOX
RETAINER
RETAINER
RETAINER ASSEMBLY
● Apply grease the rim position of LH. Side dust seal.
● Assemble retainer
● Assemble LH. Side dust seal
● Attach dust seal and combine speedometer gear box
by fitting the prominent area of speedometer gear
box retainer to the home of gear.
● Assemble side collar to front wheel.
SIDE COLLAR
SIDE
SIDE COLLAR
COLLAR
ASSEMBLY OF FRONT
WHEEL
● Insert front wheel between front forks.
● Combine wheel for pads not to be damaged by
inserting disc.
● Fit the concaved area of speedometer gear box to
the prominent area of RH. Fork slider.
● Insert the front axle to speedometer gear box and
wheel hub.
● Assemble axle nuts.
● Assemble speedometer cable and fix screw exactly.

● Place front wheel to its original position and
assemble it with axle nut by designated torque.
TORQUE : 5.0~7.0 kgf m
CALIPER
CALIPER
CALIPER FRONT FORK
● Disassemble front caliper
● Disassemble front fender
● Disassemble front wheel
● Untie brake hose and bolts installed at clamp.
FRONT FORK
FRONT
FRONT FORK
FORK
FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT ● Untie slightly flange bolt installed at steering stem
comp when diassembling front fork.
CAUTION
•Support the engine not to be overturned by jack.
•Untie loosely fork back not to be disassembled.
● Grasp front fork by hands and disassemble front

fork.
FRONT FORK FRONT FORK BOLT DISASSEMBLY

● Disassemble front fork bolts.
CAUTION
•If screws are untied completely, be careful about
coming out bolts because of spring may occur.
•Disassemble fork spring and pull out fork oil by
stretching several times.
● Wrap bottom case by cloth and diassemble socket

bolts.
● Drain fork oil
CAUTION
•If socket bolts idles and are not pulled out, assemble
temporarily spring and fork pipe cap bolts.
•Support strongly bottom case by vice so that it is not
deformed or broken.
BOTTOM CASE FORK PIPE ● Disassemble piston, rebound spring, seat pipe, fork
spring from fork pipe.
● Check the parts of front fork.
REBOUND FORK BOLT

SPRING SEAT PIPE
OIL SEAL SPRING
FRONT FORK SPRING

DUST SEAL
CHECK
● Measure the free length of fork spring on
condition that it places on flat area.
● Replace it if it is below the value of service limit.
● Check whether component parts damaged or
abnormally worn, if yes, replace with the new
ones.
STANDARD SPECIFICATION : 281mm
ASSEMBLY
● Clean completely each part by cleaned oil before
assembling them,
● Assemble rebound spring and pipe to fork pipe.
CAUTION
•Take precautions for the inside and outside diameters
of bottom case not to be damaged.
● Assemble front fork spring.

● Fix the bottom case to vice wrapping by cloth.

● Apply screw lock agent to the screw area of socket
bolts and assemble to fork piston.
TORQUE : 2.0 kgf m
CAUTION
•When fixing the bottom case to vice, do not insert
directly to case. Surely insert to the bracket position.
● Apply fork oil
● Inject the speficied capacity of ATF(automatic

transmission fluid) to fork pipe.
CAPACITY : 130 cm2
● Deflate air by pressing 2 or 3 times fork tube.
FORK OIL
FORK OIL LEVEL
● Assemble fork pipe bolts to fork pipe.

ASSEMBLY
● Fit the home area to installation area of setting bolts.
● Assemble front fork setting bolts.
TORQUE : 1.5~2.5 kgf m
FRONTFORK
FRONT
FRONT FORK
FORK
STEERINGSTEM
STEERING
STEERING STEM
STEM STEERING STEM
DISASSEMBLY
LOCKNUT
LOCK
LOCK NUT
NUT ● Disassemble following parts
- HANDLE COVER
- STEERING HANDLE
- FRONT WHEEL
- FRONT FORK
CAUTION
•Be careful about the vehicle over turn.
● Disassemble steering lock nuts by using steering nut

socket.
● By using steering stem socket, disassemble top

TOPTHREAD
TOP
TOP THREADCOMP
THREAD COMP
COMP thread comp.
● Disassemble top cone race

LOCK NUT ● Check on the abrasion or damage of ball ass’y, cone
STEERING STEM race and ball race.
TOP THREAD COMP ● If ball race worn, damaged or its race area gets
STEERING TOP pressure, replace it with new one.
CONRACE
STEERING UPPER
BALL ASS’Y
STEERING UNDER
BALL ASS’Y
ASSEMBLY
● Assemble under ball ass’y to steering stem.
● Assemble steering upper ball and top cone race to
head pipe.
● Assemble steering stem to head pipe.
BALLASS’Y
BALL
BALL ASS’Y
ASS’Y
● Assemble top cone race and top thread comp to

steering stem.
● Fasten completely top thread and untie it 1/8 turn.
● Check whethere moves smoothly up,down and left,
right.
●Assemble temporariily lock nut.

● Install lock nut by using steering stem lock nut

socket.
TORQUE : 7.0 kgf m
TOOL : STEERIING STEM LOCK NUT SOCKET
STEERING STEM SOCKET
● Assemble following parts

- FRONT FORK
- HANDLE STEERING
- HANDLE COVER
- FRONT WHEEL

REAR WHEEL / REAR SWING ARM / REAR CUSHION
14. REAR WHEEL / REAR SWING ARM / REAR CUSHION

REAR SWING ARM 14-5
REAR CUSHION 14-6
REAR WHEEL 14-3
SERVICE INFORMATION
GENERAL SAFETY
● When disassembling or assembling tire from rim, use the exclusively used tire lever and rim protector in order for
rim not to be damaged.
SPECIFICATIONS
REAR WHEEL RIM RUN OUT - 2.0
REAR CUSHION SRPING FREE LENGTH 247 242
TORQUE VALUES
REAR CUSHION UPPER BOLT 3.5~4.5kgf・m

REAR CUSHION UNDER BOLT 3.5~4.5kgf・m
REAR CUSHION ROD LOCK NUT 3.0~4.0kgf・m
REAR AXLE NUT 12~13kgf・m
13.2 TROUBLE SHOOTING

Rear wheel wobbling or vibration
● Deformed wheel, rim
● Bad tire
● Axle bad fastening
● Bad tire air pressure
● Improper wheel balancing
Soft rear suspension

● Bad spring
● Bad rear damper, oil leakage
Hard suspension
● Twisted damper rod
● Bad tire air pressure
Rear cushion noise

● Looseness of fastening and assmbled points
MUFFLER
MUFFLER
MUFFLER REAR WHEEL
REMOVAL
● Erect the motorcycle on the main stand.
● Remove the muffler.
● Disassemble rear cushion.
BRAKEHOSE
BRAKE
BRAKE HOSE
HOSE ● Disassemble rear brake caliper ass’y from rear
swing arm on condition that rear brake caliper ass’y
assembled with brake hose.
REARSWING
REAR
REAR SWING
SWING
ARM
ARM
ARM
RAER CALIPER
RAER
RAER CALIPER
CALIPER
● Untie rear axle nut.

● Disassemble rear wheel inside collar
● Disassemble rear wheel outside collar

● Disassemble rear wheel
REAR WHEEL
CHECK
ROTATE
ROTATE
ROTATE ● Rotate wheel and check on its shaking
SERVICE LIMIT : longitudinal 2.0 mm
lateral 2.0mm
TOOL : Dial gauge
ASSEMBLY
● Assemble real wheel to final shaft
● Assemble rear wheel inside collar
INSIDE COLLAR
● Assemble rear swing arm
● Assemble rear wheel outside collar
● Assemble rear axle U nut.

TORQUE : 12~13kgf m
● Assemble rear swing arm on condition that rear

brake caliper ass’y and brake hose assembled
together.
● Assemble EX. Muffler.
REAR SWING ARM

DISASSEMBLY
● Untie rear axle U nut.
REARCALIPER
REAR
REAR CALIPER
CALIPER

● Disassemble rear wheel outside collar from rear
swing arm.
● Disassemble radial ball bearing(6302UU).
● Replace rear swing arm bearing if it has something
wrong.
SWING ARM
ASSEMBLY
REAR CUSHION
DIASSEMBLY
● Diassemble air cleaner
● Untie upper, lower bolts of LH. Rear cushion and
disassemble rear cushion.
● Untie upper, lower bolts of RH. Rear cushion and
diassemble rear cushion.
REAR CUSHION
DISASSEMBLY
COMPRESSOR ATTACHMENT ● Install compressor attachement as the photo.
● Install cushion compressor to cushion and compress
spring.
TOOL : REAR CUSHION COMPRESSOR
ATTACHMENT
REAR CUSHION COMPRESSOR
● Fix upper metal and untie hex nut.

● Disassemble upper metal
● Disassemble hex nut, upper metal, stopper rubber,
spring from rear damper comp.
UPPER METAL
HEX NUT
REAR CUSHION SPRING CHECK

● Check on bent or damaged of damper rod.
HEX NUT
STOPPER RUBBER
SPRING ADJUSTER
REAR DAMPER UPPER METAL
● Measure the free play length of rear cushion spring

SERVICE LIMIT : 247mm
ASSEMBLY
● Assemble spring, stopper rubber to damper comp.
CAUTION
•At assembly of spring, do it so that its
lean pitch side goes up.
● Apply screw lock detergent and install rear cushion

compressor attachment to damper rod.
● Fix upper metal and fasten hex nut.
TORQUE : 3.0~4.0kgf¶Um
TOOL : REAR CUSHION COMPRESSOR
REAR CUSHION COMPRESSOR
ATTACHMENT
● Combine LH/RH. Rear cushion.
● Install LH/RH. Rear cushion with upper, lower
under bolts.
TORQUE : upper 3.5~4.5kgf m
Under 3.5~4.5kgf m
BRAKES
FRONT REAR
15. BRAKES
FRONT BRAKE CALIPER 15-6
REAR BRAKE CALIPER 15-8
BRAKE FLUID REPLACEMENT 15-3
MASTER CYLINDER 15-11
FRONT BRAKE PAD 15-5
BRAKE DISK 15-13
REAR BRAKE PAD 15-6
SERVICE INFORMATION
CAUTION
● Take precautions not to mix alien material or water with brake fluid at replacing brake fluid.
● Do not use different brake fluid to prevent certain chemical change.
● Do not use again contaminated brake fluid.
● Because brake fluid gives damage to painting, parts, plastics, rubbers, then take precautions that brake fluids does not
touch with these materials.
● Do not use again sealing washer.
● Clean diassembled parts with brake fluid and check whether these parts°Ø holes are not cogged.
● Deflate air at separating brake hose.
● Take precautions so that oils or brakes fluids are not stained with brake disk or pad.
● This may get the braking power lower, then if these parts contaminated, replace with the new pad and clean disk
completely.
DESIGNATED BRAKE FLUID DOT3 or DOT4 -

BRAKE DISK THICKNESS 4.0 3.5
BRAKE DISK WOBBLING 0.1 0.3
INNER DIAMETER OF MASTER CYLINDER 12.700~12.743 12.755
OUTER DIAMETER OF PISTON 12.657~12.684 12.645
INNER DIAMETER OF CALIPER CYLINDER 24.440~25.410 25.420
OUTER DIAMETER OF CALIPER PISTON 24.278~24.328 24.270
DESIGNATED BRAKE FLUID DOT3 or DOT4 -
THICKNESS OF BRAKE DISK 4.0 3.0
BRAKE DISK WOBBLING 0.1 0.3
INNER DIAMETER OF MASTER CYLINDER 14.000~14.043 14.055
OUTER DIAMETER OF PISTON 113.878~13.905 13.866
INNER DIAMETER OF CALIPER CYLINDER 25.278~25.328 25.270
OUTER DIAMETER OF CALIPER PISTON 24.914~24.935 24.870
BRAKES
TROUBLE SHOOTING
BAD BRAKING POWER
● Air mixed in brake system
● Brake fluid spoils because of water mixing.
● Contamination of braked pad, disk
● Abrasion of caliper piston seal
● Abrasion of master cylinder piston seal
● Abrasion of brake pad
● Internal contamination of caliper
● Bad operation of caliper slide
● Side abrasion of brake pad, disk
● Insufficient capacity of brake fluid
● Cogging of the brake fluid path
● Twist or deformation of disk
● Hardening or abrasion of caliper piston
● Hardening or abrasion of master cylinder piston
● Abrasion of disk
● Internal contamination of master cylinder
● Brake lever bent
HARD OPERATION AND BAD RETURNING OF BRAKE LEVER

● Cogging of brake system
● Hardening or abrasion of caliper piston
● Cogging of brake fluid path
● Abrasion of caliper piston seal
● Hardening or abrasion of master cylinder piston
● Brake lever bent
BRAKE DRAGGING
● Contamination of brakd pad, disk
● Assembled at the status of wrong wheel array
● Side abrasion of brake pad, disk
● Disk bent, deformed
● Contamination in oil pressure system because of dust
BRAKES
FRONTBRAKE
FRONT
FRONT BRAKEMASTER
BRAKE MASTERCYLINDER
MASTER CYLINDER
CYLINDER REARBRAKE
REAR
REAR BRAKEMASTER
BRAKE
CYLINDER
CYLINDER
CYLINDER
MASTER
MASTER BRAKE FLUID
REPLACEMENT
CAUTION
•Oils not to be stained with disk, pad because
braking performance loses.
•If stained, replace pad and clean completely
contaminated materials in disk.
•Being careful about capacity of brake fluid in
reserve, replace with new brake fluid and keep
working. Brake fluids not to be stained with
painting,plastic, rubbers like these kinds of parts.
● Disassemble oil cap cup, diaphragm plate,

diaphragm from master cylinder.
● Replenish brake fluids, DOTS or DOT4 into master
cylinder.
● Connect breather valve to breather hose.
● Disassemble breather valve, repeat grasping and
releasing brake lever
● If the stream of brake fluid stops, stop brake lever
operation.
AIR SUBTRACTION
BRAKE BREATHING <IN CASE OF USING BREATHER HOSE>
CAUTION
•To prevent chemical change, do not use different
brake fluid.
● Assemble brake breather to breather valve

● Repeat grasping and releasing brake lever, then
loosen breather valve
● Repeat this work enough by the time that brake fluid
comes out brake breather.
● Replenish brake fluid
CAUTION
•Check brake fluid capacity often, and if it reduces
under lower line, replenish.
•In case of disassembling brake breather, read
manual carefully and use correctly.
•In order for air not to be mixed around breather
valve, protect it with tape.
BRAKES
<When the brake bleeder is not available>

BREATHER VALVE
BREATHER
BREATHER VALVE
VALVE
● Fill the brake fluid up to the upper limit line.
● Connect the transparent bleeder hose to the bleeder
valve and place the other end of the hose in a
container.
① Squeeze the brake lever, then open the bleeder

BREATHERHOSE
BREATHER
BREATHER HOSE
HOSE valve 1/2 turn, and close the valve.
FRONT CALIPER
FRONT
FRONT CALIPER
CALIPER
NOTE
•Do not release the brake lever until the bleeder
valve has been closed.
② Release the brake lever slowly and wait several

seconds after it reaches the end of its travel.
③ Repeat the above steps ① and ② until bubbles
cease to appear in the fluid at the end of the hose.
● Check the fluid level often, and add fluid if the fluid
level is near the lower level.
● If no air leaks out of the bleeder hose, operate the
brake lever to check the presence of air.
● Tighten the bleeder valve.
TORQUE VALUE : 0.4~0.7 kgf·m
● Check the brake fluid capacity often and if it reduces

under the lower line, replenish it.
● If air does not come out of breather hose, operate
lever and check on air mixing.
● Assemble breather valve
● Replenish brake fluid to the upper level. Assemble

diaphragm, diaphragm plate, oil cup cap.
TORQUE : 1.0kgf m
BRAKES
REAR BRAKE BLEEDLING (INTERLOCK)

REAR BRAKE
REAR
REAR BRAKE
BRAKE
BREATHERVALVE
BREATHER
BREATHER VALVE
VALVE
● The rear brake is apply to interlocking system, when
squeezing the right side brake lever, the front and rear
brake works at once.
① Fill the brake fluid up to the upper limit line.

② Connect the breeder hose to the breeder valve on
the rear caliper and bleed air.
BREATHERHOSE
BREATHER
BREATHER HOSE
HOSE
REARCALIPER
REAR
REAR CALIPER
CALIPER
FR./RR. BRAKE
FR./RR. BRAKE LEVER
LEVER ③ If no air leaks out of the breeder hose after
FR./RR. BRAKE LEVER
operate the brake lever, stop pumping it.
④ Connect the breeder hose to the breeder valve on

FRONTBRAKE
BRAKEHOSE
HOSE
the front caliper and bleed air.
FRONT
FRONT BRAKE HOSE
⑤ Fill the brake fluid up to the upper limit line and
install the diaphragm, plate and oil cup cap.
⑥ Install the fluid maintenance lid.
FRONTBRAKE
FRONT
FRONT BRAKE
BRAKE
BREATHERVALVE
BREATHER
BREATHER VALVE
VALVE
INTERLOCKBRAKE
INTERLOCK
INTERLOCK BRAKEHOSE
BRAKE HOSE
HOSE
BRAKES
FRONT BRAKE PAD

FLANGEBOLTS
FLANGE
FLANGE BOLTS
BOLTS
HANGERPIN
PIN
REPLACEMENT
HANGER
HANGER PIN
● Disassemble loosely the hanger pin of front caliper.
● Untie flange bolt
CAUTION
•Be sure to replace brake pads as the set.
•When replacing pad, do not disassemble brake
hose.
● Disassemble brake pad from front fork.

● Check on abrasion of brake pad
● Assemble hanger pin to new brake pad.

● Install hanger pin and assemble brake calipr to front
BRAKEPAD
BRAKE
BRAKE PAD
PAD fork.
REAR BRAKE PAD

REPLACEMENT
● Replace muffler
● Unfold the prominent position of lock plate and
untie loosely.
CAUTION
•Be sure to replace brake pads as the set.
•When replacing brake pads, do not disassemble
brake hose.
● Untie rear brake installing bolt and disassemble

brake caliper.
BRAKES
● Disassemble brake pad, lock plate, hanger pin

● Check on abrasion of brake pad
HANGER PIN
HANGER
HANGER PIN
PIN
● Assemble hanger pin to new brake pad

BRAKEPAD
BRAKE
BRAKE PAD
PAD
FRONT BRAKE CALIPER

DISASSEMBLY
● Untie brake tube bolt.
● Untie 2 bolts installing caliper.
CAUTION
•Take precaution so that brake fluid is stained with
painting, plastic, rubbers.
DISASSEMBLY
CAUTION
•Because oils may lose braking performance, take
precaution so that brake fluid is not stained with
disk, pad
If stained, replace with new pad and clean disk.
BRAKES
DISASSEMBLY
AIR
AIR
AIRGUN
GUN
GUN
● Remove the pad spring, pad comp, caliper bracket,
boot from the caliper body.
● Wrap the caliper with a piece of cloth to avoid piston
and brake fluid leakage and facing the piston
downward.
● Remove the piston from the caliper while blowing
the low-pressure air in the opening of the brake hose.
PISTON
PISTON
PISTON
PISTON
CAUTION
PISTON
PISTON
PISTON SEAL
PISTONSEAL
SEAL •Never use the high-pressure air or bring the air gun
DUST
DUST
DUST SEAL
DUSTSEAL
SEAL too close.
•Never touch the inside of the caliper.
● Disassemble the piston seal and the dust seal.

NOTE
•Pay attention not to damage the inner sunface of
the caliper.
● Clean the piston and inside of the caliper with the

brake fluid.
CALIPER
CALIPER
CALIPERBODY
BODY
BODY INSPECTION
● Check the caliper cylinder bore for scoring,
scratches, or other damage.
● Measure the caliper cylinder I.D.
SERVICE LIMIT : CYLINDER I.D.A : 34.01mm

CYLINDER I.D.B : 25.46mm
● Check the caliper piston outer diameter part for

scratches or other damage.
● Measure the piston outer diameter.
SERVICE LIMIT : PISTON O.D.A : 33.848MM

PISTON I.D.B : 25.30MM
PISTON
PISTON
PISTON
BRAKES
LH
LH CALIPER
LHCALIPER BODY
CALIPERBODY
BODY HANGER
HANGER
HANGERPIN
PIN
PIN RH
RHCALIPER
RH CALIPERBODY
CALIPER BODY
BODY ASSEMBLY
PISTON
PISTON
PISTONAAA PISTON
PISTON
PISTONAAA
● Clean the piston seal and the dust seal with the brake
fluid and install them in the caliper.
● Install the piston in the caliper with the groove side
of the piston facing the pad.
BRAKE
BRAKEPAD
BRAKE PAD
PAD
PISTON
PISTONBB
PISTON
PISTON BB
PAD
PAD
PADSPRING
SPRING
SPRING
SOCKET
SOCKET BOLT
SOCKETBOLT
BOLT
● Install the RH./LH. caliper body.
SOCKET BOLT
● Install the socket bolt.
● Install pad spring to the caliper.
● Install caliper hanger pin bolt to the pad comp and
caliper bracket to the caliper body.
● Install the brake pad to the caliper.
INSTALLATION
● Install the brake caliper to the from fork, and front axle.
● Install the caliper to the specified torgue.
TORQUE VALUE : 3.0 kgf·m
● Install the brake hose to the caliper body with the

new 2 oil bolts washer and oil bolts.
● Install the oil bolt to the specified torgue.
TORQUE VALUE : 3.4 kgf·m
● Fill the brake fluid, and bleed air.
REAR BRAKE CALIPER

DISASSEMBLY
● Untie rear brake tube and separate brake tube
● Untie 2 bolts and disassemble rear brake caliper.
REARBRAKE
REAR
REAR BRAKECALIPER
BRAKE CALIPER
CALIPER
BRAKES
DISASSEMBLY
● Disassemble pad spring, slide pin, caliper bracket,

AIR GUN
boot from caliper body.
● Wrap caliper with cloth, and face it down.
● Blow slowly low pressed air to the assembled place
of brake hose and separate piston from caliper.
CAUTION
•Do not use high pressed air or do not close air gun.
•Do not hand insert to the inside of caliper
● Disassemble piston seal, dust seal
CHECK
● CLena the inside of caliper and piston with brake
fluid
● Check whether there is flaw and damaged in the
contact place of caliper.
BRAKES
● Measure inner diameter of caliper cylinder

● Check whether there is flaw or scratch in outer side
of piston.
● Measure the outer diameter of piston

● Assemble caliper
WASHER DUST SEAL PAD SPRING
PISTON BRACKET
CALIPER BODY PISTON SEAL BRAKE PAD
HANGER PIN

BRAKES
UPPER HANDLE COVER MASTER CYLINDER

DISASSEMBLY
● Disassemble upper handle cover and under handle
cover.
● Drain, front and rear brake fluid.
● Disassemble rear stop switch coupler.
UNDER HANDLE
UNDER
UNDER HANDLE
HANDLE
COVER
COVER
COVER
● Untie brake tube bolt.

BRAKEHOSE
BRAKE
BRAKE HOSE
HOSE MASTER CYLINDER ● Untie master cylinder holder bolt.
BOLT ● Disassemble master cylinder.
CAUTION
•Be careful for brake fluid not to be stained with
painting, plastic, rubbers. If brake fluid stained,
clean it by cloth or wash with water. For
preventing leakage of brake fluid, cover the hose
connecting area.
•After disassembly, wash parts with brake fluid and
check about air ventilation in each hole.
•Put disassembled parts in order not to be stained
with dirty material or dust.
DISASSEMBLY
● Disassemble boot, cir clip from master cylinder.
TOOL : SNAP RING PLIER.
CIR CLIP
CYLINDER
MASTER CYLINDER SET ● Disassemble washer, piston, spring from master

cylinder.
STOP SWITCH
● Wash inside master cylinder, reserve, master piston
with brake fluid.
LEVER
BOOT
CIR CLIP MASTER CYLINDER BODY
BRAKES
PISTON
CHECK
● Check whether there is flaw or scratch in outer place
of piston.
● Check on abrasion or damage of primary cup,
secondary cup.
SECONDARY PRIMARY
CAP CAP
CAUTION
•If fluid leaks out at assembly of new piston, it
means side abrasion of cylinder. In this case,
replacement of master cylinder body is necessary
as well.
● Check whether there is flaw or abrasion of slide

selective place of master cylinder.
OIL CUPCAP ASSEMBLY

DIAPHRAGM PLATE CAUTION
BOOT
CIR CLIP DIAPHRAGM •Replace surely based on set when disassemblying
SPRING of piston, spring, cup, snap ring.
•Check whether dust or alien material is attached to
each part.
WASHER •Use the designated brake fluid surely at cleaning
MASTER CYLINDER with brake fluid.
BODY
● Apply the designated and recommended clean brake

fluid to cup, piston, inner place of cylinder and
LEVER STOP SWITCH
assemble piston.
CAUTION
•When assembling cup, be careful for the end of
cup not to be cogged.
•Assemble spring so that the end of its small coil
goes forward to piston.
•Attach the primary cup to the way of spring.
● Assemble circlup to the home of master cylinder
correctly.
TOOL : SNAPPING PLIER
● Assemble boot to master cylinder.
BRAKES
INSTALLATION
● Assemble front/reat master cylinder to the handle.
CAUTION
•Face the UP mark of holder up and fit the contact
place to the punch mark of handle.
•Assemble the upper bolt of holder first
● Assemble brake hose with 2 new sealing washer to

master cylinder
● Untie flat screw and disassemble oil cup cap,
diaphragm plate, diaphragm.
● Apply brake fluid and pull out the mixed air( 16-2)
● Assemble oil cup cap, diaphragm plate, diaphragm
BRAKE DISK
CHECK
● Meause the thicknes of brake disk
SERVICE LIMIT ; 3.0mm
MICRO METER
● Check on wobbling of brake disk

SERVICE LIMIT
TOOL : DIAL GAUGE
FRONTDISK
FRONT
FRONT DISK
DISK
DIALGAUGE
DIAL
DIAL GAUGE
GAUGE
MEMO
CHARGING SYSTEM
CHARGING SYSTEM
Y
G
Y
R/W
Y FUSE(30A)
R
SMART
KEY
B
REGULATOR BATTERY
FUSE
RECTIFIER (15A) (12V 10AH)
AC. GENERATOR ELECTRICAL PARTS
16. CHARGING SYSTEM

INSPECTION OF CHARGING SYSTEM 16-4
SERVICE STANDARDS 16-1
INSPECTION OF REGULATOR RECTIFIER 16-5
TROUBLE SHOOTINGS 16-2
INSPECTION OF AC. GENERATOR CHARGING COIL 16-6
BATTERY 16-3
SERVICE INFORMATION
WARNING
·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created
dyrign charging battery
·Do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact can cause burns or loss
of eye sight. If contact occurs, thoroughly clean with water, and if acid enters eyes, flush with watr and see a doctor.
·If battery acid gets on clothing, as it can seep through or make a hole through the clothign and make its way to the
skin, make sure to change clothing that has come into contact with battery acid and wash the battery acid from the
clothes.
CAUTION
·This vehicle has a maintenance-free(MF) battery. Because MF batteries use different charging equipment, take spe-
cial care when performing maintenance and especially when repalcing parts. Not all regular battery equipment is
compatible with MF batteries.
·When charging the battery, remove the battery from the frame and do not open stopper.
·There is the possibility of damaging th regulator/rectifier, etc. if the terminal or coupler is separated / connected when
electricity is over flowing through the electrical devices. Make sure to turn the main switch OFF when performing
maintenance to the charging equipment.
● If the battery is allowed to repeatedly lose all its charge, is repeatedly over-charged, or if it is left in an un-charged
state, the battery can be damaged, its life can be reduced, or it can lose some of its strength. It is important to note
here that the battery will naturally last 2-3 years of normal use, and although it will re-charge, its load is reduced,
leadign to a loss in battery strengh.
● It is possible for the battery to become overcharged from battery body load. If a battery cell becomes short-circuited
and if a state develops where voltage is not created between the temrinals, the regulator will not operate and exces-
sive voltage will develops where voltage is not created between the terminalsd, the regulator will not operate and
excessive voltage will develop in the battery and normal cell electrolytes will decrease.
● If the vehicle is not used for a long period, make sure to change the battery every three months. If not so, the battery
ability to store electricity is reduced.
● For information on generator disassembly, refer to section 8.
SPECIFICATIONS UNIT :mm

ITEM STANDARD VALUES
Capacity 12V-10AH(MF)
BATTERY Terminal to terminal voltage 13.0-13.2V
(When fully charged) (at the time in‘OFF‘ for 30 minuites )
Charging coil resistance value(20°C) 0.1~1.5Ω(20°C)
A.C. GENERATOR
Rpm at charging start 1,350rpm
Type Thyristor
REGULATOR / RECTIFIER
Regulator voltage 14.5±1.0V / 5,000(rpm)
TOOL
MULTI TESTER, SCANNER, BATTERY TESTER, PVA(Pick Voltage Adapter)
CHARGING SYSTEM
16-2 TROUBLE SHOOTING

No power(key turned on) Low power(engine running)
● Dead battery ● Battery undercharged
- Low fluid level ● Battery is failing
- Complete discharged ● Charging system failure
● Disconnected battery cable
Intermittent power
● Main fuse cut or bad contacted(between fuse and holder)
● Loose battery connection
● Faulty main switch lever
● Loose charging system connection
● Wire harness cut or bad contacted
● Loose starting systme connection
Low power(key turned on) ● Loose connection or short circuit in ignition system
● Battery undercharged ● Loose connection or short circuit in lighting system
- Low fluid level
- Battery discharged Charging system failure
● Charging system failure ● Loose, broken or shorted wire or connection
● Loose battery connection ● Faulty regulator rectifier
● Faulty A.C. Generator
CHARGING SYSTEM
Measure battery current leakage(16-4) INCORRECT

Check the regulator rectifier.
CORRECT CORRECT
·Shorres harness wire
·Fagulty main switch
INCORRECT
Inspec the charging status OVER 15V ·Faulty regulator rectifier
UNDER 14V 14~15V Battery is failing
Check the voltage between battery line and Open circuit in wire harness
INCORRECT
ground wire of regulator rectifier. Poorly connected coupler
CORRECT
Check the resistance of th charging coil at the INCORRECT Check the charging coil of the A.C. generator
checking coil line of regulator rectifier cou- CORRECT
pler.
Poorly connected A.C. Generator coupler
INCORRECT
CORRECT Faulty charging coil
Check the regulator rectifier. INCORRECT Faulty regulator rectifier
CORRECT
Faulty battery
CHARGING SYSTEM
BATTERYCOVER
BATTERY
BATTERY COVER
COVER BATTERY
DISASSEMBLY / INSTALLMENT
● Open seat
● Disassemble battery cover
● Untie battery(-) cord, disassemble (+) cord and battery

CAUTION
§]CORD
§]CORD
§]CORD CORD
§^CORD
§^ CORD
§^ •At assemblying of battery, in order to prevent short
circuit, first connect + terminal then - cord.
VOLTAGE INSPECTION
● Use multi tester and measure the voltage of battery.
VOLTAGE : Full charging : 13.0~13.2V
Insufficient charging : under 12.3V
TOOL : Multi tester
NOTE
•Use a voltmeter that will accurately indicate 0.1V
difference.
•When measuring the battery voltage after charging,
leave it for at least 30 minutes, or the accurate
results cannot be obtained because the battery volt-
age fluctuates just after charging.
BATTERY CHARGING
● Remove the battery.
● Connect the charging + cable and battery + terminal.
● Connect the charging - cable and battery - terminal.
NOTE
•Be sure to the battery charging is not allow to
exceed the specified charging time and current.
•To avoid the rapid charging could be possible to
reduce the battery life and cause of damage.
CHARGING SYSTEM
CHARGING SYSTEM
AMPEREMETER
INSPECTION
LEAK TEST
BATTERY⊖ TERMINAL ● Turn off the ignition switch, and disconnect the
ground (-) cable from the battery.
● Connect an ampere meter between negative (-) termi-
nal and ground cable.
● With the ignition switch off, measure the leakage cur-
rent.
Leak current : 0.1A(below)
TOOL : MULTI TESTER or AMPEREMETER
EARTH CABLE
CAUTION
•Current flow larger than the range selected may
blow out the fuse in the tester.
•While measuring current, do not turn the ignition
on. A sudden surge of current may blow out the
fuse in the tester.
LEAK CURRENT.
CHARGING VOLTAGE INSPECTION

VOLTMETER CAUTION
•Be sure that the battery is fully charged before per-
AMPEREMETER forming this test. The amount of current flow may
change abruptly if not sufficiently charged. Use a
battery whose voltage between its terminals is
13.0~13.2V
•When engine is started using the starter motor, a
MAIN FUSE large amount of current may flow from the battery
TERMINAL temporarily. Use the kick starter to start the engine.
•If the probes are connected in reverse order, the
registered current flow direction when charging
and discharging the battery will be reversed as
well.
MAIN FUSE
● Perform heating engine operation and assemble fullt
charged battery.
● Connect tester between battery terminals
● Disassemble main fuse and connect amperemeter
between terminals.
● Operate engine and increase engine rpm slowly, mea-
sure charging voltage.
CHARGING CURRENT : OVER 0.5A / 5,000rpm
CONTROLLING VOLTAGE : 14.5 1.0V/5,000rpm
TOOL : SCANNER, MULTI TESTER
CAUTION
•Take precaution not to control the tester or wiring
when flowing the current.
•It can cause the damage for the other parts by over-
flowing the current.
CHARGING SYSTEM
INSPECTION OF REGU-
LATOR RECTIFIER.
● Open seat
● Check wire diagram from terminal of main harness.
ITEM MEASUREMENT CRITERIA
BATTERY WIRE(RED) Voltage between red(+) and green(-) Shall be battery Voltage
GROUND WIRE(GREEN) Current flow between green and earth wire Flow shall be done
※Standard resistance value between each yellow wire 0.1~1.5 Ω
CHARGING COIL (YELLOW)
Whether flow between each yellow and earth wire Flow not to be done
※ Check at the time when 10 mins is over after engine stop.
● Check charging voltage

● Connect multi tester to battery
● After connecting scanner, accelerate engine rpm at
5,000 rpm to check the voltage.
Charging voltage : over 13.5V(headlight ‘ON’)
● Check harness and if everthing is OK, measure the

resistance between regulator rectifier and terminals.
CAUTION
•During checking, if finger touches with metal area
of tester, the resistance of human body shows. The
be careful about this.
•Check by using designated tester. If using other
tester except designated one, measure by fitting
correctly measuring range.
● If the resistance between terminals is different,

replace with new regulator rectifier.
TOOL : MULTI TESTER
● “∞”: If more than [㏁], it shows
REPLACEMENT
● Disassemble the coupler of regulator rectifier.
● By untieing 2 bolts of regulator rectifier, disassemble.
REGULATORRECTIFIER
REGULATOR
REGULATOR RECTIFIER
RECTIFIER
CHARGING SYSTEM
CHECKING OF AC. GENER-

ATOR CHARGING COIL
● Disassemble seat
● Disassemble connected coupler of AC. Generator
cord.
● Measure the resistance between each yellow lead

wire.
STANDARD RESISTANCE VALUE : 0.1~1.5
(20°C) between yellow and yellow.
● If there is flow between terminal and earth terminal
or if the resistance value is big, replace with the new
stator.
CAUTION
•This test shall be done on condition that the engine
installed to the vehicle.
MEMO
MEMO
IGNITION SYSTEM
IGNITION SYSTEM
R/Y
ENGINE STOP
SWITCH
FUSE(15A) G/R
G
SMART KEY
(DESS)
B B/Br R L/Gr L/Y G L G W/B R/Y
FUSE(15A)
RED/WHITE R/Y
B/R B/R
FUSE(30A) IGNITION CRANK POSITION FUEL PUMP

COIL ISA INJECTOR FUEL PUMP SENSOR RELAY
R G
BATTERY
SPARK
PLUG
17. IGNITION SYSTEM
SERVICE INFORMATION 17-1 CHECKING OF CRANK

SERVICE STANDARDS 17-1 POSITION SENSOR 17-3
TROUBLE SHOOTINGS 17-2 CHECKING OF IGNITION COIL 17-4
SERVICE INFORMATION
GENERAL SAFETY
● Follow the steps described in the troubleshooting flow chart when servicing the igntion system
● If ECU falls down or gets strong out force, it may cause out of order. Then, take precaution because falling down
may cause out of order.
● If the connector is disconnected when the current is flowing, the execessive voltahe may damage the unit.
Always turn off the ignition switch before servicing.
● ECU is controlling equipment in ignition system, then temporary adjustment is impossible because adjusting.
● Use spark plug of the correct heat range. Using spark plug iwith an incorrect heat range can damage the engine.
● Connect the same color cords. Pay particular attention to colors prior to removing wiring. Connect the same color
couplers.
● A faulty iginition system is often related to poorly connected connectors. Check those connections before proceeding
● This manual gives explanations on inspections to receive peak voltage. As inspections for coil resistance values are
also included, it may be difficult to make a correct determination
● Conduct inspection on the main switch by referring to the wiring system continuity chart( 21)
SPECIFICATIONS
ITEM STANDARD VALUE
PRIMARY COIL 0.73 ± 0.08Ω, 23℃± 5℃
IGNITION COIL
SECONDARY WITH PLUG CAP
RESISTANCE VALUE 20 C (15 KΩ)
COIL WITHOUT PLUG CAP
CRANK POSITION SENSOR RESISTANCE VALUE 80Ω~150Ω,20℃
IGNITION TIMING IDLE(1,600±100rpm) BTDC 0°

(Cold water temperature : 70°
C)
TOOL
MULTI TESTER
PVA MULTI-TESTER
IGNITION SYSTEM
TROUBLE SHOOTING
No spark at spark plug : Surely check peak voltage tester.
UNUSUAL CONDITION PROBABLE CAUSE(CHECK IN NUMERICAL ORDER)
1. Cranking speed is too slow

- Battery is undercharged(or operating force of kick starter is
weak)
2. Effect of test sampling(After several times testing, if the voltage
Low peak voltage is over standard value, it means normal)
3. The wires of ignition system are taken off.
Ignition coil primary voltage
4. Faulty ignition coil

5. Faulty ECU(in case when above No. 1~5 spark plug does not
work-not lighting)
1. Incorrect peak voltage adaptor connections

2. Faulty ignition switch
3. Loose or poorly connected ECU coupler
No the maximum voltage or almost not.
4. ECU earth wire cut or bad contact
5. Faulty ECU(in case when above 1~5 are normal, but not flame
in spark plug)
1. Faulty spark plug or leaking ignition coil secondary current

Peak voltage is normal, nut no spark
ampere
jump at plug
2. Faulty ignition coil
Crank position sensor
1.Cranking speed is too slow

- Battery is undercharged(or operating force of the kick starter
is weak)
Low peak voltage 2. Effect of test sampling time(after several times test, if voltage is
over standards, it means normal)
3. Faulty crank position senso(if normal in 1~3)
PULSE GENERATOR
1. Faulty peak voltage adopter

No peak voltage or almost not
2. Faulty crank position sensor
IGNITION SYSTEM
CHECKING POINTS
No spark at spark plug : Surely check peak voltage tester.
UNUSUAL CONDITION PROBABLE CAUSE(CHECK IN NUMERICAL ORDER)
IGNITION KEY When starting, measure the battery voltage between ignition key’s
black and green wire.
Measure the resistance between blue and green wire of coil.

CRANK POSITION SENSOR
(80~150 , 20°C)
Measure the resistance between black/yellow and green wire of coil

IGNITION COIL PRIMARY
(0.73° 0.08 , 23°C° 5°C)
GROUND WIRE Check the electricity flow between ground wire and frame body.
● If the measure value is over designated range or spark plug does not make flame, check ignition coil by using tester.
CHECKING OF CRANK
POSITION SENSOR
MEASURING RESISTANCE
● Open the seat
● Disassemble the coupler of AC. Generator
● Measure the resistance between blue and green wire.
Standard value : 80~150 (20°C)
MEASURING THE MAXIMUM VOLT-

AGE
● Disassemble the coupler of AC. Generator
● Connect the + code of PVA tester to blue terminal
● Connect - code of PVA tester to green terminal
● Crack by starter motor and measure the maximum
voltage of pulse generator coil
The maximum voltage : over 1.5V
Tool : PVA, Multi-tester
PVA
PVA
PVA
IGNITION SYSTEM
IGNITION COIL
IGNITION
IGNITION COIL
COIL
CHECKING OF IGNITION
COIL
PUSH
PUSH
PUSH
● Pull backward the fixing pin of ignition coil, press
the coupler and disassemble it.
CAUTION
•Because the resistance value of primary coil is low,
PULL then it is difficult to decide whether it is out of
order or not.
IGNITIONCOIL
IGNITION
IGNITION COIL
COIL
PRIMARY COIL
● Measure the resistance value of primary from igni-
tion coil terminal.
● If its value is within the designated range, it is OK.
STANDARDS : (Resistance) 0.73 0.08 , 23°C°
0.5°C(voltage) over 100V.
REPLACEMENT
IGNITIONCOIL
IGNITION
IGNITION COIL
COIL ● Disassemble high tension cord from plug and plug
cap.
● Disassemble wires from ignition coil cord terminal.
● Untie 2 ignition coil flange bolts assembled at frame
and disassemble ignition coil.
● Assemble in the reverse order disassembly.
GROUNDWIRE
GROUND
GROUND WIRE
WIRE
CAUTION
•At assembly, be sure to connect the ground
wire(earth wire).
MEMO
STARTER SYSTEM
18. STARTER SYSTEM
SERVICE INFORMATION 18-1 STARTER MOTOR 18-3

TROUBLE SHOOTING 18-2 STARTER MAGNETIC SWITCH 18-6
SERVICE INFORMATION
GENERAL SAFETY
● The starter motor can be maintained without removing the engine from the vehicle
● Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing seri-
ous injury.
● A weak batter mau be unable to turn the starter motor quickly enough, or, supply adequete ignition current
● The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over
● The engine may not be turned over if the stop switch is faulty
SPECIFICATIONS
UNIT : mm
STARTER MOTOR BRUSH LENGTH 10.2mm 5mm
TOOL
MULTI-TESTER
VERNIER CALIPERS
SCANNER
STARTER SYSTEM
TROUBLE SHOOTING
STARTER MOTOR DOES NOT TURN
● Check for a blown main fuse before servicing
Connect the stater motor (+) terminal to the

With the ignition switch ‘ON’ and squeeze CLICKS battery positive terminal. (Because a large
the brake lever, check for “click” sound from amount of current flows, do not use thin
starter magnetic switch wire)
Stater motor turns Starter motor does not turn

NO CLICK
● Loose or disconnect- ● Faulty starter motor

ed wire or cable
Disconnect starter magnetic switch coupler,

● Faulty starter switch
and check the starter magnetic switch coil
NO CONTINUITY ● Loose or poor contact at connector or open
ground wire (18 6)
circuit in wire harness
CONTINUITY
Connect the starter magnetic switch coupler.

Measure the starter magnetic voltage at the VOLTAGE MEASURED ● WIRE HARNESS CUT .
starter magnetic switch coupler(18 6) ● BAD CONNNECTED CONNECTOR
● FUSE CUT
NO VOLTAGE
Check the starter magnetic switch opera- NORMAL ● Loose or poor contact at starter magnetic
tion(18 6) switch coupler
ABNORMAL ● Faulty starter magnetic switch
Starter motor turns, but crankshaft does not The rolling power of starter motor is weak
● Faulty starting clutch ● Battery discharged
● Faulty starter gear ● Poorly connected battery terminal cord
● Slided starter clutch ● Poorly connected starter motor cord
● Poorly connected ground cable
Idling starter ● Worn or damaged brush
● Reverse rolling of motor
● Reversely assembled brush Starter motor, crankshaft turn, but engine does
● Reversely assembled motor cable not startStarter motor, crankshaft turn, but
● Motor terminal reversely assembled engine does not start
● Faulty ignition system
● Engine problems
STARTER SYSTEM
STARTERMOTER
STARTER
STARTER MOTERCABLE
MOTER CABLE
CABLE FLANGEBOLT
FLANGE
FLANGE BOLT
BOLT
STARTER MOTOR
DISASSEMBLY
● Turn the main switch “OFF”, disassemble battery(-)
cable before maintaining starter motor.
● Take off rubber cap and untie nut, disassemble starter
motor cable from starter motor.
● Untie 2 starter motor flange bolts and separate earth
cable and starter motor from case.
DISASSEMBLY
FLANGE BOLT ● Untie 2 installation bolts and disassemble the follow-
ing parts
- O-RING
- STARTER MOTOR CASE BOLT/ SPRING
WASHER
- FRONT COVER
- SEAL RING
- LOCK WASHER
- WASHER
- CIR CLIP
- REAR COVER ASS°ØY
- SEAL RING
- 2 WASHERS
- AMATEUR
CAUTION
•Be sure to turn the main switch off when reparing
starter motor. If the power connected, starter motor
may exceptionally operate then cause to be dam-
aged.
INSPECTION
● Check whether the inner bushing in rear cover are
damaged or worn.
● Check whether the inner bushin of front cover and oil
seal are damaged or worn.
● Check on discolor of amateur commutator.

● Replace if each segment is seriously discolored
meaning abnormal.
STARTER SYSTEM
● Check on continuoity of each segment of commuta-

tor.
- If continuoity, normal.
● Check on continuoity between amateur shaft and

each segment of commutator.
- If not continuoity, means normal.
● Check on continuoity between + brush and cable ter-

minal.
- If continuoity, means normal.
● Check on continuoity between cable terminal and

case.
- If not continuoity, means normal.
STARTER SYSTEM
● Check abrasion of brush and measure the length of

brush.
SERVICE LIMIT : 5mm
BRUSH
● Insert 2 washers.
● Assemble the new seal ring to motor case.
● Apply slightly grease to the end position of amateur
shaft.
● Assemble brush to terminal.
● Fit brush into brush holder and assemble amateur to

motor case.
● Combine rear cover to the mark of motor case.
CAUTION
•Take precautions that there is not any flaw in con-
tact side of amateur and brush. When case is
assembled to amateur, both parts may be crashed
each other because magnet may be pulled out. If
strongly crashed then coil may be damaged, be
sure to pull it by hand and fit into.
STARTER
STARTER MOTOR
STARTER MOTOR CABLE
MOTOR CABLE
CABLE ASSEMBLY
● Apply oil to the new O-ring and assemble starter
motor home.
● Insert starter motor to LH. Crank case.
● Assemble 2 starter motor assembly bolts.
● Assemble starter motor cable.
● Wrap up correctly rubber cap to terminal.
STARTERMOTOR
STARTER
STARTER MOTOR
MOTOR
STARTER SYSTEM
STARTERMAGNETIC
STARTER
STARTER MAGNETIC
MAGNETIC
STARTER MAGNETIC
SWITCH
SWITCH
SWITCH SWITCH
DISASSEMBLY
● Open seat
● Disassemble battery + wire assembled at starter mag-
netic switch terminal(When disassembling, take pre-
cautions not to short circuit and grounding.
● Disassemble sarter motor cable assembled at starter
magnetic switch terminal.
● Disassemble wire harness and assembled yellow/red
connector and green/yellow connector.
● Disassemble starter magnetic switch from the fixed
bracket of frame.
INSPECTION
● Turn the main switch “ON”, when pushing starter
switch button, check whether it sounds precisely con-
nected.
- It sounds
Bad contacting between battery terminal and
motor terminal(Check operation of starter mag-
netic switch).
- It does not sound
Do not input the voltage to starter magnetic
switch.
Bad starter magnetic switch
STARTER MAGNETIC SWITCH VOLT-

AGE
● Measure the voltage between starter magnetic switch
yellow/red wire(+) and frame earth(-).
● When the main switch turned ON and pushing starter
switch, if there is battery voltage, it is normal
STARTER MAGNETIC SWITCH EARTH

WIRE DIAGRAM
● Disassemble connection of starter magnetic switch
green/yellow wire connector, if there is continuoity
between the terminal of harness and frame earth.
CHECKING OF OPERATION.
● When connecting the battery (+) to yellow/red wire
disassembled connecting of magnetic switch wire
connector and battery (-) to green/yellow wire, if
there is continuoity between terminals by connecting
multi tester like the photo, the switch operates well.
MEMO
LIGHTS / SWITCHES / HORN
19. LIGHTS// SWITCHES / HORN

MAIN SWITCH 19-5
TROUBLE SHOOTINGS 19-1
HANDLE BAR SWITCH 19-5
HEAD LIGHT 19-2
HORN SWITCH 19-6
FRONT WINKER 19-3
FRONT/ REAR STOP SWITCH 19-6
REAR COMBINATION LIGHT 19-3
SEAT SWITCH 19-7
REAR WINKER 19-3
SMART KEY SET(DESS) 19-7
SPEEDOMETER 19-4
SERVICE INFORMATION
GENERAL SAFETY
● Connect the same color wires together. Connect couplers carrying the same color and the same number of pins
together.
● All couplers are equipped with tabs which can be locked. Remove these locks prior to disassembling ; and insert
these tabs all the way until locked when assembling
● Carry out continuity test on circuits or parts to diagnose electric systems. The continuity test on normal parts can be
carried out without removing the parts from the vehicle. Simply disconnect the wires and connect a continuity tester
or and ohmmeter to the coupler terminal or connectors.
● The continuity test is conducted to check if electric power is connected between 2 terminald. If these is coil resistance
within circuits, or to check the large resistance resulting from the connector corrosion, an ohmmeter is required to
check the circuit resistance value.
TROUBLE SHOOTING
Light not turned on when the main switch is Fuel meter indicator malfunctioning
ON. ● Coupler separated
● Faulty light bulb ● Harness disconnected
● Wire cut or faulty wires ● Float operation malfunction
● Faulty or disconnected wiring ● Fuel unit damaged
● Fuse cut
● Battery discharged Fuel meter needle unstable
● Coupler loose
Dim headlight ● Fuel unit damaged
● Battery discharged ● Meter damaged
● Wiring and switch resistance high
Headlight Hi-low beam can not be charged

● Faulty light bulb
● Faulty dimmer switch
LIGHTS/ SWITCHES / HORN
FRONT UNDER A COVER POSITION LAMP HEAD LIGHT

DISASSEMBLY
● Disassemble front under A cover.
● Disassemble headlight wires
● Disassemble head light ass’y
FRONTWINKER
FRONT
FRONT WINKER
WINKER HEAD LIGHT DUST COVER
REPLACEMENT OF HEAD LIGHT

BULB
● Disassemble head light dust cover from under the
front under A cover.
● Disassemble head light socket
● Replace with new head light bul
CAUTION
•When replacing bulb, if touching the glass surface
of bulb by hand or contaminated gloves, oil
FRONTUNDER
FRONT
FRONT UNDERAAACOVER
UNDER COVER
COVER
contents may be stained causing heating. Then it it
may cause heat deformation of glass surface and
break. At replacing bulb, refer to the followings.
•When light turns on, do not replace. Turn main
switch OFF surely then bulb gets cold and do the
following works.
- When replacing bulb, wear glean gloves to be
careful for oil content not to be stained in glass.
- If oil content stained in bulb, clean it completely
by clean gloves stained with alcohol or gasoline
like thinner and next clean once more by clean
gloves.
- After replacing bulb, assembled rear cover
completely.
POSITIONDUST
POSITION
POSITION DUSTCOVER
DUST COVER
COVER POSITION LAMP
● Disassemble front unver A cover
● Untie 4 screws and disassemble position dust cover.
● Disassemble the position lamp wires

● Untie 2 screws and disassemble position lamp
● Disassemble RH/LH position lamp ass’y
WINKER SOCKET
WINKER
WINKER SOCKET
SOCKET WINKERBULB
WINKER
WINKER BULB
BULB
FRONT WINKER
REPLACEMENT OF WINKER BULB
● By rotating winker socket from front under cover A
clockwise, disassemble it.
● Disassemble bulb from winkerr bulb socket next
replace.
CAUTION
•When disassembling lens, do not press
unnecessary force.
REAR COMBINATION
LIGHT
REPLACEMENT OF BULB
● Disassemble rear combination light ass’y
● Replace with the new rear combination light ass’y
CAUTION
•At diassembling, be careful for lens not to be
broken and do not press uncessary force.
•Check on whether lens seal assembled correctly at
assembling tail light lens.
REAR WINKER
REPLACEMENT OF BULB
● Untie 4 tail light lens fixing tapping screws of rear
combination light.
● Pulling backward the left and right of tail light
slightly and breaking away from home, diassemble.
● By disassembling bulb from winker bulb socket,

and replace it.
SPEEDOMETER
DISASSEMBLY
● Disassemble front under, upper handle cover
● Disassemble speedometer(in the meter side) cable.
● Disassemble meter cover
● Disassemble speedometer ass’y

MAIN SWITCH
● Disassemble main switch coupler

MAIN SWITCH
MAIN
MAIN SWITCH
SWITCH ● Test the continuoity between each terminal
RED BLACK
OFF
ON
DIMMER SWITCH HANDLE BAR SWITCH

● Disassemble connecting of handle bar switch
connector.
● Check the continuoity between each terminal of
handle bar switch.
WINKER SWITCH HORN SWITCH

HORN
HORN SWITCH
SWITCH
WINKER SWITCH
W R L
R
N
L
COLOR GRAY SKY BLUE ORANGE
DIMMER SWITCH
BAT4 HI LO
HI
(N)
LO
COLOR BROWN/WHITE BLUE WHITE
ENGINE SWITCH
STARTER SWITCH
ST E
FREE
PUSH
COLOR GREEN/RED GREEN
HAZARD SWITCH
STARTER SWITCH
HAZARD SWITCH
HAZARD
W R L
OFF
HAZARD
COLOR GRAY SKY BLUE ORANGE
HORN HORN
● Remove the wire connector from the horn.
● Connect the horn terminal with 12V battery.
● Normal if it sounds.
HORN SWITCH
HO BAT2
FREE
PUSH
COLOR LIGHT GREEN BLACK
FRONT / REAR STOP

SWITCH
INSPECTION
● Remove the front handle cover.
● Check the continuoity between the black wire of
under the key and the terminal of green/yellow wire.
At pulling brake lever - continuoity
At releasing brake lever - no continuoity
SEAT SWITCH
SEATOPEN
SEAT
SEAT OPENSOLENOID
OPEN SOLENOID
SOLENOID
● Check the resistance of seat open solenoid material
RESISTANCE VALUE : about 2
● If it is over the designated resistance value range or
, it means faulty part then replace.
● After connecting tester to orange/blue(+) cord and

green cord(-) of seat open solenoid, push the seat
button and check the voltage.
STANDARD VOLTAGE : Battery voltage
SMART KEY SET(DESS)

● When push the main switch lever and LED of smart
key lights, check whether blue LED at key lights or
not.
LIGHTING
LIGHTING
LIGHTING
BLUELED
BLUE
BLUE LED
LED
LIGHTS
LIGHTS
LIGHTS
● Check the resistance of green and white/yellow of

main switch lever.
● Check the continuoity when pushing the main
switch lever.
● Check the resistance after connecting tester to the

red/white and black/blue of solenoid.
RESISTANCE VALUE : about 30
● If it is over the designated resistance value or , it
means faulty part then replace.
● Check the continuoity between key set terminals

after main switch lever ON.
SMART KEY RECEIVER

● Check the voltage between red/white and green of
smart key receiver.
STANDARD VOLTAGE : Battery voltage
● Check the continuoity and wire status of each part of
receiver.
SMARTKEY
SMART
SMART KEYRECEIVER
KEY RECEIVER
RECEIVER
AUTOCOMBI
AUTO
AUTO COMBI&&&LOCK
COMBI LOCKSWITCH
LOCK SWITCHASS’Y
SWITCH ASS’Y
ASS’Y
KEY SET DISASSEMBLY
● Disassemble 3 flange bolts
● Disassemble coupler and auto combi. & lock switch
ass’y.
● Disassemble auto combi. & lock switch ass’y lever

cover.
AUTO COMBI & LOCK SWITCH ASS’Y
● Disassemble LED bulb.

● Assemble in the reverse order of LED bulb.
ANTENNA
SMARTKEY
SMART
SMART KEYANTENNA
KEY ANTENNA
ANTENNA
● Check on damage or flaw off outer antenna and
connection of coupler and wires.
MEMO
20. TROUBLE SHOOTING
ENGINE WON’T STARTING OR IS HARD TO START 20-1 POOR STARTING 20-5

IDLEING, POOR LOW SPEED AFTER STARTING 20-2 UNSTABLE PRM OR STOP AT ENGINE STARTING 20-6
POOR ENGINE SPEEDING AT MIDDLE OR HIGH SPEED 20-3 IDLE RPM INCREASES OVER 2,000 RPM 20-6
POOR PERFORMANCE AT HIGH SPEED 20-3 FAULTY OPERATION 20-7
* This section explains about diagnosis of principal trouble shooting in engine. Except this section, refer to each
section’s trouble shooting.
BAD ENGINE STARTING

CHECKING ON FUSE SHORT ·Main fuse(30A), each fuse(15A) short circuit
CUT ·Check battery voltage
·Check assembly of spark plug

CHECK THE SPARK PLUG ·Check combustion of spark plug
·Check trembling of spark plug cap
·Check fault of spark plug

·Check wires of ignition system(loosing, deflating)
·Faulty ignition coil
CHECK THE FLAME OF SPARK ·Checking crank position sensor
PLUG - When causing error, checking is possible
from scanner
- Checking fly wheel, stator pulse
·Checking fault of ECU
·Checking whether bad operation or discharge rate

CHECK FUEL PUMP ·Checking abnormal sound
·Fault of fuel injection system

CHECK INJECTOR - Refer to trouble shooting manual
·Check on fuel injected or not.
·Valve does not close

- Checking valve clearance, cam timing
TEST CYLINDER COMPRESSION ·Checking abrasion of cylinder, piston ring
·Damage of cylinder head gasket
·Valve damaged
·Though engine starts, but soon stops

- Checking opening of throttle body valve
- Checking fault of performance of idle speed actutator.
CHECK ENGINE IDLING - Checking of damage and assembly status of insulator
- Checking usage of bad gasoline
TROUBLE SHOOTING
IDLING AFTER STARTING, BAD LOW SPEED
·Checking assembly of spark plug

CHECKING SPARK PLUG ·Checking flaming of spark plug
·Checking trembling of spark plug cap
·Checking fault of spark plug

·Checking the wires of ignition
system(loosing, pulled out)
CHECKING FLAME OF SPARK ·Checking fault of ignition coil
PLUG ·Checking cra nk position sensor
- At causing error, cheking is possible from
scanner
·Checking fault of ECU
·Checking performance and discharge rate

CHECKING FUEL PUMP ·Checking abnormal sound
·Fault of fuel injection system

CHECKING OF FUEL INJECTOR - Refer the trouble shooting diagnosis manual
·Checking whether fuel injection does work
or not well.
CHECKING IDLE SPEED ·Check on the assembly of ISA

ACTUATOR(ISA) ·Check the air capacity of ISA(checked by
SCANNER)
CHECKING 2ND AIR (INLET ·Check on opening of throttle body valve

MANIFOLD) INHALATION ·Check on assembly of insulator and its damage
CHECKING OF VALVE ·Is the valve clearance normal or not ?

CLEARANCE
TROUBLE SHOOTING
POOR ENGINE SPEEDING AT MIDDLE, HIGH SPEED

·CHECKING CRANK POSITION SENSOR
1. CHECKING OF IGNITION - At causing error, checking is possible by
TIMING scanner
·BAD ECU
·CHECKING ON OPERATING OR NOT,

DISCHARGING RATE
2. CHECKING FUEL PUMP - Refer to checking points of fuel pump of each
product
·FAULTY FUEL INJECTION SYSTEM

3. CHECKING INJECTOR - Refer the trouble shooting diagnosis manual
·CHECKING WHETHER VALVE TIMING

4. CHECKING VALVE TIMING IS ABNORMAL OR NOT
- Refer to the Service Manua
·CHECKING THE FREE PLAY OF VALVE

4. CHECKING VALVE TIMING TIIMING
- Refer to the Service Manual
POOR PERFORMANCE AT HIGH SPEED

·Checking rotating of FR/RR wheel at
standing up the main stand.
- Checking whether brake works or not
1. CHECKING DRIVING SYSTEM - Checking on abrasion or damage of wheel
bearing
- Checking on abrasion or damage of
final(drive) shaft bearing
2. CHECKING TIRE AIR ·CHECKING WHETHER AIR PRESSURE

PRESSURE OF TIRE IS NORMAL OR NOT
·Pull slightly throttle grip

- Can RPM of Engine rise up smoothly ?
3. CHECKING ENGINE
·Cogged air cleaner ?
PERFORMANCE
·Cogged muffler ?
·Cogged in fuel system ?
·Checking on assembly of spark plug

4. CHECKING SPARK PLUG ·Checking on combustion status of spark plug
·Checking on trembling of spark plug cap
·Checking the capacity of engine oil

5. CHECKING ENGINE OIL ·Checking on contamination of engine oil
TROUBLE SHOOTING
POOR PERFORMANCE AT HIGH SPEED

·CHECKING CRANK POSITION SENSOR
6. CHECKING OF IGNITION - Checking fly wheel, stator pulse
TIMING ·CHECKING ECU
·The valve is not closed.

- Checking valve clearance, cam timing
7. CHECKING THE COMPRESSION ·Checking abrasion of cylinder, pistion ring
PRESSURE OF CYLINDER ·Checking damage of cylinder head gasket
·Valve damaged
8. CHECKING FUEL PUMP ·Checking on operation and discharging rate
·Faulty fuel injection system

- Refer to the trouble shooting diagnosis
9. CHECKING INJECTOR manual of EMS
·Checking whether fuel injected or not
·Checking on lubrication of valve contacted

point.
10. CHECKING LUBRICATION - Is oil not enough at valve contacted point ?
SYSTEM ·Checking driving system of oil pump
·Faulty oil pump
·Cogged oil strainer, oil path
·Overheated ?
- Checking capacity of cooling water
11. CHECKING ON OVER - Checking on opening of thermostat
HEATING(WATER COOLING ENGINE) - Checking on carbon deposit in cylinder
- Checking on usage of low quality fuel
·Checking the free play of valve timing

12. CHECKING VALVE SPRING - Refer to the Service Manual
·Open fast throttle at high speed

- Abrasion of piston, piston ring, cylinder
- Using low quality fuel
- The thermostat does not open
13. CHECKING KNOCKING - Carbon accumulated at cylinder
- Fast ignition timing
- Checking crank position sensor(fly wheel,
stator pulse)
14. CHECKING TRANSMISSION ·Checking tolerance of clutch(bikes)

·Checking on something wrong in CVT
15. CHECKING ON USAGE ·Checking on usage of fuel long kept

STATUS OF FUEL
TROUBLE SHOOTING
BAD STARTING
WHEN ENGINE CAUTION(CHECK) LAMP LIGHTS
·Checking faulty points of scanner
·Checking on damage like being stabbed at signal position of fly
ERROR OF CRANK POSITION wheel
SENSOR ·Checking whether abnormal voltage is generated within the
range where A, B pulse signals of AC.
·Generator are not generated.
·Checking on operation of fuel pump relay component parts by
BAD PERFORMANCE OF FUEL scanner
PUMP RELAY ·Checking on being cut of ECU 39 by checking wire harness.
·Refer to EMS trouble shooting dignosis manual about detail
checking methods of each number of ECU.
·Checking faulty points by scanner
·Checking on operation of injector component parts by scanner
INJECTOR ·Checking on being cut of ECU 40 by checking wire harness
·Refer to EMS trouble shooting diagnosis manual about detail
WHEN ENGINE CAUTION(CHECK) LAMP DOES NOT LIGHT

·At connecting with scanner, communication error occurs.
(There is no operation sound of fuel pump)
CHECKING ON BEING CUT OF ·Checking whether battery voltage at ECU 10,17,25 is or not by
checking wire harness(in case of separate cut in 10, in case of
ECU POWER CORD simultaneous cut in 17 and 25, it makes problem)
·As for detail checking methods of each number of ECU, refer
to the EMS trouble shooting dignosis manual)
·Checking whether engine think is ON or not by scanner.
CHECKING ON BEING CUT OF ·If not being ON, check on being cut of ECU 22, 30 by
checking wire harness.
CRANK A,B SIGNAL CORDS ·As for detail checking methods about being cut, refer to the
EMS trouble shooting diagnosis.
·Connect with scanner then check whether switch turns ON, OFF.
·Check on being cut in ECU 5(scooter), ECU13(bikes) with
CHECKING SIDE STAND checking wire harness. In case of bikes, the signall of neutral
SWITCH gear of ECU 29 occurs.
·Regarding detail checking methods about each number of
ECU, refer to the EMS trouble shooting diagnosis manual.
·Checking on abnormal or not of ignition coil externally
·Checking on being cut of ECU 35,37 by checking wire
CHECKING IGNITION COIL harness.
·As for detail checking methods of each number of ECU, refer
to the EMS trouble shooting dignosis manual.
·VJF125/250, VS : 3.8 bar Checking discharge rate of fuel pump
VL,VJ,SQ,SLU,SN : 3.0 bar
·Checkig discharge rate of fuel pump. When the min key
CHECKING FUEL PUMP operates three times, in case of VJF, VS, its value shall be over
130cc, Except above, those of VL,VJ,SQ,SLY,SN shall be
over 100cc (But, the battery voltage shall be over 12.6V and
the capacity fuel in fuel tank shall enough
·Check on ON/OFF of engine kill switch(scanner)
CHECKING ENGINE KILL ·Checking on being short circuit of ECU No. 5(bike)
SWITCH ·Refer to the EMS trouble shooting diagnosis manual for detail
TROUBLE SHOOTING
AFTER ENGINE STARTING, IT STOPS SOON AND ITS RPM

IS UNSTABLE.
·Checking on something wrong of ignition coil
·Checkiing the flame of spark plug
CHECKING OF IGNITION COIL (Reference) Fuel value of spark plug - bike : CR9EH-9,
scooter : CR8EH-9
·Checking trouble shooting contents by scanner

·Checking on being stabbed of the signal position of fly wheel
CRANK POSITION SENSOR ·Checking whether abnormal voltage occurs or not in the
ERROR range where A,B pulse signals of AC. Generator does not
occur.
·Checking the value of idle speed actuator by scanner

(designated value : over 100°ΔC in engine temperature, the
IDLE SPEED ACTUATOR value of ISA : about 20%)
·Checking on operation of ISA component parts by scanner
·Checking the discharge rate of fuel pump

- VJF125/250, VS : 3.8 bar VL,VJ,SQ,SLU.SN : 3.0 bar
·Checking the discharge rate of fuel pump - At operation of
main key three times, in case of VJF,VS, it shall be over
CHECKING OF FUEL PUMP 130°CC Except other models(VL, VJ, SQ, SLU, SN), it shall
be over 100°CC
(But, the fuel capacity in fuel tank and over 12.6V of battery
voltage are required
·Checking on trouble shooting points by scanner

·Checking the voltage of oxygen sensor by scanner
IF THE ELECTRICE WIRE OF ·Checking on being cut of ECU 2,12,34 by checking wire
OXYGEN SENSOR IS CUT harness.
·Refer to the EMS trouble shooting diagnosis manual for detail
checking of each number of ECU.
THE RPM OF IDLE INCREASES OVER 2,000 RPM

·Checking the value of throttle position sensor by scanner(the
designated value : 0~1.2)
·Initialize ECU by scanner
CHECKING THROTTLE ·Checking on being cut of ECU 4,18,19 by cheking wire
POSITION SENSOR harness
·Refer to the EMS trouble shooting diagnosis manual for detail
TROUBLE SHOOTING
BAD OPERATION
MOVABLE DROVE FACE ASS’Y TROUBLE SHOOTING REASONS
·DRIVE BELT WORN OR BROKEN
·LAMP PLATE BROKEN
·BAD WEIGHT ROLLER OPERATION
ENGINE IS OPERATED, BUT, ·MOVABLE DRIVE FACE OPERATION
DOES NOT START ·BAD DRIVEN PULLEY WEIGHT
SHOE SPRING
·BAD TRANSMISSION
·CLOGGED TRANSMISSION
THE SCOOTER SLOWLY ·DRIVEN PULLEY WEIGHT SPRING
MOVES AND ENGINE STARTS, ·CLUTCH OUTER AND WEIGHT
BUT STOPS. CLOGGED
·DRIVE BELT ABRASION AND SLIPPERY

·WEIGHT ROLLER ABRASION
AT STARTING, LOW ENGINE ·DRIVEN FACE BEARING CLOGGED
POWER ·WEAK DRIVEN SPRING
·MOVABLE DRIVEN FACE BAD
OPERATION
·DRIVE BELT ABRASION AND SLIPPERY

AT HIGH SPEED, LOW ENGINE ·WEIGHT ROLLER ABRASION
POWER
·DRIVEN PULLEY BEARING ABRASION
·OIL OR GREASE STAINNED IN

DRIVE BELT AND PULLEY
ABNORMAL SOUND OR ·DRIVE BELT ABRASION
SMELLING ·BAD DRIVEN FACE WEIGHT SPRING
·DRIVE PULLEY BEARING
HANDLE/ WHEEL ABRASION AND CLOGGED
·EXCESSIVELY FASTENING OF
STEERING TOLP THREAD
·INSUFFICIENT TIRE AIR PRESSURE
HEAVY HANDLING OPERATION ·STEERING BEARING BROKEN
·BALL RACE BROKEN
·VIOLENT PULLING CABLE
·INSUFFICIENT TIRE AIR PRESSURE

·TIRE ABRASION AND BAD TIRE
·BAD WHEEL BALANCE
HANDLE TREMBLES ·DEFORMED RIM
·WHEEL BEARING ABRASION AND
BROKEN
·AXLE SHAFT LOOSED
·NOT MATCHED THE CENTER

BETWEEN FRONT AND REAR WHEEL
·FRONT CUSHION POWER
HANDLE LEANS TO THE ONE ·REAR CUSHION POWER
WAY ·BAD ENGINE HANGER
·NOT SMOOTH OPERATION OF
STEERING
·BAD WHEEL ALIGNMENT
·BAD WHEEL BEARING
HEAVY WHEEL ROTATING ·BENT AXLE SHAFT
·BENT BRAKE DISK
·CALIPER PISTON BAD OPERATION
MEMO
MEMO
MEMO
MEMO
MEMO
21. WIRING DIAGRAM
SERVICE MANUAL
2010. 10 PRINTED
COPY PROHIBIT
2010. 10 PUBLICATION

Daelim S3 125cc Service Manual ENG PDF

Uploaded by

Copyright:

Available Formats

Daelim S3 125cc Service Manual ENG PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Daelim S3 125cc Service Manual ENG PDF

Uploaded by

Copyright:

Available Formats

SM63-1010-01E

ENGINE LH. CRANK CASE COVER / CONTINOUSLYVARIABLE TRANSMISSION

AC GENERATOR / FLY WHEEL

CYLINDER HEAD / VALVE

CRANKCASE / TRANSMISSION/ CRANK SHAFT

FRONT WHEEL / FRONT FORK / STEERING

REAR WHEEL / REAR CUSHION

LIGHTS / SWITCHES / HORN

Copyright 2010. DAERIM MOTOR Co., LTD. WIRING DIAGRAM

SERIAL NUMBER LOCATION 1-1 SYMBOLS / ABBREVIATIONS 1-12

SERIAL NUMBER LOCATIONS

OVERALLLENGTH 2,110 mm 2,140 mm

TYPE Underbone Underbone

TYPE Air cooled 4cycle DOHC engine (4 valves)

CLUTCH DRY PLATE SHOE TYPE

IGNITION SYSTEM TRANSISTOR

STEERING STEM NUT

CYLINDER HEAD COVER BOLT M6×1.0 1.0 ~ 1.2

4㎜ BOLT, NUT 0.15 ~ 0.4 4㎜ SCREW 0.15 ~ 0.3

※ SH(Small Head) : presents 6mm bolt of 8mm flange head

The following abbreviations are used in this manual.

ASS’Y Assembled part

Indicates to apply grease(NLG 1#2)

Indicates to apply silicone grease.

Indicates to apply ointment onto screw lock.

Indicates the replacement part as new one whenever disassembly

Indicates to apply brake fluid. Use the recommended one(DOT3 or DOT4)

Indicates to apply the recommended oil

Indicates to use special tools

PARTS COMPOSITION MAP

RH. FRONT SIDE RH. CENTER SIDE RH. REAR SIDE

TOTAL AREA DETAIL COMPOSITON MAP

COMBINATION METER ASS’

HAZARD / START SWITCH CODE

WATER PATH TUBE

HEAD LIGHT ASS’

DESS CORD COMP

REAR BRAKE CODE

RH. FRONT SIDE

REAR BRAKE HOSE

HAZARD / START SWITCH COUPLER

FRONT BRAKE HOSE

FUEL LID LOCK CABLE

SEAT LOCK CABLE

FUEL BREATHER TUBE

FUEL SPLY TUBE

FRONT BRAKE HOSE

LH. FRONT SIDE

FUEL BREATHER TUBE

HIGH TENSION CODE

LF ANTENNA TRUNK LAMP CODE

OXYGEN SENSOR COUPLER

SEAT LOCK CABLE

LH. CENTER SIDE

STARTER MAGNETIC(+) CABLE

STARTER MOTOR CABLE REAR BRAKE PIPE

FUEL HOSE RADIATOR HOSE B

REAR BRAKE HOSE PIPE

WATER PIPE HOSE