FORWARD CONTENTS

HOW TO USE THIS MANUAL MECHANISM ILLUSTRATIONS

HD125 / 200
SERVICE MANUAL
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This service manual contains the technical data of each component inspection and
repair for the SANYANG HD 125 / 200 motorcycle. The manual is shown with
illustrations and focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment” so that provides technician with service guidelines.

If the style and construction of the motorcycle, HD 125 / 200, are different from that
of the photos, pictures shown in this manual, the actual vehicle shall prevail.
Specifications are subject to change without notice.

Service Department
SANYANG INDUSTRY CO., LTD.
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HOW TO USE THIS MANUAL

This service manual describes basic information of different system parts and
system inspection & service for SANYANG HD 125/200 motorcycles. In addition,
please refer to the manual contents in detailed for the model you serviced in
inspection and adjustment.

The first chapter covers general information and trouble diagnosis.

The second chapter covers service maintenance information and special tools
manual.
The third to the 11th chapters cover engine and driving systems.
The 12th chapter is cooling system.
The 13th to the 16th chapter is contained the parts set of assembly frame body.
The 17th chapter is electrical equipment.
The 18th chapter is wiring diagram.
Please see index of content for quick having the special parts and system
information.

There are 4 buttons, “Forward”, “Contents”, “How to use this manual” and
“Mechanism Illustrations” on the CD-R version, and can be access to these items
by click the mouse.
If user wants to look for the content of each chapter, selecting the words of each
chapter on the contents can reach to each chapter. There are two buttons,
“Homepage and contents, onto the top line of first page of the each chapter. Thus,
if the user needs to check other chapters, he can click the top buttons to back the
homepage or contents. The content of each chapter can be selected too.
Therefore, when needs to checking the content inside of the chapter, click the
content words of the chapter so that can back to the initial section of the content.
In addition, there is a “To this chapter contents” button at the second page of each
content so that clicking the button can back to the contents of this chapter.
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CONTENTS

Page Content Index

1-1 ~ 1-18 GENERAL INFORMATION 1

2-1 ~ 2-16 SERVICE MAINTENANCE INFORMATION 2

3-1 ~ 3-8 LUBRICATION SYSTEM 3

4-1 ~ 4-12 FUEL SYSTEM 4

5-1 ~ 5-8 ENGINE REMOVAL 5

6-1 ~ 6-14 CYLINDER HEAD/VALVE 6

7-1 ~ 7-8 CYLINDER/PISTON 7

8-1 ~ 8-14 “V” TYPE BELT DRIVING SYSTEM/KICK-STARTER 8

9-1 ~ 9-10 FINAL DRIVING MECHANISM 9

10-1 ~ 10-8 ALTERNATOR 10

11-1 ~ 11-8 CRANKSHAFT/ CRANKCASE 11

12-1 ~ 12-14 COOLING SYSTEM 12

13-1 ~ 13-16 BODY COVER 13

14-1 ~ 14-14 BRAKE SYSTEM 14

15-1 ~ 15-10 STEERING/FRONT WHEEL/SUSPENSION 15

16-1 ~ 16-6 REAR WHEEL/SUSPENSION 16

17-1 ~ 17-20 ELECTRICAL EQUIPMENT 17

18-1 ~ 18-2 ELECTRICAL DIAGRAM 18

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MECHANISM ILLUSTRATIONS

LH12W / LH18W
Battery/CDI
Front brake lever
Oil lever / Oil filter
Water pump
AC. Generator
Winker relay
Horn Fuel unit
Radiator

Ignition coil

Rear brake lever

Luggage box

Spark plug

Fuel tank cap

Front winker light

Tail light/
Headlight Rear winker light

Air cleaner

Gear oil drain bolt

Engine number
Engine oil drain bolt

Winker light / Horn /

Dimmer & Passing switches Headlight/Start switches

Main switch
Radiator filler cap

Fuse box /
Reserve tank cap Regulator rectifier
Starter relay
Headlight relay

Exhaust muffler
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1. GENERAL INFORMATION

Symbols and Marks............................... 1-1 Specifications..................................... 1-10 1

General safety........................................ 1-2 Torque Values .................................... 1-11
Service Precautions .............................. 1-3 Troubles Diagnosis ............................ 1-13
Specifications ........................................ 1-9 Parts to Be Greased ........................... 1-17
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special service are needed, in
case supplemental information is procedures needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.

Means that serious injury or even death may result if procedures are not
Warning
followed.

Caution Means that equipment damages may result if procedures are not followed.

Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
Engine oil damage that caused by not apply with the limited engine oil.
(Recommended oil: KING MATE G-3 oil)

Grease King Mate G-3 is recommended.

King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil # 140)
Apply sealant, medium strength sealant should be used unless otherwise
Locking sealant
specified.

Oil seal Apply with lubricant.。

Renew Replace with a new part before installation.

Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid.

Special tools Special tools

Correct Meaning correct installation.

Wrong Meaning wrong installation.

Indication Indication of components.

Directions Indicates position and operation directions

Components assembly directions each other.

Indicates where the bolt installation direction, --- means that bolt cross
through the component (invisibility).

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1. GENERAL INFORMATION

General safety
Carbon monoxide Battery
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed Caution
area. Run your engine in an open area, if you • Battery emits explosive gases; flame is strictly
have to run your engine in a closed area, be sure prohibited. Keep the place well ventilated
to use an extractor. when charging the battery.
Caution • Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
Exhaust contains toxic gas which may cause one do not be spray on your eyes or skin. If you
to lose consciousness and even result in death. get battery acid on your skin, flush it off
immediately with water. If you get battery acid
Gasoline in your eyes, flush it off immediately with
Gasoline is a low ignition point and explosive water and then go to hospital to see an
material. Work in a well-ventilated place, no flame ophthalmologist.
or spark should be allowed in the work place or • If you swallow it by mistake, drink a lot of
where gasoline is being stored. water or milk, and take some laxative such as
castor oil or vegetable oil and then go to see a
Caution doctor.
Gasoline is highly flammable, and may explode • Keep electrolyte beyond reach of children.
under some conditions, keep it away from
children. Brake shoe
Do not use an air hose or a dry brush to clean
Used engine oil components of the brake system, use a vacuum
cleaner or the equivalent to avoid dust flying.
Caution
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer although Inhaling brake shoe or pad ash may cause
it might not be verified. disorders and cancer of the breathing system
We recommend that you wash your hands with
soap and water right after contacting. Keep the Brake fluid
used oil beyond reach of children.
Caution
Hot components
Spilling brake fluid on painted, plastic, or rubber
Caution parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
Components of the engine and exhaust system protection when servicing the brake system.
can become extremely hot after engine running. Keep the brake fluid beyond reach of children.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until cooling off.

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1. GENERAL INFORMATION

Service Precautions
y Always use with Sanyang genuine parts and y Never bend or twist a control cable to prevent
recommended oils. Using non-designed parts unsmooth control and premature worn out.
for Sanyang motorcycle may damage the
motorcycle.

y Rubber parts may become deteriorated when

old, and prone to be damaged by solvent and oil.
y Special tools are designed for remove and Check these parts before installation to make
install of components without damaging the sure that they are in good condition, replace if
parts being worked on. Using wrong tools may necessary.
result in parts damaged.
y When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosen first, small fasteners may
receive too much stress.
y Store complex components such as
transmission parts in the proper assemble order
and tie them together with a wire for ease of
installation later.
y When servicing this motorcycle, use only metric
tools. Metric bolts, nuts, and screws are not
interchangeable with the English system, using
wrong tools and fasteners may damage this
vehicle.
y Clean the outside of the parts or the cover
before removing it from the motorcycle.
Otherwise, dirt and deposit accumulated on the
part's surface may fall into the engine, chassis,
or brake system to cause a damage. y Note the reassemble position of the important
components before disassembling them to
y Wash and clean parts with high ignition point
ensure they will be reassembled in correct
solvent, and blow dry with compressed air. Pay
dimensions (depth, distance or position).
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on y Components not to be reused should be
them. replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.

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1. GENERAL INFORMATION
y The length of bolts and screws for assemblies, y Remove residues of the old gasket or sealant
cover plates or boxes is different from one before reinstallation, grind with a grindstone if
another, be sure they are correctly installed. In the contact surface has any damage.
case of confusion, Insert the bolt into the hole to
compare its length with other bolts, if its length
out side the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.

y The ends of rubber hoses (for fuel, vacuum, or

coolant) should be pushed as far as they can go
to their connections so that there is enough
room below the enlarged ends for tightening the
clamps.
Groove

y Tighten assemblies with different dimension Clamp

fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with Connector
special tool first diagonally from inside toward
outside, important components should be
tightened 2 to 3 times with appropriate y Rubber and plastic boots should be properly
increments to avoid warp unless otherwise reinstalled to the original correct positions as
indicated. Bolts and fasteners should be kept designed.
clean and dry. Do not apply oil to the threads.

Boots

y The tool should be pressed against two (inner

and outer) bearing races when removing a ball
y When oil seal is installed, fill the groove with bearing. Damage may result if the tool is
grease, install the oil seal with the name of the pressed against only one race (either inner race
manufacturer facing outside, check the shaft on or outer race). In this case, the bearing should
which the oil seal is to be installed for be replaced. To avoid damaging the bearing,
smoothness and for burrs that may damage the use equal force on both races.
oil seal.

Manufacturer's name

Both of these examples can result in

bearing damage.

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1. GENERAL INFORMATION
y Lubricate the rotation face with specified y After service completed, make sure all
lubricant on the lubrication points before connection points is secured.
assembling. Battery positive (+) cable should be connected
firstly.
y And the two posts of battery have to be greased
after connected the cables.

y Check if positions and operation for installed

parts is in correct and properly.

y Make sure that the battery post caps are

located in properly after the battery posts had
been serviced.
y Make sure service safety each other when
conducting by two persons.

y If fuse burned, it has to find out the cause and

solved it. And then replace with specified
capacity fuse.
y Note that do not let parts fall down.
Capacity
verification

y Before battery removal operation, it has to

remove the battery negative (-) cable firstly.
Notre tools like open-end wrench do not contact
with body to prevent from circuit short and
create spark.

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1. GENERAL INFORMATION
y When separating a connector, it locker has to y Insert the terminal completely.
be unlocked firstly. Then, conduct the service Check if the terminal is covered by the boot.
operation. Do not let boot open facing up.

y Secure wires and wire harnesses to the frame

y Do not pull the wires as removing a connector with respective wire bands at the designated
or wires. Hold the connector body. locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.

y Make sure if the connector pins are bent,

extruded or loosen.

y Wire band and wire harness have to be

clamped secured properly.

y Insert the connector completely.

If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check if any wire loose.
y Do not squeeze wires against the weld or its
clamp.

y Check if the connector is covered by the twin

connector boot completely and secured
properly.

y Before terminal connection, check if the boot is

crack or the terminal is loose.

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1. GENERAL INFORMATION
y Do not let the wire harness contact with rotating, y Protect wires or wire harnesses with electrical
moving or vibrating components as routing the tape or tube if they contact a sharp edge or
harness. corner. Thoroughly clean the surface where
tape is to be applied.

y Keep wire harnesses far away from the hot y Secure the rubber boot firmly as applying it on
parts. wire harness.

Never Touch

y Route wire harnesses to avoid sharp edges or y Never use wires or harnesses which insulation
corners and also avoid the projected ends of has been broken. Wrap electrical tape around
bolts and screws. the damaged parts or replace them.

y Route harnesses so that they neither pull too y Never clamp or squeeze the wire harness as
tight nor have excessive slack. installing other components.
Never clamp or
squeeze the wire
harness

Never too tight

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1. GENERAL INFORMATION
y Do not let the wire harness been twisted as y With sand paper to clean rust on connector
installation. pins/terminals if found. And then conduct
connection operation later.

Clean rust

y Wire harnesses routed along the handlebar

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

y Before operating a test instrument, operator

should read the operation manual of the
instrument. And then, conduct test in
accordance with the instruction.

Do you know how to set the

instrument to its
measurement position and
the insert locations of its
two probes?

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1. GENERAL INFORMATION

Specifications
MAKER SANYANG MODEL LH18W-6
Overall Length 2064 mm Suspension Front Telescopic Fork
Dimension

Overall Width 760 mm System Rear Unit Swing

Overall Height 1165 mm Front 100 / 80 – 16 50P/TL
Tire Specifications
Wheel Base 1385 mm Rear 120 / 80 - 16 60P/TL
Front 53 kg Front Disk (ψ220mm)
Curb Weight Rear 82 kg Brake System
Rear Drum (ψ130mm)
Total 135 kg
Weight

Passengers/Weight Two /110 kg Max. Speed Above 108 km/hr

Performance
Front 75 kg Climb Ability Below 28°
Primary
Rear 170 kg Belt
Total Weight Reduction
Secondary
Total 245 kg Gear
Reduction Reduction
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and Vertical, below center,
Transmission C.V.T.
arrangement incline 80°
Fuel Used Unleaded Speedometer 0 ~ 140 km/hr
Cycle/Cooling 4-stroke/water cooled Horn 93~112 dB/A
Expansion & Pulse
Bore 61 mm Muffler
Type
Cylinder

Exhaust Pipe Position and Right side, and

Stroke 58.6 mm
Engine

Direction Backward
Number/Arrange Forced circulation &
Single Cylinder Lubrication System
ment splashing
Concentrati

Displacement 171.2 cc Solid Particulate

Exhaust

on

Compression Ratio 10.8 : 1 CO Below 5.5 g/ km

Max. HP 11.4kw / 8000rpm HC Below 1.0g/ km
Max. Torque 15.3Nm / 6500rpm E.E.C. ─
Ignition C.D.I. P.C.V. ─
Catalytic reaction control
Starting System Power & Foot ─
system

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1. GENERAL INFORMATION

Specifications
MAKER SANYANG MODEL LH12W-6
Overall Length 2064 mm Front Telescopic Fork
Dimension

Suspension System
Overall Width 706 mm Rear Unit Swing
Overall Height 1165 mm Front 100 / 80 -16 50P/TL
Tire Specifications
Wheel Base 1385 mm Rear 120 / 80 -16 60P/TL
Front 53 kg Front Disk (ψ220mm)
Curb Weight Rear 82 kg Brake System
Total 135 kg Rear Drum (ψ130mm)
Weight

Passengers/ Weight Two/110 kg Max. Speed Above 100 km/hr

Performance
Front 75 kg Climb Ability Below 28°
Primary
Rear 170 kg Belt
Total Weight Reduction
Secondary
Total 245 kg Gear
Reduction Reduction
Type 4-Stroke Engine Clutch Centrifugal, dry type
Installation and Vertical, below center,
Transmission C.V.T.
arrangement incline 80°
Fuel Used Unleaded Speedometer 0 ~ 140 km/hr
Cycle/Cooling 4-Stroke/Water Cooled Horn 93~112 dB/A
Expansion & Pulse
Bore 57 mm Muffler
Type
Cylinder

Exhaust Pipe Position and Right side, and

Stroke 48.8 mm
Engine

Direction Backward
Number / Forced circulation &
Single Cylinder Lubrication System
Arrangement splashing
Concentr

Displacement 124.5 cc Solid Particulate

Exhaust

ation

Compression Ratio 10.5 : 1 CO Below 5.5g/km

Max. HP 9.2kw / 8500rpm HC Below 1.2 g/km
Max. Torque 10.9Nm / 6500rpm E.E.C. ─
Ignition C.D.I. P.C.V. ─
Catalytic Reaction Control
Starting System Power & Foot Yes
System

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1. GENERAL INFORMATION

Torque Values

The torque values listed in above table are for more important tighten torque values. Please see standard
values for not listed in the table.

Standard Torque Values for Reference

Type Tighten Torque Type Tighten Torque
5 mm bolt、nut 0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
6 mm bolt、nut 0.8~1.2kgf-m 6 mm screw、SH nut 0.7~ 1.1kgf-m
8 mm bolt、nut 1.8~2.5kgf-m 6 mm bolt、nut 1.0 ~1.4kgf-m
10 mm bolt、nut 3.0~4.0kgf-m 8 mm bolt、nut 2.4 ~3.0kgf-m
12 mm bolt、nut 5.0~6.0kgf-m 10 mm bolt、nut 3.5~4.5kgf-m

Engine Torque Values

Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder head nut 4 8 2.0~2.4
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head stud bolt (inlet pipe) 2 6 0.7~1.1
Cylinder head stud bolt (EX. pipe) 2 7 0.5~1.0
Tappet adjustment hole cap bolt 6 6 1.0~1.4
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Spark plug 1 10 1.0~1.2
Carburetor insulator bolt 2 6 0.7~1.1
Cylinder stud bolt 4 8 0.7~1.1
Engine left cover bolt 7 6 1.1~1.5
Engine oil draining bolt 1 12 1.1~1.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 0.8~1.2
Mission filling bolt 1 10 0.8~1.2
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 12 5.0~6.0
Drive face nut 1 12 5.0~6.0
Flywheel nut 1 12 5.0~6.0
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.0~2.4

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1. GENERAL INFORMATION
Frame Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Stopper nut for engine hanger
1 8 1.8~2.2
rubber
Engine hanger nut 2 12 4.0~5.0
Engine hanger bolt 1 12 4.0~5.0
Engine connection bolt 1 10 3.5~4.5
Front wheel axle nut 1 12 5.0~7.0
Rear wheel shaft nut 1 14 10.0~12.0
Rear fork 2 8 4.0~5.0
Rear cushion upper bolt 2 10 3.5~4.5
Rear cushion under bolt 2 8 2.4~3.0
Nut for steering post 1 10 4.0~5.0
Front cushion 4 8 2.4~3.0
Brake lever nut 2 6 0.8~1.2
Nut for the rear brake arm 1 6 0.5~0.6
Front brake hose bolt 4 10 3.0~4.0
Front brake caliper bolt 4 6 3.0~3.5
Front brake disk mounting bolt 7 8 4.0~4.5
Air-bleed valve 1 5 0.5~0.6
Speedometer cable locking screw 1 5 0.15~0.3
Exhaust muffler bolt 3 8 3.2~3.8
Exhaust muffler connection nut 2 7 1.0~1.2

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1. GENERAL INFORMATION

Troubles Diagnosis
A. Engine hard to start or can not be started

Check and adjustment Fault condition Probable causes

Loosen carburetor drain bolt to

check if there is gasoline inside
the carburetor 1. No fuel in fuel tank
2. Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
3. Float valve clogged
Fuel supplied tom No fuel is supplied to
carburetor sufficient carburetor 4. Lines in fuel tank evaporation system
clogged
5. Malfunction of fuel pump
6. Loosen or damaged fuel pump vacuum
Remove spark plug, install it
into spark plug cap, and perform hose
a spark test against engine 7. Fuel filter clogged
ground.
1. Malfunction of spark plug
2. Spark plug foul
Check if sparks Weak sparks, no spark at
all 3. Malfunction of CDI set
4. Malfunction of AC generator
5. Ignition coil is in open or short circuit
Perform cylinder compression 6. Ignition coil leads open or short circuit
pressure test. 7. Malfunction of main switch

Cylinder compression Low compression 1. Piston ring seized

pressure normal pressure or no pressure
2. Malfunction of cylinder valves
3. Worn cylinder and piston ring
4. Cylinder gasket leak
Re-start by following the starting 5. Sand hole in compression parts
procedures

No ignition There are some signs of 1. Malfunction of throttle valve operation

ignition, nut engine can 2. Air sucked into intake manifold
not be started 3. Incorrect ignition timing

Remove the spark plug again

and check it.

1. Fuel level in carburetor too high

Dry spark plug Wet spark plug 2. Malfunction of throttle valve operation
3. Throttle valve opening too wide

Remove carburetor after 30

minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air

Blowing in normal Blowing clogged 1. Malfunction of automatic by- starter

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1. GENERAL INFORMATION

B. Engine run sluggish (Speed does not pick up, lack of power)

Check and adjustment Fault condition Probable causes

Try gradual acceleration and

check engine speed
1. Air cleaner clogged
2. Poor fuel supply
Engine speed can be Engine speed can not be
increased. increased. 3. Lines in fuel tank evaporation system
clogged
4. Exhaust pipe clogged
Check ignition timing (Using 5. Fuel nozzle clogged in carburetor.
ignition lamp) 6. Fuel nozzle clogged in carburetor.

Ignition timing correct Incorrect ignition timing 1. Malfunction of CDI

2. Malfunction of AC alternator

Check cylinder compression

pressure (using compression
pressure gauge)
1. Cylinder & piston ring worn out
2. Cylinder gasket leaked
Compression pressure No compression pressure 3. Sand hole in compression parts
correct 4. Valve deterioration
5. Seized piston ring
Check if carburetor jet is
clogged

No clogged Clogged 1. Remove foreign

Remove spark plug

No foul or discoloration Fouled and discoloration 1. Remove dirt

2. Incorrect spark plug heat range

Check if engine over heat

1. Piston and cylinder worn out
2. Lean mixture
3. Poor fuel quality
Normal Engine overheat 4. Too much carbon deposited in
combustion chamber
5. Ignition timing too advanced
6. Poor circuit on the cooling system
Continually drive in acceleration
or high speed
1. Too much carbon deposited in
combustion chamber
No knock Knock 2. Lean mixture
3. Poor fuel quality
4. Ignition timing too advanced

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1. GENERAL INFORMATION

C. Engine runs sluggish (especially in low speed and idling)

Check and adjustment Fault condition Probable causes

Check ignition timing (using

ignition lamp)

Normal Abnormal 1. Incorrect ignition timing

(malfunction of CDI or AC
alternator)
Adjust the air screw of
carburetor

Good Poor 1. Rich mixture (loosen the screw)

2. Lean mixture (tighten the screw)
Air sucked through carburetor
gasket
1. Poor heat insulation gasket
2. Carburetor lock loose
No air sucked Air sucked 3. Poor intake gasket
4. Poor carburetor O-ring
Remove spark plug, install
5. Vacuum hose crack
spark plug into spark plug cap
and perform spark test against
engine ground 1. Spark plug fouled
2. Malfunction of CDI
3. Malfunction of AC generator
Good spark Poor 4. Malfunction of ignition coil
5. Open or short circuit in spark plug
leads
6. Malfunction of main switch
D. Engine runs sluggish (High speed)

Check and adjustment Fault condition Probable causes

Check ignition timing

Normal Abnormal 1. Malfunction of CDI

2. Malfunction of AC alternator
Check for fuel supplying system
in automatic fuel cup

1. Insufficient fuel in fuel tank

Good Abnormal 2. Fuel filter clogged
3. Restricted fuel tank vent

Check if carburetor clogged

No clogged Clogged 1. Cleaning

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1. GENERAL INFORMATION

E. Clutch, driving and driving pulley

FAULT CONDITIONS PROBABLE CAUSES

1. Drive belt worn out or deformation

Engine can be started but 2. Ramp plate of movable drive face damaged
motorcycle can not be moved. 3. Driving pulley spring broken
4. Clutch weights broken
5. Drive slide-shaft gear groove broken
6. Transmission gear damaged

Engine running and misfire as 1. Clutch weights spring broken

motorcycle initial forward moving or
jumping suddenly (rear wheel 2. Clutch outer stuck with clutch weights
rotating as engine in running) 3. Connection parts in clutch and shaft worn out or burned

1. Drive belt worn out or deformation

Poor initial driving ( Poor climbing 2. Weight roller worn out
performance) 3. Movable drive face shaft worn out
4. Driven pulley spring deformation
5. Driven pulley shaft worn out
6. Greased in drive belt and driven face.

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1. GENERAL INFORMATION

Parts to Be Greased

Acceleration cable/ Front &

rear brake lever pivot

Steering shaft bearing Seat catch

Speedometer gear/ Side stand pivot Main stand pivot Rear wheel bearing
front wheel bearing

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1. GENERAL INFORMATION

Note:

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2. MAINTENANCE INFORMATION

Precautions in Operation ······················ 2-1 Brake Light Switch/Starting Inhibitor

Switch ················································· 2-10
Periodical Maintenance Schedule ········ 2-2
Headlight Beam Distance ·················· 2-10 2
Fuel Lines / Cable ·································· 2-3
Air Cleaner·············································· 2-4 Clutch Disc Wear································ 2-10

Spark Plug ·············································· 2-4 Side Stand··········································· 2-11

Cushion··············································· 2-11
Valve Clearance ····································· 2-5
Nuts, Bolts Tightness ························ 2-11
Carburetor Idle Speed Adjustment······· 2-6
Wheel/Tire ··········································· 2-12
Ignition System ······································ 2-7
Steering Handle Top Bearing ············ 2-12
Cylinder Compression Pressure ·········· 2-7
Drive Belt ················································ 2-8 Special Tools List······························· 2-13

Brake System (Front Disk Brake) ········· 2-8

Precautions in Operation
Specification
Fuel Tank Capacity 8000 c.c.
Capacity 1000 c.c.
Engine Oil
Change 800 c.c.
Capacity 110 c.c.
Transmission Gear oil
Change 100 c.c.
Engine + radiator 780 c.c.
Capacity of coolant
Reservoir upper 420 c.c.
Clearance of throttle valve 2~6 mm
Type NGK CR8E
Spark plug
Gap 0.8 mm
“F” Mark in idling speed BTDC 13º / 1000 rpm
Full timing advanced BTDC 27º / 6000 rpm
Idling speed 1600±100 rpm
Cylinder compression pressure 12.0 ±2 kgf/cm²
Valve clearance: IN/EX 0.12 ± 0.02 mm
Front 100/80-16 50P
Tire dimension
Rear 120/80-16 60P
Single Front: 1.75 kg/cm² rear : 2.25 kg/cm²
Tire pressure (cold)
Two persons Front: 1.75 kg/cm² rear : 2.50 kg/cm²
Battery 12V8Ah (MF battery) type: YTX9-BS

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2. MAINTENANCE INFORMATION

Periodical Maintenance Schedule

1 Month 3 month 6 month 1 year 15 month
Maintenance Every
Item every every every every every
Code 300KM
1,000KM 3,000KM 6000KM 12,000KM 14,500KM
1 ☆Air cleaner I C R
2 ☆2nd air jet leaner I C R
3 ☆Fuel filter I I R
4 ☆Oil filter C C
5 ☆Engine oil change R Replacement for every 1000 km
6 Tire pressure I I
7 Battery inspection I I
8 Brake & free ply check I I
9 Steering handle check I I
10 Cushion operation check I I
11 Every screw tightening I I
h k
12 Gear oil check for leaking I I
13 ☆Spark plug check or change I I R
14 ☆Gear oil change R Replacement for every 5000 km
15 Frame lubrication L
16 Exhaust pipe I I
17 ☆Ignition timing I I
18 ☆emission check in Idling A I
19 ☆Throttle operation I I
20 ☆Engine bolt tightening I I
21 ☆CVT driving device(belt) I R
22 ☆CVT driving device(roller) C
Lights/electrical
23 I I
equipment/multi-meters
24 Main/side stands & springs I I
25 Fuel lines I I
26 Cushions I
27 Cam chain I I
28 ☆Valve clearance I A
29 ☆Crankcase evaporative I C
30 ☆Crankcase blow-by Replacement for every 2000 km
31 ☆2nd air jet system I I C
32 ☆Evaporative control system I
33 Lines & connections in cooling I I
t
34 Coolant reservoir I I
35 Coolant I I R
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your SYM Authorized Dealer to maintain
the motorcycle at the optimum condition
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
Remarks: 1. These marks “☆” in the schedule are emission control items. According to EPA regulations, these items must
be performed normally periodical maintenance following the use r manual instructions. They are prohibited to
be adjusted or repaired by unauthorized people. Otherwise, SYM is no responsible for the charge.
2. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the
Heavily- polluted environment.
3. Maintenance should be performed more often if the motorcycle is frequently operated in high speed and after the
motorcycle has accumulated a higher mileage.
4. Preventive maintenance
a. Ignition system－Perform maintenance and check when continuous abnormal ignition, misfire, after-burn, overheating occur.
b. Carbon deposit removal－Remove carbon deposits in cylinder head, piston heads, exhaust system when power is obvious
lower. Than ever

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2. MAINTENANCE INFORMATION

Fuel Lines / Cable Fuel tank Vacuum hose

Remove luggage box.
Remove rear carrier.
Remove body covers.
Check all lines, and replace it when they are
deterioration, damage or leaking.
Warning
Gasoline is a low ignition material so any kind of
fire is strictly prohibited as dealing it.

Fuel filter Fuel hose

Acceleration Operation Throttle grip

Have a wide open of throttle valve as handle in
any position and release it to let back original (full
closed) position.
Check handle if its operation is smooth.
Check acceleration cable and replace it if
deteriorated, twisted or damaged.
Lubricate the cable if operation is not smooth
Measure the throttle grip free play in its flange
part.

Adjustment can be done in either end. Adjustment nut

Secondary adjustment is conducted from top side.
Remove rubber boot, loosen fixing nut, and then
adjust it by turning the adjustment nut. Adjustment nut

Primary adjustment is conducted from bottom

side.
Loosen fixing nut, and adjust by turning the
adjustment nut.
Tighten the fixing nut, and check acceleration
operation condition.
Free play: 2~6 mm.

Lock nut

2~6 mm

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2. MAINTENANCE INFORMATION

Air Cleaner 6 screws

Air Cleaner Element

Remove 6 screws from the air cleaner cover and
then remove the cover.

Remove 4 screws, and then remove the air

4 screws
cleaner element.
Caution
The air cleaner element is made of paper so do
not soap it into water or wash it with water.

Spark Plug
Remove central cover.
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.

Spark plug cap

Measure the spark plug gap.

Spark plug gap：0.8 mm
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten torque: 1.0~1.2kgf-m
Connect spark plug cap.
Recommended spark plug: CR8E
0.8mm

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2. MAINTENANCE INFORMATION

Valve Clearance Timing mark

Caution
Checks and adjustment must be performed when
the engine temperature is below 35℃.
Remove trunk.
Remove central cover.
Remove valve adjustment cap.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that piston is placed at TDC position
in compression stroke.
Caution
Do not turn the bolt in C.C.W. direction to prevent
from camshaft bolt looseness.

Valve clearance inspection and adjustment.

Check & adjust valve clearance with feeler gauge.
Valve clearance (IN/EX): 0.12 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightened the
fixing nut.

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2. MAINTENANCE INFORMATION

Carburetor Idle Speed Adjustment Ignition cable

Caution
y Inspection & adjustment for idle speed have to
be performed after all parts in engine that
needed adjustment have been adjusted.
y Idle speed check and adjustment have to be
done after engine is being warm up. (It is
enough that operates engine from stop to
running for 10 minutes.)
Park the motorcycle with main stand and warm up
engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Open carburetor cover from the luggage box.
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1600 ± 100 rpm

Stopper screw

Emission adjustment in idle speed

Warm up the engine for around 10 minutes and
then conduct this adjustment.
1. Connect the tachometer onto engine.
2. Adjust the idle speed adjustment screw and let
engine runs in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that
emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust Air adjustment screw
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm

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2. MAINTENANCE INFORMATION

Ignition System
Caution
y C.D.I ignition system is set by manufacturer so
it can not be adjusted.
y Ignition timing check procedure is for checking
whether CDI function is in normal or not.
Remove right side cover.
Remove ignition timing hole cap located in front
upper side of engine right cover.
Connect tachometer and ignition lamp.
Start engine.
As engine in idle speed: 1600 rpm, aim at the
mark “F” with the ignition lamp. Then, it is means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it is means that the
ignition advance degree is in normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace it if
malfunction of these parts is found.

Cylinder Compression Pressure

Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Full open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
no more increasing.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
y Incorrect valve clearance.
y Valve leaking.
y Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.

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2. MAINTENANCE INFORMATION

Drive Belt
Remove mounting bolt located under air cleaner.
Remove 7 bolts of the engine left side cover and
the cover.
Check if the belt is crack or worn out.
Replace the belt if necessary or in accord with the
periodical maintenance schedule to replace it.
Width limit: 18.5mm or above

7 bolts

Teeth
Width

Brake System (Front Disk Brake)

Brake System Hose
Make sure the brake hoses for corrosion or
leaking oil.

Brake Fluid
Brake hose
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found
Caution
y In order to maintain brake fluid in the reservoir
in horizontal position, do not remove the cap
until handle stop.
y Do not operate the brake lever after the cap
had been removed. Otherwise, the brake fluid
will spread out if operated the lever.
y Do not mix non-compatible brake fluid together.
LOWER

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2. MAINTENANCE INFORMATION

Filling Out Brake Fluid

Tighten the drain valve, and add brake fluid. Screws
Operate the brake lever so that brake fluid Master cylinder cap
contents inside the brake system hoses.
Diaphragm plate
Air Bleed Operation Diaphragm Upper
Connect a transparent hose to draining valve.
Hold the brake lever and open air bleeding valve.
Perform this operation alternative until there is no
air inside the brake system hoses.
Caution
Before closing the air bleed valve, do not release
the brake lever.
Air bubble Drain valve

Added Brake Fluid

Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4 WELL
RUN brake fluid.
Caution
Never mix or use dirty brake fluid to prevent from
damage brake system or reducing brake
performance. Transparent hose

Lining
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark
closed to the edge of brake disc.
Caution
It is not necessary to remove brake hose when
replacing the brake lining.
Remove the brake clipper bolt, and take out the Brake disk
clipper. Brake caliper

Caution
Do not operate the brake lever after the clipper
removed to avoid clipping the brake lining.
Pry out the brake lining with a flat driver if lining is
clipped. Caliper bolt

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2. MAINTENANCE INFORMATION

Make sure the brake lining condition. Replace Lining

Brake lining wear
the lining if the brake lining wear limitation groove limitation groove
close to the brake disc.
Brake Lining Replacement
Compress the caliper and let the brake lining out
of the caliper mounting plate. Compress the brake
lining locking spring. Remove the inner brake
lining firstly and then remove the outer brake
lining.
Compress the brake caliper at first as installation.
Install the inner brake lining firstly, and then install
the outer brake lining.
Caution
In order to maintain brake power balance, the
brake lining must be replaced with one set. Master cylinder

Brake Light Switch/Starting Inhibitor

Switch
The brake lamp switch is to light up brake lamp as
brake applied.
Make sure that electrical starter can be operated
only under brake applying. Brake switch

Headlight Beam Distance

Turn on main switch
Headlight beam adjustment. Turn the headlight
adjustment screw to adjust headlight beam high.
Caution
y To adjust the headlight beam follows related
regulations.
y Improper headlight beam adjustment will
make in coming driver dazzled or insufficient
lighting.
Adjust screw

Clutch Disc Wear

Clutch weight
Run the motorcycle and increase throttle valve
opening gradually to check clutch operation.
If the motorcycle is in forward moving and shaking,
check clutch disc condition. Replace it

Drive plate

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2. MAINTENANCE INFORMATION

Side Stand
Check side stand spring for damage or looseness.
Press down side stand and pull it with spring
gauge. If gauge reading is over 2 kg, it means that
the spring capacity is in normal.
Check if side stand set is operated smoothly.
Make sure that side stand is no bending or
deformation.

Side stand

Cushion
Warning
y Do not ride the motorcycle with poor cushion.
y Looseness, wear or damage cushion will make
poor stability and drive-ability.

Front cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Tighten all nuts and bolts.

Rear Cushion
Press down the front cushion for several times to
check it operation.
Check if it is damage
Replace relative parts if damage found.
Park motorcycle with main stand.
Turn the rear wheel forcefully and check if engine
bracket bushing worn out
Replace the bushing if looseness found.
Tighten all nuts and bolts.

Nuts, Bolts Tightness

Perform periodical maintenance in accord with the
Periodical Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamps, and
wire holders for security.

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2. MAINTENANCE INFORMATION

Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.

Check if tire surface is ticked with nails, stones or

other materials.
Appointed tire pressure

Tire size Front tire Rear tire

Tire Load for

under 90 Kg 1.75 2.25
pressure as
cold engine
(Kg/cm²) Full loaded 1.75 2.5

Check if front and rear tires’ pressure is in normal.

Measure tire thread depth from tire central
surface.
Replace the tire if the depth is not come with
following specification:
Front tire: 1.5 mm 〝△〞mark
磨損極限指標
Rear tire: 2.0 mm

Steering Handle Top Bearing

Caution
Check all wires and cables if they are interfered
with the rotation of steering handle bar.

Lift the front wheel out of ground.

Turn handle from right to left alternative and check
if turning is smoothly.
If handle turning is uneven and bending, or the
handle can be operated in vertical direction, then
adjust the handle top bearing.

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2. MAINTENANCE INFORMATION

Special Tools List

NAME R/L. CRANK DISASS. TOOL NAME CRANK SHAFT PULLER NAME L. CRANK SHAFT BRG. DRIVER

NO SYM-1120000-H9A NO SYM-1130000-H9A NO SYM-9100200-H9A

(ψ30mm) (ψ22mm)
CRANK SHAFT BRG. FIXING
NAME SOCKET NAME CRANK CASE BUSH PULLER NAME CRANK CASE BUSH PULLER

NO SYM-9100210-H9A NO SYM-1120310 NO SYM-1120320

VALVE COTTER REMOVE &

NAME ASSEMBLY TOOL NAME TAPPET ADJUSTING WRENCH NAME TAPPET ADJUSTER

NO SYM-1471110/20 NO SYM-9001200 NO SYM-9001209

CLUTCH SPRING
NAME UNIVERSAL HOLDER NAME CLUTCH NUT WRENCH NAME COMPRESSOR
NO SYM-2210100 NO SYM-9020200 NO SYM-2301000

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2. MAINTENANCE INFORMATION

NAME INNER BEARING PULLER NAME OUTER BEARING PULLER NAME AC.G. FLYWHEEL PULLER

NO SYM-6204002 NO SYM-6204001 NO SYM-3110A00

(12*20*5) (6901)
WATER PUMP OIL SEAL WATER PUMP BEARING WATER PUMP MECHANICL
NAME DRIVER NAME DRIVER NAME SEAL DRIVER
NO SYM-9120500-H9A NO SYM-9100100 NO SYM-1721700-H9A

(6301) (6204) (6203/6004UZ)

NAME BEARING DRIVER NAME BEARING DRIVER NAME BEARING DRIVER Ø17mm

NO SYM-9610000 NO SYM-9110400 NO SYM-9620000

(20*32*6) (25*40*8) (27*42*7)

NAME OIL SEAL DRIVER NAME OIL SEAL DRIVER NAME OIL SEAL DRIVER

NO SYM-9120200 NO SYM-9121600 NO SYM-9125500

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2. MAINTENANCE INFORMATION

NAME Drive shaft puller NAME Drive shaft install bush NAME Extension bush (long)
NO SYM-1130000-L NO SYM-1130010 NO SYM-1130031

NAME Extension bush (short) NAME NAME

NO SYM-1130032 NO NO

NAME NAME NAME

NO NO NO

NAME NAME NAME

NO NO NO

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2. MAINTENANCE INFORMATION

Note:

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3. LUBRICATION SYSTEM

Precautions in Operation ···················· 3-2 Engine Oil Strainer Clean ···················· 3-3
Troubleshooting ·································· 3-2 Oil Pump ··············································· 3-4
Engine Oil ············································· 3-3 Gear Oil ················································· 3-7

3
Valve Rocker Arm

Press-In Lubrication

Cam Shaft

Oil Route

Spray Lubrication

Con-Rod

Spray Lubrication

Press-In Lubrication

Oil Route

Oil through

Rotate Direction

Oil Strainer

Oil Pump

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3. LUBRICATION SYSTEM

Precautions in Operation
General Information:
z This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1000 c.c.
Change: 800 c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 110 c.c.
Change: 100 c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)

單位:mm

Items Standard (mm) Limit (mm)

Inner rotor clearance 0.15 0.20

Oil pump Clearance between outer rotor and body 0.15~0.20 0.25

Clearance between rotor side and body 0.04~0.09 0.12

Torque value
Torque value oil strainer cap 1.5~3.0kgf-m
Gear oil drain plug 1.0~1.5kgf-m
Gear oil inspection bolt 1.0~1.5kgf-m
Oil pump connection bolt 0.8~1.2kgf-m

Troubleshooting
Low engine oil level Dirty oil
y Oil leaking y No oil change in periodical
y Valve guide or seat worn out y Cylinder head gasket damage
y Piston ring worn out y Piston ring worn out

Low oil pressure

y Low engine oil level
y Clogged in oil strainer, circuits or pipes
y Oil pump damage

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3. LUBRICATION SYSTEM

Engine Oil
Turn off engine, and park the motorcycle in flat
surface with main stand.
Check oil level with oil dipstick
So not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.

Oil Change

Caution
Drain bolt
Drain oil as engine warmed up so that make sure
oil can be drained smoothly and completely.

Place a oil pan under the motorcycle, and remove

oil drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value：1.9~2.5kgf-m

Engine Oil Strainer Clean

Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Oil strainer cap
Torque value：1.9~2.5kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.

Engine oil capacity: 0.8L when replacing

Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.

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3. LUBRICATION SYSTEM

Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) 。
Remove snap ring and take out oil pump driving
chain and sprocket.

Clip

Make sure that pump shaft can be rotated freely.

Remove 2 bolts on the oil pump, and then
remove oil pump.

2 screws

Oil Pump Disassembly

Remove the screws on oil pump cover and
disassemble the pump as illustration shown.

Oil Pump Inspection

Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm

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3. LUBRICATION SYSTEM

Check clearance between inner and outer rotors.

Limit: 0.20 mm

Check clearance between rotor side face and

pump body
Limit: 0.12 mm

Oil Pump Re-assembly

Install inner and outer rotors into the pump body
Align the indent on driving shaft with that of inner
rotor. Install the driving shaft
Install fixing pin

Pin

1 Screw

Install the oil pump cover and fixing pin properly

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3. LUBRICATION SYSTEM

Oil Pump Installation

Install the oil pump, and then tighten bolts.
Torque value：0.8~1.2kgf-m

Make sure that oil pump shaft can be rotated

freely.

Install oil pump driving chain and sprocket, and

then install snap ring onto oil pump shaft.

Install starting gear and generator.

(Refer to chapter 10)

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3. LUBRICATION SYSTEM

Gear Oil
Oil level inspection
Park the motorcycle on flat surface with main
stand.
Turn off engine and remove oil inspection bolt.

Gear oil Inspection Bolt

Gear lubrication oil quantity has to be measured

with measure device.
If oil level is too low, add gear oil. Recommended
using King series oils.
Install oil inspection bolt.

Gear oil drain plug

Gear Oil Change

Remove oil level inspection bolt.
Remove drain plug and drain oil out.
Install the drain plug after drained.
Torque value: 1.0~1.4kgf-m
Make sure that the drain plug washer can be
re-used.
Add oil to specified quantity from the inspection
hole.
Gear Oil Quantity: 100 c.c. when replacing
Make sure that the bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.

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3. LUBRICATION SYSTEM

Notes:

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4. FUEL SYSTEM

Precautions in Operation....................4-2 Auto By-Starter .................................. 4-7

Trouble Diagnosis...............................4-3 Float Chamber.................................... 4-8
Carburetor removal.............................4-4 Fuel Tank ............................................ 4-10
Vacuum chamber ................................4-4 Air Cleaner.......................................... 4-11
Air Cut-Off Valve .................................4-6
4

To fuel vapor separator

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4. FUEL SYSTEM

Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.

Cautions
y Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
y When disassembling fuel system parts, pay attention to O-ring position, replace with new one as
re-assembly
y There is a drain screw in the float chamber for draining residual gasoline.
y Do not disassemble auto by-starter and air cut valve arbitrarily.

Specification
ITEM LH12W-6 LH18W-6

Carburetor diameter 24 mm 25 mm

I.D. number CVK039 CVK066

Fuel level 20.5 mm 20.5 mm

Main injector #105 #108

Idle injector #35 #35

Idle speed 1600±100 rpm 1600±100 rpm

Throttle handle clearance 2~6 mm 2~6 mm

Pilot screw 2 1/4 turns 1 1/2 turns

Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge

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4. FUEL SYSTEM

Trouble Diagnosis
Poor engine start Mixture too lean
y No fuel in fuel tank y Clogged fuel injector
y Clogged fuel tube y Vacuum piston stick and closed
y Too much fuel in cylinder y Malfunction of float valve
y No spark from spark plug(malfunction of ignition y Fuel level too low in float chamber
system ) y Clogged fuel tank cap vent
y Clogged air cleaner y Clogged fuel filter
y Malfunction of auto by-starter y Obstructed fuel pipe
y Malfunction of throttle operation y Clogged air vent hose
y Air existing in intake system

Stall after started

y Malfunction of auto by-starter Mixture too rich
y Incorrect ignition timing y Clogged air injector
y Malfunction of carburetor y Malfunction of float valve
y Dirty engine oil y Fuel level too high in float chamber
y Air existing in intake system y Malfunction of auto by-starter
y Incorrect idle speed y Dirty air cleaner

Rough idle
y Malfunction of ignition system
y Incorrect idle speed
y Malfunction of carburetor
y Dirty fuel

Intermittently misfire as acceleration

y Malfunction of ignition system

Late ignition timing

y Malfunction of ignition system
y Malfunction of carburetor

Power insufficiency and fuel consuming

y Fuel system clogged
y Malfunction of ignition system

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4. FUEL SYSTEM

Carburetor removal Throttle cable

Remove the luggage box.

Loosen the adjustment nut and fixing nut of throttle
valve cable, and release the cable from carburetor.
Disconnect automatic by-starter connector.
Release the clamp strip of air cleaner.

Auto by-starter Air cleaner clamp

Air cleaner clamp Fuel pipe

Remove fuel pipe, vacuum hose.
Release the clamp strip of carburetor insulator.

Vacuum hose

2 Screws
Vacuum chamber
Removal
Loosen drain screw, and drain out residual fuel in
float chamber.
Remove 2 screws of vacuum chamber cover and
the cover.

Spring
Remove compress spring and vacuum piston.

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4. FUEL SYSTEM
Check if the vacuum piston for wear out, crack or
other damage.
Check if the diaphragm for damage or crack.

Installation
Install needle, spring and needle seat to vacuum Needle seat Spring
piston.

Piston

Needle

Install vacuum piston to carburetor body and align

the indent on the diaphragm.
Install compress spring.

Install vacuum chamber cover and tighten 2

screws. 2 Screws

Caution
y Do not damage vacuum diaphragm.
y When tightening the vacuum chamber screw,
hold down vacuum piston.

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4. FUEL SYSTEM

Air Cut-Off Valve

Inspection
Disconnect vacuum hose and air vent hose from
the air cut-off valve.
Connect a hose from vacuum hose connector to
vacuum pump.
Connect air pump to air vent hose.
Apply with specified vacuum to air cut-off valve.
Vacuum value: 420~500 mm-Hg
Pump compressed air from air pump to air vent
hose.
Caution
The vacuum can not be over 600 mm-Hg. Or the
air cut-off will be damaged.

If the valve is in normal, it will restrict air-flow.

If air-flow is no restrict, replace carburetor
assembly.

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4. FUEL SYSTEM

Auto By-Starter
Inspection
Turn off engine and waiting for over 10 minutes for
cooling.
Check resistance across the two terminals of the
auto by-starter.
Resistance value: Max. 10Ω (Measured after
engine stopped for more than 10 minutes)
Replace the auto starter with a new one if
resistance value exceeds standard.
Remove carburetor, allow it to cool off for 30
minutes.
Connect a pressure tester from air pump.
Connect by-starter circuit.
Pump compressed air to the circuit.
Replace the auto by-starter if the circuit clogged.
Connect battery posts (12V) to starter’s
connectors. After 5 minutes, test the by-starter
circuit with compressed air. If air flows through
the circuit, then, replace the starter.

Screw ×1
Removal Auto by– starter
Remove fixing plate screw, and then remove the
plate and auto by-starter from carburetor.

Plate
Valve inspection
Check if auto by-starter and valve needle for
Screw ×1
damage or wear out.

Installation
Install auto by-starter to the bottom of carburetor
body.
Install fixing plate to the upper groove of auto Needle
by-starter, and install its flat surface to carburetor.
Install screw and tighten it.

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4. FUEL SYSTEM

Float Chamber Float

Pin 3 Screws

Disassembly
Remove 3 mounting screws and remove float
chamber cover.
Remove the float pin and float.

Checking
Check float valve and valve seat for damage,
blocking.
Check float valve for wearing, and check valve
seat face for wear, dirt.

Caution Float Pin

In case of worn out or dirt, the float valve and 1 Screw
valve seat will not tightly close causing fuel level
to increase and as a result, fuel flooding. A worn
out or dirty float valve must be replaced with a
new a new one.

Float valve

Needle jet Slow jet

Remove main jet, fuel needle jet holder, needle jet,
slow jet, pilot screw.

Caution
Take care not to damage jets and adjust screw.
y Before removing adjustment screw, turn it all
the way down and note the number of turns.
y Do not turn adjust screw forcefully to avoid
damaging valve seat face.

Needle jet
Clean jets with cleaning fluid. Then use
compressed air to blow the dirt off. Needle jet holder
Blow carburetor body passages with compressed
air.

Slow jet
Main jet

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4. FUEL SYSTEM

Assembly
Install main jet, fuel needle jet holder, fuel needle
jet slow jet and pilot screw.
Caution
Set the pilot screw in according to number of turns
noted before it was removed.
Install the float valve, float, and float pin.
Checking fuel level
Caution Pilot screw
y Check again to ensure float valve, float for
proper installation.
y To ensure correct measurement, position the
float meter in such a way so that float chamber
face is vertical to the main jet.
Fuel level: 20.5 mm

Installation of carburetor
Install carburetor in the reverse order of removal.
Following adjustments must be made after
installation.
˙Throttle cable adjustment. Float gauge
˙Idle adjustment
Adjustment of pilot screw
Throttle cable adjust nut
Caution
y Pilot screw was set at factory, so no
adjustment is needed. Note the number of
turns it takes to screw it all the way in for ease
of installation.
y The main stand must be used to support the
motorcycle to perform the adjustments.
Use a tachometer when adjusting engine RPM.
Screw in adjustment screw gently, then back up to
standard turns.
Standard turns:2±1/2(1 1/2~2 1/2) turns Idle adjustment screw
Warm up engine, adjust the stopper screw of
throttle valve to standard RPM.
Idle speed rpm: 1600 ± 100 rpm
Connect the hose of exhaust analyzer to exhaust
front end. Press test key on the analyzer.
Adjust the pilot screw and read CO reading on the
analyzer
CO standard value: 1.0~1.5 %
Accelerate in gradual increments, make sure rpm
and CO value are in standard value after engine
running in stable. If rpm and CO value fluctuated,
repeat the procedures described above for
Pilot screw
adjusting to standard value.

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4. FUEL SYSTEM

Fuel Tank
Fuel unit removal
Open the seat.
Remove the luggage box (6 bolts and 1 screw).
Remove rear carrier (4 bolts).)
Remove body cover.
Disconnect fuel unit connector.
Remove fuel unit (4 screws).
Caution
˙Do not bend the float arm of fuel unit
Fuel unit connector
˙Do not fill out too much fuel to fuel tank.

Fuel unit inspection. (Refer to electrical equipment

chapter 17)

Fuel unit installation

Install the gauge in the reverse order of removal.
Caution
Do not forget to install the gasket of fuel unit or
damage it.

Fuel cut valve

Fuel tank removal

Remove the Fuel cut valve assembly and Fuel
tube.

Fuel tube

4 bolts
Remove fuel tank (4 screws).

Installation
Install the tank in the reverse order of removal.

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4. FUEL SYSTEM

Air Cleaner Clamp strip of air cleaner

Removal
Open the seat.
Remove the luggage box (6 bolts and 1 screw).
Loosen the clamp strip of air cleaner.
Remove the Vapor hose.
Remove the Air cleaner (2 bolts).

Installation
Install the tank in the reverse order of removal.

Cleaning air cleaner element

Remove air cleaner cover (6 screws).

6 Screws

Remove the Air cleaner element. (Screw×4) Screw×4

With compressed air to cleaning dirty around the
element. Replace it if it is too dirty to clean.
Caution
The air cleaner element is made of paper so do
not soap it into water or wash it with water.

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4. FUEL SYSTEM

Notes:

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5. ENGINE REMOVAL

Precautions in Operation ....................5-1 Removal of Engine Hanger Bush .........5-6

Removal of Engine ..............................5-2 Engine Hanger Installation ...................5-7
Engine Hanger removal.......................5-5 Engine Installation.................................5-7

Precautions in Operation
General Information
y The engine has to be supported with special service tools that can be lifted or adjustable.
y The following parts can be serviced as engine mounted on frame.
5
y Carburetor.
y Driving pulley, driving belt, clutch, and driving disc assembly.
y Final gear reduction mechanism.

Specification
Item Capacity

Replacement 800 c.c.

Engine oil capacity
Disassembly 1000 c.c.

Replacement 100 c.c.

Gear oil capacity
Disassembly 110 c.c.

Engine & radiator 780 c.c.

Coolant capacity Reservoir 420 c.c. AS indicator shown

Total 1200 c.c.

Torque Value
Engine mounting bolt 4.0~5.0kgf-m
Rear cushion upper connection bolt 3.5~4.5kgf-m
Rear cushion under connection bolt 2.4~3.0kgf-m
Engine hanger bolt 4.0~5.0kgf-m
Rear wheel axle nut 11.0~13.0kgf-m

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5. ENGINE REMOVAL

Removal of Engine Auto by-starter &

Open seat and remove the luggage box (6 bolts AC. G. coupler

and 1 screw).
Remove rear carrier (4 bolts).
Remove battery cover (2 screws).
Remove battery negative (-) post.
Remove battery positive (+) post.
Remove tail light connector.
Remove right and left body cover (2 bolts).
Disconnect the auto by-starter wire connector.
Disconnect A.C.G wire connectors.
A.C.G wire coupler Starter relay
Remove starter motor wire from relay.

Remove spark plug cap.

Spark plug cap

Remove fuel pipe, vacuum tube and throttle valve

wire from carburetor.
Loosen the screw of air cleaner duct strip, and
then remove the duct.

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5. ENGINE REMOVAL

Remove water hoses from water pump. Water hoses

Water pump

Remove the thermo-sensor wire. Thermo-sensor wire

Remove the muffler (3 bolts, 2 nuts).

3 bolts

2 nuts

Remove rear inner fender

Right side Left side

2 Bolts 1 Bolt

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5. ENGINE REMOVAL

Remove the mounting bolt of right-rear cushion. 2 Bolts

Remove the rear fork mounting bolt. (2 bolts)
Remove rear wheel mounting nut.

Rear wheel axle nut

Remove rear fork and collars.

Remove rear wheel.

Remove the mounting bolt of left-rear cushion.

Left-rear cushion bolt

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5. ENGINE REMOVAL

Remove the right and left side engine hanger Left side
mounting bolts and nuts, then remove engine.

Caution

˙Support engine and frame separately with

special supporters to prevent from engine or
frame falling down.

Engine hanger nut and bolt

Right side

Engine mounting nut and bolt

Engine Hanger removal

Remove the engine mounting bolt and nut, then
remove engine hanger.

Engine mounting nut and bolt

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5. ENGINE REMOVAL

Removal of Engine Hanger Bush Bush

Check if engine hanger bush and cushion rubber
bush for damage.

Pressing out
If engine hanger and the rear cushion rubber bush
damaged. Then, with the bush remover / presser,
Ø 30mm & Ø 22mm, to press the bush out, and
replace it with new one.
Engine hanger bush: ψ 30mm
Rear cushion bush: ψ 22mm

Place the detent section of the bush remover

toward the bush, and drive both the pressing ring
and bolt in to press the bush out.

Pressing In
Place the flat section of the remover toward the
bush, and then drive the bush, pressing ring, and
bolt in to install the bush.

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5. ENGINE REMOVAL

Engine Hanger Installation

Install engine hanger onto engine.
Install engine mounting bolts & nuts and then
tighten the nuts.
Torque value: 4.0~5.0kgf-m

Engine Installation
Check if the bush of engine hanger parts and
cushion for damage.
Install engine in the reverse procedures of
removal.

Caution

y Pay attention of foot & hand safety as engine

installation to avoid hurting.
y Do not bend or twist wires.
y Cables wires have to be routed in accordance
with normal layout.
y Small-end bearing collar has to forward to
inside (bearing) as assembling the rear fork.

Bearing collar

Engine hanger Bolt:

Torque value: 4.0~5.0kgf-m
Rear cushion bolt:
Torque value: upper：3.5~4.5kgf-m
under：2.4~3.0kgf-m
Rear wheel axle nut:
Torque value: 11.0~13.0kgf-m

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5. ENGINE REMOVAL

Note:

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6. CYLINDER HEAD/VALVE

Mechanism Diagram ··························· 6-1 Valve Stem Replacement··················· 6-8

Precautions in Operation ··················· 6-2 Valve Seat Inspection and Service ··· 6-9
Troubleshooting·································· 6-3 Cylinder Head Reassembly ··············· 6-11
Cylinder Head Removal······················ 6-4 Cylinder Head Installation ················· 6-12
Cylinder Head Disassembly··············· 6-6 Valve Clearance Adjustment············· 6-14
Cylinder Head Inspection··················· 6-7

Mechanism Diagram

0.8~1.2kgf-m
6

0.8~1.2kgf-m

2.0~2.4kgf-m

1.0~1.2kgf-m

2.0~2.4kgf-m

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6. CYLINDER HEAD/VALVE

Precautions in Operation
General Information
y This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as
rocker arm.
y Cylinder head service can be carried out when engine is in frame.

Specification
Item Standard Limit
Compression pressure 12+/2 kg/cm2 ---
Camshaft Height of cam lobe Intake 30.800~30.920 3.075
Exhaust 30.411~30.531 30.26
Rocker arm ID of valve rocker arm 12.000~12.018 12.10
OD of valve rocker arm shaft 11.966~11.984 11.910
Valve OD of valve stem Intake 4.975~4.990 4.900
Exhaust 4.955~4.970 4.900
Guide seat 5.000~5.012 5.030
Clearance between Intake 0.010~0.037 0.080
valve stem and guide
Exhaust 0.030~0.057 0.100
Free length of valve spring 35.000 31.500
Valve seat width 1.000 1.6
Tilt angle of cylinder head --- 0.05

Torque Value
Cylinder head bolt (LH) 2.0~2.4kgf-m
Cylinder head Nut 2.0~2.4kgf-m
Sealing bolt of cam chain auto-tensioner 0.8~1.2kgf-m
Bolt of cam chain auto-tensioner 1.2~1.6kgf-m
Cam sprocket cover bolts 0.8~1.2kgf-m
Cam sprocket bolt 0.8~1.2kgf-m
Spark plug 1.0~1.2kgf-m

Tools
Special service tools
Valve reamer: 5.0mm
Valve guide driver: 5.0mm
Valve spring compressor

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6. CYLINDER HEAD/VALVE

Troubleshooting
Engine performance will be effected by troubles on engine top parts. The trouble usually can be
determined or by performing cylinder compression test and judging the abnormal noise generated.

Low compression pressure

1. Valve
y Improper valve adjustment
y Burnt or bent valve
y Improper valve timing
y Valve spring damage
y Valve carbon deposit.
2. Cylinder head
y Cylinder head gasket leaking or damage
y Tilt or crack cylinder
3. Piston
y Piston ring worn out.

High compression pressure

y Too much carbon deposit on combustion chamber or piston head

Noise
y Improper valve clearance adjustment
y Burnt valve or damaged valve spring
y Camshaft wear out or damage
y Chain wear out or looseness
y Auto-tensioner wear out or damage
y Camshaft sprocket
y Rocker arm or rocker arm shaft wear out

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6. CYLINDER HEAD/VALVE

Cylinder Head Removal Vacuum tube

Clamp strip
Remove seat, luggage box and body cover.
Remove engine. (Refer to chapter 5)
Remove the clamp strip bolt of carburetor, and
disconnect vacuum tube from the carburetor
insulator.
Remove Air Injection system (AI) pipe mounting
bolt.

AI. Pipe bolt

Remove 1 bolt of thermostat and then remove the Thermostat bolt

thermostat.
Remove hole cap for the adjustment bolt of cam
chain tensioner, and then loosen the tensioner by
turning a flat-driver in C.W direction.

Hole cap of adjustment bolt

Remove the side cover mounting blots of cylinder 2 bolts

head, and then take out the side cover.

Remove cam sprocket bolts and then remove the 2 bolts

sprocket by prying chain out.

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6. CYLINDER HEAD/VALVE
Remove the 2 cylinder head mounting bolts from 4 Nuts
2 Insulator bolts
cylinder head right side, and then remove 4 nuts
and washers from cylinder head upper side.

Cylinder head mounting

Remove the cylinder head.

Remove 2 bolts of carburetor insulator and then

take the insulator out.

Carburetor insulator

Remove cylinder head gasket and 2 dowel pins.

Dowel pin
Remove chain guide.
Clean up residues from the matching surfaces of
cylinder and cylinder head.
Caution
Gasket
y Do not damage the matching surfaces of
cylinder and cylinder head.
y Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.

Chain guide

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6. CYLINDER HEAD/VALVE

Cylinder Head Disassembly

Remove the hole cap of intake & exhaust valve
clearance adjustment. There are 6 bolts. Then,
remove the cap.

Remove the rocker arm pin stopper plate, and

then screw a 5mm bolt into the rocker arm pin.
Finally, remove the pin and the rocker arm.

Screw a 6 mm bolt into cam sprocket mounting

bolt hole, and then pull the camshaft out.

Stopper plate bolt

Use a valve compressor to press the valve spring.

Caution
y In order to avoid loosing spring elasticity, do not
press the spring too much. Thus, press length
is based on the valve cotter in which can be
removed.

Special Service Tool:

Valve spring remover (SYM-1471110)
Valve spring installer (SYM-1471120)

Remove valve stem guide seal.

Clean carbon deposits in combustion chamber.
Clean residues and foreign materials on cylinder
head matching surface.

Caution
Do not damage the matching surface of cylinder
head.

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6. CYLINDER HEAD/VALVE

Cylinder Head Inspection

Check if spark plug and valve holes are cracked.
Measure cylinder head warp with a straightedge
and thickness gauge.
Service limit: 0.5 mm

Valve spring free length

Measure the free length of intake and exhaust
valve springs.
Service limit: 28.90 mm

Valve stem
Check if valve stems are bend, crack or burn.
Check the operation condition of valve stem in
valve guide, and measure & record the valve stem
outer diameter.
Service Limit: IN: 4.90 mm
EX: 4.90 mm

Valve guide
Caution
Before measuring the valve guide, clean carbon
deposits with reamer.
5.0 mm valve guide reamer
Tool: 5.0 mm valve guide reamer
Measure and record each valve guide inner
diameters.
Service limit: 5.03 mm
The difference that the inner diameter of valve
guide deducts the outer diameter of valve stem is
the clearance between the valve stem and valve
guide.
Service Limit: IN→0.08 mm
EX→0.10 mm

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6. CYLINDER HEAD/VALVE

Caution
If clearance between valve stem and valve guide
exceeded service limit, check whether the new
clearance that only replaces new valve guide is
within service limit or not. If so, replace valve
guide.

Correct it with reamer after replacement.

If clearance still exceeds service limit after
replaced valve guide, replace valve stem too.
Caution
It has to correct valve seat when replacing valve
guide.

Valve guide driver

Valve Stem Replacement 5.0mm
Heat up cylinder head to 100~150 ℃ with heated
plate or toaster.
Caution
y Do not let torch heat cylinder head directly.
Otherwise, the cylinder head may be deformed
as heating it.
y Wear on a pair of glove to protect your hands
when operating.

Hold the cylinder head, and then press out old

valve guide from combustion chamber side.
Tool: Valve guide driver: 5.0 mm
Valve guide driver
Caution 5.0 mm
y Check if new valve guide is deformation after
pressed it in.
y When pressing in the new valve guide, cylinder
head still have to be kept in 100~150℃.
Adjust the valve guide driver and let valve guide
height is in 13 mm.
Press in new valve guide from rocker arm side.
Tool: Valve guide driver: 5.0 mm
Wait for the cylinder head cooling down to room
temperature, and then correct the new valve guide
with reamer. Valve guide reamer 5.0 mm

Caution
y Using cutting oil when correcting valve guide
with a reamer.
y Turn the reamer in same direction when it be
inserted or rotated.
Correct valve seat, and clean up all metal residues
from cylinder head.
Tool: Valve guide reamer: 5.0 mm

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6. CYLINDER HEAD/VALVE

Valve Seat Inspection and Service

Clean up all carbon deposits onto intake and
exhaust valves.
Apply with emery slightly onto valve contact face.
Grind valve seat with a rubber hose or other
manual grinding tool.
Caution
y Do not let emery enter into between valve stem
and valve guide.
y Clean up the emery after corrected, and apply
with engine oil onto contact faces of valve and
valve seat.
Remove the valve and check its contact face.
Caution
Replace the valve with new one if valve seal is
roughness, wear out, or incomplete contacted
with valve seat.
Valve seat width

Valve seat inspection

If the valve seat is too width, narrow or rough,
correct it.

Valve seat width

Service limit: 1.6mm
Check the contact condition of valve seat.

Valve seat grinding

The worn valve seat has to be ground with valve
Roughness
seat chamfer cutter.
Refer to operation manual of the valve seat
chamfer cutter.
Use 45° valve seat chamfer cutter to cut any rough
or uneven surface from valve seat.
45°
Caution
After valve guide had been replaced, it has to be
ground with 45° valve seal chamfer cutter to
correct its seat face.

Use 32° cutter to cut a quarter upper part out.

Old valve seat width

32°

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6. CYLINDER HEAD/VALVE
Use 60° cutter to cut a quarter lower part out.
Remove the cutter and check new valve seat.
Old valve seat width

60°

Use 45° cutter to grind the valve seat to specified

width.
1.0mm
Caution
Make sure that all roughness and uneven faces
had been ground.

Grind valve seat again if necessary.

45°

Coat the valve seat surface with red paint.

Install the valve through valve guide until the valve Contact surface too high
contacting with valve seat, slightly press down the
valve but do not rotate it so that a seal track will be Old valve seat width
created on contact surface.
Caution
32°
The contact surfaces of valve and valve seat are
very important to the valve sealing capacity.

If the contact surface too high, grind the valve seat

with 32° cutter.
Then, grind the valve seat to specified width. Contact surface too low Old valve seat width

If the contact surface too low, grind the valve seat

with 60° cutter.
Then, grind the valve seat to specified width.

60°

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6. CYLINDER HEAD/VALVE
After the valve seat ground, coat valve seat
surface with emery and then slightly press the
ground surface.
Clean up all emery coated onto cylinder and valve
after ground.

Cylinder Head Reassembly Intake valve

Lubricate valve stem with engine oil, and then
insert the valve into valve guide.
Install new valve stem oil seal.
Install valve springs and retainers.
Caution
The closed coils of valve spring should face down Valve spring retainer
to combustion chamber. Exhaust valve

Valve cotter Valve stem seal

Valve spring

Use valve spring compressor to press valve

spring.
Caution
In order to avoid damaging the valve stem and
the cylinder head, in the combustion chamber
place a rag between the valve spring
remover/installer as compressing the valve spring
directly.

Special Service Tool:

Valve spring remover (SYM-1471110)
Valve spring installer (SYM-1471120)

Tap valve stem to make valve retainer and valve

stem sealing properly.
Caution
Place and hold cylinder head on to working table
so that can prevent from valve damaged.

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6. CYLINDER HEAD/VALVE

Cylinder Head Installation

Install a new O-ring into the indent of carburetor
insulator, and then install the insulator onto
cylinder head with 2 bolts.

Carburetor insulator

Install camshaft into cylinder head, and align

rocker pin with rocker arm pin hole. Then, insert
the rocker arm pin.
Install rocker arm pin mounting plate.

Stopper plate bolt

Clean up all residues and foreign materials onto Dowel pin

the matching surfaces of both cylinder and
cylinder head.
Install chain guide.
Install 2 set pins and cylinder head gasket. Gasket
Caution
Do not damage the matching surfaces of cylinder
and cylinder head.
Avoid residues of gasket or foreign materials
falling into crankcase as cleaning.
Chain guide

Loosen the tensioner by turning a flat-driver in

C.W direction.
Install cylinder head.

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6. CYLINDER HEAD/VALVE
Tighten 4 nuts and washers on the cylinder head 4 Nuts
2 Insulator bolts
upper side, and then tighten 2 cylinder head
mounting bolts of cylinder head side cover.
Torque value: 2.0~2.4kgf-m

Install and tighten spark plug

Torque value: 2.0~2.4kgf-m
Caution
This model is equipped with more precision
4-valve mechanism so its tighten torque can not
be exceeded standard value in order to avoid Cylinder head mounting bolts
causing cylinder head deformation, engine noise
and leaking so that motorcycle’s performance be
effected.

Install cam chain on to sprocket and align the

timing mark on the sprocket with that of cylinder
head.
Align sprocket bolt hole with camshaft bolt hole.
Tighten the sprocket mounting bolt.
Caution
Make sure timing marks are matched.
Timing mark

Thermostat bolt
Install a new O-ring onto thermostat and tighten its
mounting bolts.
Loosen sprocket chain tensioner and let it contact
with chain plate tightly. Tighten the bolt cap of
tensioner adjustment hole.

Hole cap of adjustment bolt

Vacuum tube
Install Air Injection system (AI) pipe. (2 bolts) Clamp strip
Install carburetor insulator onto carburetor and
tighten clamp strip bolt. Install the vacuum hose
of carburetor insulator.

AI. Pipe bolts

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6. CYLINDER HEAD/VALVE

Valve Clearance Adjustment

Loosen valve clearance adjustment nuts and bolts
located on valve rocker arm.
Measure and adjust valve clearance with feeler
gauge.
After valve clearance had been adjusted to
standard value, hold adjustment bolt and then
tighten the Adjustment nut.
Standard Value: IN 0.12 ± 0.02 mm
EX 0.12 ± 0.02 mm
Install the valve clearance adjustment hole cap.
(3 bolts)
Caution
The gasket is paper type. In case of broken,
replace it and clean the Remnant gasket.

Start the engine after assembly. Remove the

intake valve adjustment hole cap and make sure
that engine oil flows onto the cylinder head.
Stop the engine after confirmed, and then install
the intake valve adjustment hole cap.
Install the seat, luggage box and the body cover.
Caution
y If lubricant does not flow to cylinder head,
engine components will be worn out seriously.
Thus, it must be confirmed.
y When checking lubricant flowing condition, run
the engine in idle speed. Do not accelerate
engine speed.

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7. CYLINDER/PISTON

Mechanism Diagram ······························ 7-1 Piston Removal ··································7-4

Precautions in Operation ······················ 7-2 Piston Ring Installation ·····················7-6
Trouble Diagnosis·································· 7-2 Piston Installation ······························7-7
Cylinder Removal··································· 7-3 Cylinder Installation ···························7-7

Mechanism Diagram

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7. CYLINDER/PISTON

Precautions in Operation
General Information
y Both cylinder and piston service cannot be carried out when engine mounted on frame.

Specification Unit：mm
LH12W & LH18W
Item Standard Limit
ID ( LA18W not included) 56.995~57.015 57.016
Cylinder
Bend - 0.050
Clearance between piston Top ring 0.015~0.050 0.090
rings nd
2 ring 0.015~0.050 0.090
Top ring 0.150~0.300 0.500
nd
Piston/ Ring-end gap 2 ring 0.300~0.450 0.650
Piston ring Oil ring side rail 0.200~0.700 -
OD of piston ( LA18W not included) 56.985~57.005 56.900
Clearance between piston and cylinder 0.010~0.040 0.100
ID of piston pin boss 15.002~15.008 15.040
OD of piston pin 14.960~15.000 14.930
Clearance between piston and piston pin 0.002~0.014 0.020
ID of connecting rod small-end 15.016~15.034 15.060

LH18W
Item Standard Limit
Cylinder ID 60.995~61.015 61.016
Piston OD of piston 60.985~61.005 60.900

Trouble Diagnosis
Low or Unstable Compression Pressure Smoking in Exhaust Pipe
y Cylinder or piston ring worn out y Piston or piston ring worn out
y Piston ring installation improperly
y Cylinder or piston damage

Knock or Noise Engine Overheat

y Cylinder or piston ring worn out y Carbon deposits on cylinder head top side
y Carbon deposits on cylinder head top-side y Cooling pipe clogged or not enough in coolant
y Piston pin hole and piston pin wear out flow

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7. CYLINDER/PISTON

Cylinder Removal
Remove cylinder head (refer to chapter 6).
Remove coolant hose from cylinder.
Remove cylinder.

Coolant hose

Remove cylinder gasket and dowel pin.

Cover the holes of crankcase and cam chain with
a piece of cloth.
Clean up all residues or foreign materials from
the two matching surfaces of cylinder and
crankcase.
Caution
y Soap the residues into solvent so that the
residues can be removed more easily.

Inspection
Check if the inner diameter of cylinder is wear out
or damaged.
In the 3 positions, top, center and bottom, of
cylinder, measure the X and Y values respective
in the cylinder. Top
Service limit: LH12W: 57.016 Center
Bottom
LH18W: 61.10 mm

Check cylinder if warp.

Service limit: 0.05 mm

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7. CYLINDER/PISTON

Piston Removal
Plug crankcase opening with a cleaning cloth to
prevent from piston pin snap ring or other foreign
materials falling into crankcase when
disassembling.
Hold another snap ring with pliers.
Push out the piston pin from the side that not
removed the snap ring.

Inspection
Measure clearance between piston ring and its
grooves.
Service Limit: Top ring: 0.09 mm
2nd ring: 0.09 mm

Remove piston rings

Check if the piston rings are damaged or its
grooves are worn.
Caution
Pay attention to remove piston rings because
they are fragile.

Place piston rings respective into cylinder below

20 mm of cylinder top. In order to keep the piston
rings in horizontal level in cylinder, push the rings
with piston.
Service Limit: Top ring: 0.50 mm
2nd ring: 0.65 mm

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7. CYLINDER/PISTON

Measure the outer diameter of piston pin.

Service Limit: 15.040 mm

Measure the inner diameter of connecting rod

small end.
Service Limit: 15.06 mm

Measure the inner diameter of piston pin hole.

Service Limit: 15.04 mm
Calculate clearance between piston pin and its
hole.
Service Limit: 0.02 mm

Measure piston outer diameter.

Caution
The measurement position is 10 mm distance
from piston bottom side, and 90° to piston pin.
Service limit：60.90 mm
Compare measured value with service limit to
calculate the clearance between piston and
cylinder.

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7. CYLINDER/PISTON

Piston Ring Installation

Clean up piston top, ring groove, and piston surface.
Install the piston ring onto piston carefully.
Place the openings of piston ring as diagram shown.
Caution
y Do not damage piston and piston rings as installation.
y All marks on the piston rings must be forwarded to up side.
y Make sure that all piston rings can be rotated freely after installed.

Top ring

nd
2 ring

Oil ring

Top groove

nd
2 groove

Oil groove

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7. CYLINDER/PISTON

Piston Installation
Install piston and piston pin, and place the IN
marks on the piston top side forward to intake
valve.
Install new piston pin snap ring.
Caution
y Do not let the opening of piston pin snap ring
align with the opening piston ring.
y Place a piece of cloth between piston and
crankcase in order to prevent snap ring from
falling into crankcase as operation.

Cylinder Installation
Clean up all residues and foreign materials on
the matching surface of crankcase. Pay
attention to not let these residues and foreign
materials fall into crankcase.
Caution
Soap the residues into solvent so that the
residues can be removed more easily.

Install dowel pins and new gasket.

Coat engine oil to inside of cylinder, piston and

piston rings.
Care to be taken when installing piston into
cylinder. Press piston rings in one by one as
installation.
Caution
Do not push piston into cylinder forcefully
because piston and piston rings will be
damaged.。

Install coolant hose onto cylinder.

Install cylinder head (refer to Chapter 6).

Coolant hose

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7. CYLINDER/PISTON

Notes:

7-8
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8. V-BELT DRIVING SYSTEM/KICK STARTER

Mechanism Diagram ··························· 8-1 Driving Belt···········································8-4

Maintenance Description ···················· 8-2 Drive Face·············································8-6
Trouble Diagnosis ······························· 8-2 Clutch Outer/Driven Pulley··················8-9
Left Crankcase Cover ························· 8-3

Mechanism Diagram

3.5~4.5kgf-m

5.0~6.0kgf-m

5.0~6.0kgf-m

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Maintenance Description
Precautions in Operation
General Information
y Drive face, clutch outer, and driven pulley can be serviced on the motorcycle.
y Driving belt and driving pulley must be free of grease.

Specification Unit：mm
Item Standard value (mm) Limit (mm)
Driving belt width 19.000 17.500
ID of drive face boss 27.000~27.021 27.060
OD of drive face 26.970~26.990 26.940
OD of roller 19.950~20.100 19.500
ID of clutch outer 130.000~130.200 130.500
Thickness of clutch weight 4.000~4.100 2.000
Free length of driven pulley spring 88.300 83.200
OD of driven pulley 33.965~33.985 33.940
ID of drive face 34.000~34.025 34.060

Torque value Special Service Tools

y Driven face nut: 5.0~6.0kgf-m Clutch spring compressor: SYM-2301000
y Clutch outer nut: 5.0~6.0kgf-m Inner bearing puller: SYM-6204002
Clutch nut wrench 39 x 41 mm: SYM-9020200
Universal holder: SYM-2210100
Bearing driver: SYM-9100100

Trouble Diagnosis
Engine can be started but motorcycle can Insufficient horsepower or poor high
not be moved speed performance
1. Worn driving Belt 1. Worn driving belt
2. Worn drive face 2. Insufficient spring force of driven pulley
3. Worn or damaged clutch weight 3. Worn roller
4. Broken driven pulley 4. Driven pulley operation un-smoothly

Shudder or misfire when driving

1. Broken clutch weight
2. Worn clutch weight

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Left Crankcase Cover

Left crankcase cover removal
Remove body cover.
Remove air cleaner. (2 bolts)
Remove L crankcase cover. (7 bolts)

Left crankcase cover install

Install left crankcase cover in the reverse
procedures of removal.

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Driving Belt
Removal
Remove left crankcase cover
Hold drive face with universal holder, and remove
nut and drive face.

Universal holder

Hold clutch outer with universal holder, and

Nut
remove nut and clutch outer.
Caution
y Using special service tools for tightening or
loosening the nut.
y Fixed rear wheel or rear brake will damage
reduction gear system.
Drive belt

Universal holder

Push the driving belt into belt groove as diagram

shown so that the belt can be loosened, and then
remove the driven pulley.
Remove driven pulley. Do not remove driving
belt.
Remove the driving belt from the groove of driven
pulley.

Inspection
Check the driving belt for crack or wear. Replace
it if necessary.
Measure the width of driving belt as diagram
shown.
Service Limit: 17.5 mm Belt tooth
Replace the belt if exceeds the service limit.
Width
Caution
y Using the genuine parts for replacement.
y The surfaces of driving belt or pulley must be
free of grease.
y Clean up all grease or dirt before installation.

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Installation
Caution
Pull out driven face to avoid it closing.
Driven face
Install driving belt onto driven pulley.

Install the driven pulley that has installed the belt

onto drive shaft.
On the drive belt another end to the movable drive
face.

Install the clutch outer with universal holder, and Clutch outer
then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m

Nut

Universal holder

Install the drive face with universal holder, and

then tighten nut to specified torque value.
Torque value: 5.0~6.0kgf-m

Universal holder

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Drive Face
Removal
Remove left crankcase cover.
Hold generator flywheel with universal holder, and
then remove drive face nut.
Remove drive face.

Universal holder

Remove driving belt and movable drive face comp

Movable drive face
from crankshaft.

Crankshaft Drive face boss

Remove ramp plate.

Ramp plate

Remove weight rollers from movable drive face. Movable drive face

Weight roller

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Inspection Weight roller

The weight rollers are to press movable drive face
by means of centrifuge force.
Thus, if weight rollers are worn out or damaged,
the centrifuge force will be effected.
Check if rollers are worn or damaged. Replace it
if necessary.
Measure each roller’s outer diameter. Replace it if
exceed the service limit.
Service limit: 19.50 mm
Weight: 14.5g

Movable drive face

Check if drive face boss is worn or damaged and
replace it if necessary.
Measure the outer diameter of movable drive face, Drive face boss

and replace it if it exceed service limit.

Service limit: 26.94 mm
Measure the inner diameter of movable drive face,
and replace it if it exceed service limit.
Service limit: 27.06 mm

Reassembly/installation
Install weight rollers. Weight roller

Caution
The weight roller two end surfaces are not
certainly same. In order to lengthen the roller
life and prevented exceptionally wears the
occurrence, Please end surface of the closure
surface counter clockwise assembles onto
movable drive face.

Closure surface

Install ramp plate.

Guide collar

Ramp plate

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8. V-BELT DRIVING SYSTEM/KICK STARTER

With 4~5g grease spreads wipes drives in the

movable drive face axis hole.
Install drive face boss.
Caution
The movable drive face surface has to be free of
grease. Clean it with cleaning solvent.

Drive face boss

Install movable drive face comp. onto crankshaft.

Movable drive face Drive face boss

Crank shaft

Driven pulley installation

Press down
Press driving belt into pulley groove, and then pull
the belt onto drive shaft.

Drive belt

Nut
Install drive face, washer and nut.
Caution
Make sure that two sides of pulley surfaces have
to be free of grease. Clean it with cleaning
solvent.
Hold drive face with universal holder.
Tighten nut to specified torque.
Torque value: 5.0~6.0kgf-m
Install left crankcase cover. Drive face

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch Outer/Driven Pulley Clutch nut wrench

Disassembly
Remove drive belt and clutch outer/driven pulley.
Install clutch spring compressor onto the pulley
assembly, and operate the compressor to let the
wrench be installed more easily.
Caution
Do not press the compressor too much.
Clutch spring compressor
Hold the clutch spring compressor onto bench vise,
and then remove mounting nut with special service
tool.
Release the clutch spring compressor and remove
clutch weight and spring from driven pulley.

Remove seal collar from driven pulley.

Collar

Remove guide pin, guide pin roller, and movable Movable driven face Guide pin
Seal
driven face, and then remove O-ring & oil seal
seat from movable driven face.

O-ring Guide pin Guide pin roller

Inspection
Clutch outer
Measure the inner diameter of clutch outer.
Replace the clutch outer if exceed service limit.
Service limit: 130.5 mm

Inner
diameter
Clutch outer

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch lining Clutch lining

Measure each clutch weight thickness. Replace
it if exceeds service limit.
Service limit: 2.0 mm

Clutch weight

Driven pulley spring

Measure the length of driven pulley spring.
Replace it if exceeds service limit.
Service limit: 83.2 mm

Free length

Driven pulley
Check following items:
y If both surfaces are damaged or worn. Driven face
y If guide pin groove is damaged or worn.
Replace damaged or worn components.
Measure the outer diameter of driven face and the
inner diameter of movable driven face. Replace it
if exceeds service limit.
Service limit: Outer diameter 33.94 mm
Movable driven face Guide pin groove
Inner diameter 34.06 mm

Driven Pulley Bearing Inspection

Check if the inner bearing oil seal is damage.
Replace it if necessary.
Check if needle bearing is damage or too big
clearance. Replace it if necessary.
Rotate the inside of inner bearing with fingers to Needle bearing
check if the bearing rotation is in smooth and silent.
Check if the bearing outer parts are closed and
fixed. Replace it if necessary. Outer ball bearing

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Clutch weight Replacement

Spring Driving plate
Remove snap ring and washer, and then remove
clutch weight and spring from driving plate.
Caution
Some of models are equipped with one mounting
plate instead of 3 snap rings.
Check if spring is damage or insufficient elasticity.
Snap ring
Clutch weight

Check if shock absorption rubber is damage or

deformation. Replace it if necessary. Shock absorption rubber

Apply with grease onto setting pins. Setting pin

Install new clutch weight onto setting pin and then

push to the specified location. Shock absorption rubber

Apply with grease onto setting pins.

But, the clutch block should not be greased. If so,
replace it.
Caution
Grease or lubricant will damage the clutch weight
and effect the block’s connection capacity.
Clutch weight

Install the spring into groove with pliers.

Spring

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Install snap ring and mounting plate onto setting

pin.

Snap ring

Replacement of Driven Pulley Bearing

Outer bearing
Remove inner bearing. Clipper

Caution
y If the inner bearing equipped with oil seal on
side in the driven pulley, then remove the oil
seal firstly.
y If the pulley equipped with ball bearing, it has to Inner needle
remove snap ring and then the bearing. bearing

Snap ring

Remove snap ring and then push bearing forward

to other side of inner bearing.
Place new bearing onto proper position and its
sealing end should be forwarded to outside.
Apply with specified oil. Snap ring

Specified oil
Outer bearing

Install new inner bearing.

Bearing end
Caution
y Its sealing end should be forwarded to outside
as bearing installation.
y Install needle bearing with hydraulic presser.
Install ball bearing by means of hydraulic
presser.
Install snap ring into the groove of driving face.
Align oil seal lip with bearing, and then install the Inner bearing
new oil seal (if necessary).

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Installation of Clutch OUTER/Driven Pulley Oil seal

Assembly
Install new oil seal and O-ring onto movable driven
face.
Apply with specified grease to lubricate the inside
of movable driven face.

Specified grease
O-ring

Install the movable driven face onto driven face. Movable driven face Guide pin
Oil seal
Install the guide pin and guide pin roller.

O-ring Guide pin Guide pin roller

Install the collar.

Collar

Install driving belt, spring and clutch weight COMP.

into clutch spring compressor, and press down the Clutch nut wrench
assembly by turning manual lever until mounting
nut that can be installed.
Hold the compressor by bench vise and tighten
the mounting nut to specified torque with clutch
nut wrench.
Remove the clutch spring compressor.
Torque value: 5.0~6.0kgf-m
Install clutch outer/driven pulley and driving belt Clutch spring compressor
onto driving shaft.

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8. V-BELT DRIVING SYSTEM/KICK STARTER

Notes:

8-14
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9. FINAL DRIVING MECHANISM

Mechanism Diagram ··························· 9-1 Inspection of Final Driving Mechanism

······························································· 9-4
Precautions in operation ···················· 9-2
Bearing Replacement ·························· 9-5
Trouble Diagnosis ······························· 9-2
Re-assembly of Final Driving Mechanism
Disassembly of Final Driving Mechanism
······························································· 9-8
······························································ 9-3

Mechanism Diagram

Bearing (6004)

Final shaft

Final gear

Counter gear 9
Bearing (6301)

Bearing (6004)
Counter shaft

Bearing (CSB301)

Drive shaft
Bearing (6301)

1.0~1.4kgf-m

Bearing (6204)

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9. FINAL DRIVING MECHANISM

Precautions in operation
Specification
Application oil: scooter gear oil
Recommended oil: KING MATE serial gear oils
Oil quantity: 110 c.c. (100 c.c. when replacing)

Torque value
Gear box cover 1.0~1.4kgf-m

Tools
Special tools
Bearing (6203/6004UZ) driver: SYM-9620000
Bearing (6204) driver: SYM-9110400
Bearing (6301) driver: SYM-9610000
Oil seal (27*42*7) driver: SYM-9125500
Oil seal (20*32*6) driver: SYM-9120200
Inner bearing puller: SYM-6204002
Outer bearing puller: SYM-6204001
Drive shaft puller: SYM-1130000-L
Drive shaft install bush: SYM-1130010
Extension bush (long): SYM-1130031
Extension bush (short): SYM-1130032

Trouble Diagnosis
Engine can be started but motorcycle can not be moved.
y Damaged driving gear
y Burnt out driving gear

Noise
y Worn or burnt gear
y Worn gear

Gear oil leaks

y Excessive gear oil.
y Worn or damage oil seal

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9. FINAL DRIVING MECHANISM

Disassembly of Final Driving

Mechanism
Remove driven pulley.
Drain gear oil out from gear box.
Remove gear box cover bolts and then remove the
cover and drive shaft.

7 bolts

Remove final gear and shaft. Counter shaft & gear

Remove counter shaft and gear.

Final shaft & gear

Gasket
Remove gasket and dowel pin.

Dowel pin

Remove the drive shaft.

In order to avoid damaging the gear box cover, in
the cover place a rag between the cover and table.
Caution
y If non- essential do not remove the drive
shaft from the cover upper side.
y If remove the drive shaft from the gear box
cover, then its bearing has to be replaced.

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9. FINAL DRIVING MECHANISM

Inspection of Final Driving

Mechanism
Check if the countershaft is wear or damage.

Check if the final shaft and gear are burn, wear or

damage.

Check bearings on gear box. Oil seal Bearing

Rotate each bearing’s inner ring with fingers.
Check if bearings can be turned in smooth and
silent, and also check if bearing outer ring is
mounted on gear tightly.
If bearing rotation is uneven, noising, or loose
bearing mounted, then replace it.
Check oil seal for wear or damage, and replace it
if necessary.

Check gear box cover bearing as the same way

above, and replace it if necessary.
Caution
y If remove the drive shaft from the cover upper
side, then its bearing has to be replaced.
Check drive shaft and gear for wear or damage.

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9. FINAL DRIVING MECHANISM

Bearing Replacement
Caution
y Never install used bearings. Once bearing
removed, it has to be replaced with new one.

Remove driving shaft bearing and counter shaft

bearing from left crankcase using following tools:
Special tool:
Inner bearing puller

Install new drive shaft bearing and counter shaft

bearing into left crankcase.
Special tool:
Bearing driver (6301)

Remove oil seal, and then remove final shaft

bearing from left crankcase.
Special tool:
Inner bearing puller

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9. FINAL DRIVING MECHANISM
Install new final shaft seal. Oil seal driver
Special tool:
Oil seal driver (27*42*7)

Install new final shaft bearing.

Special tool:
Bearing driver
Bearing driver (6203/6004UZ)

Press out the drive shaft from gear box cover.

Inner bearing puller
Using shaft protector as operation.
Remove oil seal from gear box cover and discard
the seal.
Use inner bearing puller to remove the final shaft
bearing and counter shaft bearing from the cover.
Special tool:
Inner bearing puller

If the drive shaft is pulled out with its bearing, then

remove the bearing with bearing puller and shaft Protector
protector.
Special tool:
Multi-functional bearing puller or Outer bearing
puller
Shaft protector

Bearing puller

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9. FINAL DRIVING MECHANISM
Install a new drive shaft bearing onto gear box
cover.
Special tool:
Bearing driver (6204)
Bearing driver

Install a new final shaft bearing and counter shaft Bearing driver
bearing onto gear box cover.
Special tool:
Bearing driver (6203/6004UZ)
Bearing driver (6301)

Install drive shaft.

Special tool: Install bush
Drive shaft puller
Drive shaft install bush
Extension bush (long)
Extension bush (short)

Drive shaft puller

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9. FINAL DRIVING MECHANISM

Re-assembly of Final Driving

Mechanism
Apply with grease onto the oil seal lip of final
driving shaft.

Install countershaft, counter gear, final shaft and Final shaft

final driving gear.

Countershaft Final drive gear

Install dowel pin and new gasket.

Dowel pin Gasket

Install gear box cover and bolts, and tighten.

Torque value: 1.0~1.4kgf-m

7 bolts

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9. FINAL DRIVING MECHANISM
Apply with grease onto new oil seal lip, and then Oil seal driver
install the oil seal.
Special tool:
Oil seal driver (20*32*6)

Install driven pulley/clutch outer/belt.

Install movable drive face, drive face and left
crankcase.
Install rear wheel.
Add gear oil.

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9. FINAL DRIVING MECHANISM

Notes:

9-10
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10. ALTERNATOR/STARTING CLUTCH

Mechanism Diagram ··························10-1 Starting Clutch ··································· 10-4

Precautions in Operation···················10-2 Flywheel Installation·························· 10-7
Right Crankcase Cover Removal ······10-3 A.C.G. Set Installation························ 10-7
A.C.G. Set Removal····························10-3 Right Crankcase Cover Installation·· 10-7
Flywheel Removal ······························10-3

Mechanism Diagram

1.0~1.4kgf-m

10

5.0~6.0kgf-m

0.8~1.2kgf-m

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10. ALTERNATOR/STARTING CLUTCH

Precautions in Operation
General information
y Refer to chapter 5: Engine removal and installation
y Refer to chapter 16: The troubleshooting and inspection of alternator
y Refer to chapter 16: The service procedures and precaution items of starter motor

Specification
Item Standard value (mm) Limit (mm)

ID of starting clutch gear 20.026~20.045 20.100

OD of starting clutch gear 42.175~42.200 42.100

Torque value
Flywheel nut 5.0~6.0kgf-m
Starting clutch hexagon bolt 1.0~1.4kgf-m with adhesive
8 mm bolts 0.8~1.2kgf-m
12 mm bolts 1.0~1.4kgf-m

Tools
Special tools
A.C.G. flywheel puller: SYM-3110A00
Universal holder: SYM-2210100

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10. ALTERNATOR/STARTING CLUTCH

Right Crankcase Cover Removal 9 bolts

Remove 9 bolts from the right crankcase cover.

Remove the right crankcase cover.
Remove dowel pin and gasket.

2 bolts
A.C.G. Set Removal
Remove 2 mounted bolts from pulse generator
and then remove it.
Remove 3 screws from right crankcase cover and
A.C.G. set.

3 screws

Flywheel Removal
Remove left crankcase cover.
Remove oil through from crankshaft.

Hold the flywheel by drive face with universal

holder, and remove its nut.
Special tool:
Universal Holder

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10. ALTERNATOR/STARTING CLUTCH
Remove the oil through guide pin from crankshaft.

Pull out flywheel with A.C.G. flywheel puller.

Special tool:
A.C.G. Flywheel puller

Starting Clutch
Removal
Remove starting driven gear.

Remove mounting plate, starter reduction gear,

and the shaft.

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10. ALTERNATOR/STARTING CLUTCH

Starting Clutch Inspection

Check the starting clutch gear for wear or damage.
Measure the ID and OD of the starting clutch gear.
Service Limit: ID: 20.1 mm
OD: 42.10 mm

Check the starting reduction gear and shaft for

wear or damage.

Install one way clutch onto starting clutch gear.

Hold flywheel and rotate starting clutch gear.
The starting clutch gear should be rotated in
C.C.W direction freely, but not C.W direction.
(View as shown in this figure.)

Remove the rollers, spring caps, and springs of

Spring
clutch on the one way clutch that located on the
back of flywheel. Roller
Check each roller and plug for wear or damage.
Install rollers, plugs and springs.

Spring cap

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10. ALTERNATOR/STARTING CLUTCH
Remove 3 hexagon bolts with air and hex socket
wrenches.

Disassembly
Install the components in the reverse procedures
of removal.
Caution
Tape a tightening tape onto the thread of hexagon
bolt.
Torque value: 1.0~1.4kgf-m

Installation
Install reduction gear shaft and reduction gear.

Install starting clutch gear onto crankshaft.

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10. ALTERNATOR/STARTING CLUTCH

Flywheel Installation
Align the key on crankshaft with the flywheel
groove, and then install the flywheel.
Insert the oil through guide pin onto crankshaft.
Make sure that there is no other material stock on
it. If so, clean it up.

Hold the flywheel with flywheel holder, and tighten

its nut.
Torque value: 5.0~6.0kgf-m
Tool:
Flywheel holder
Install spring and oil through.

A.C.G. Set Installation 2 bolts

Install the A.C.G. set onto right crankcase cover (3
screws).
Install pulse generator (2 screws).
Tie the wire harness securely onto the indent of
crankcase.
Caution
Make sure that the wire harness is placed under
pulse generator.

3 screws Wire

Right Crankcase Cover Installation

Install dowel pin and new gasket.
Install right crankcase cover onto the crankcase.
Note: Align the water pump shaft indent with the oil
pump shaft.
Install right crankcase cover (9 screws).

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10. ALTERNATOR/STARTING CLUTCH
Install the water pump cover onto crankcase
cover.
Connect water hose to the right crankcase cover
and water pump cover.

10-8
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11. CRANKCASE / CRANK

Mechanism Diagram ··························11-1 Disassembly of crankcase ················ 11-3

General information ···························11-2 Crankshaft Inspection ······················· 11-5
Trouble diagnosis ······························11-2 Assembly of crankcase ····················· 11-6

Mechanism Diagram

1.2~1.6kgf-m

11

1.0~1.5kgf-m

0.8~1.2kgf-m 1.5~3.0kgf-m

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11. CRANKCASE / CRANK

General information
Operational precautions
y This Section concerns disassembly of the crankcase for repair purpose.
y Remove following components before disassembling crankcase.
－Engine Section 5
－Cylinder head Section 6
－Cylinder and piston Section 7
－Drive pulley and driven pulley Section 8
－AC generator/Start driven gear Section 10
－Starting motor Section 16

y In case it requires replacing the crankshaft bearing, the driving chain of engine oil pump or the timing
chain, it is preferably to replace crankshaft as a unit.

Specification Unit: mm
Item Standard Limit
Connecting rod side clearance of the big end 0.100~0.400 0.600
Crankshaft
Vertical clearance of the big end of the connecting rod 0~0.008 0.050
Run-out - 0.100

Torque value
Bolts for crankcase 0.8~1.2kgf-m
Bolts for cam chain adjuster 1.2~1.6kgf-m

Tools
Special tools
R/L. crank disassemble/ install tool: SYM-1300001-H9A
L. crank shaft bearing driver: SYM-9100200-H9A
Crank shaft bearing fixing socket: SYM-9100210-H9A
Crank shaft puller: SYM-1130000-H9A
L. crank shaft oil seal driver (25*40*8): SYM-9121600
Outer bearing puller: SYM-6204010
Inner bearing puller: SYM-6204020
Clutch nut wrench: SYM-9020200

Trouble diagnosis
Engine noise
y Loose crankshaft bearing
y Loose crankshaft pin bearing
y Worn out piston pin and pin hole

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11. CRANKCASE / CRANK

Disassembly of crankcase Tensioner

Remove the cam chain setting plate, and then
remove cam chain.
Loosen the bolt and remove the tensioner.

Cam chain setting plate

Loosen 2 bolts on the right crankcase. 2 bolts

Loosen 4 bolts on the left crankcase. 4 bolts

Place right crankshaft case downward and left up

crankcase.
Caution
Care should be taken not to damage the contact
surfaces.

6 R/L. crank disassemble/install tool

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11. CRANKCASE / CRANK
Remove crank by left crank shaft.
Refer to chapter 2: Special tools
Special tool:
R/L. crank case disassemble/install tool
(SYM-1120000-H9A)

Remove crankshaft from right crankcase.

Remove gasket and dowel pins.

Scrape gasket residues off the crankcase contact
surface.
Caution
Do not damage contact surface of the gasket.
It is better to moisten the gasket residue for
easy scrapping.

Check any damage in oil seal.

Replace with new one if damaged.

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11. CRANKCASE / CRANK

Crankshaft Inspection
Use a thickness gauge to measure left and right
clearance of connecting rod big end.
Service limit: 0.6 mm

Measure point for the crank

big end of the connecting rod.

Measure the clearance of the big end at the

vertical directions.
Service limit: 0.05 mm

Place the crankshaft on a V-block, measure

run-out of the crankshaft.
Service limit: 0.10 mm

90 mm 60 mm

Check crankshaft bearing

Use hand to crank the bearing to see it moves
freely, smoothly and noiseless.
Check the inner ring to see it links firmly on the
bearing.
If any roughness, noise and loose linkage are
detected, replace the bearing with new one.
Caution
The bearing shall be replaced in pair.
Special tool: outer bearing puller Crank bearing

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11. CRANKCASE / CRANK

Assembly of crankcase
Special tool:
R/L. crank case disassemble/install tool
L. crank shaft bearing driver
Crank shaft bearing fixing socket
Crank shaft puller
Clutch nut wrench
The new bearing and bearing driver, puts on the
left crank case.

Left crank shaft bearing driver

Install R/L. crank case disassemble/install tool on Clutch nut

the left crank case. wrench
Again turns on crank shaft puller on the bearing
driver spiral tooth.
Gradually tightens the crank shaft puller upper cap Crank shaft
nut, presses in the bearing to locate. puller
After the bearing presses in to locate, opens the
R/L. crank case disassemble/install tool, takes
down the bearing driver.

Crank case disassemble/install tool

Installs crank to the left crank case.

Direct the crank shaft bearing fixing socket to

crank shaft.

Crank shaft
bearing fixing
socket

11-6
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11. CRANKCASE / CRANK
Install R/L. crank case disassemble/install tool on Crank shaft
the left crank case. puller
Again turns on crank shaft puller on the crankshaft
spiral tooth.
Caution
Crank shaft puller lock into on as far as possible
the crank spiral tooth, prevented pulls the bad
crank spiral tooth.

Crank case disassemble/install tool

Gradually tightens the crank shaft puller upper cap

nut, drags into the crank to locate.

Install 2 new dowel pin and new gasket.

Install the right crankcase onto the left crankcase.

Tighten 2 bolts on the crankcase.

2 bolts
Torque value: 0.8~1.2kgf-m

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11. CRANKCASE / CRANK
Tighten 4 bolts on the crankcase. 4 bolts
Torque value: 0.8~1.2kgf-m

Clean the crankshaft.

Apply a layer of grease on the lip of oil seal, Puts
on the left crank shaft.
Install the oil seal in the left crankcase with care
not to damage the lip of the oil seal.

By oil seal driver (25×40×8), oil seal will knock into

locate.
Special tool: Oil seal
Oil seal driver (25*40*8) driver

Install the tensioner and tighten the bolts. Tensioner

Torque value: 1.2 ~1.6kgf-m
Install the cam chain.
Install the cam chain setting plate.

Cam chain setting plate

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12. COOLING SYSTEM

Mechanism Diagram ··························12-1 System Test········································ 12-5

General Information ···························12-2 Radiator ·············································· 12-6
Trouble Diagnosis ······························12-2 Water Pump ········································ 12-8
Trouble Diagnosis for Cooling System Thermostat ········································· 12-12
·····························································12-3

Thermo switch (fan)

Mechanism Diagram
Cooling fan
Radiator filler cap

Reserve tank

Radiator filler cap

Radiator

Thermo unit (temp meter)

Thermostat Cooling fan

12

Thermo switch (fan)

Reserve tank

Water pump Coolant inlet pipe Coolant outlet pipe By-pass pipe

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12. COOLING SYSTEM

General Information
General
Warning:
While the engine is running, never attempt to open the radiator filler cap, the pressurized hot coolant
may shoot out and cause serious scalding injury. No maintenance work is allowed to perform unless
the engine is completely cooled down.

y Refill the radiator with distilled water or specified additives.

y Add coolant to the reservoir.
y The cooling system can be serviced on the motorcycle.
y Never spill the coolant to the painted surface.
y Test the cooling system for any leakage after the repair.
y Please refer to Section 17 for inspection of the temperature sensor switch for the fan motor and the
water thermometer.

Technical Specification
Item Specification
Pressure to open filler cap 0.75~1.05 kg/cm2
Capacity of coolant: Engine + radiator 780 c.c.
Reservoir upper 420 c.c.
Begins to activate at 71-80℃
Thermostat
Stroke: 3.5 ~ 4.5 mm/80℃
Not-pressure: 107.7℃
Boiling point
Pressurized: 125.6℃

Torque Value
For water pump rotor 1.0~1.4kgf-m

Tools Requirement
Special tools
Water pump bearing driver (6901): SYM-9100100
Water pump oil seal driver (Inner): SYM-9120500-H9A
Water pump mechanical seal driver: SYM-1721700-H9A
Inner bearing puller: SYM-6204020

Trouble Diagnosis
The engine temperature is too high The engine temperature is too low
y The water thermometer and the temperature y The water thermometer and the temperature
sensor do not work properly. sensor malfunction.
y The thermostat is stuck to closed. y The thermostat is stuck to open.
y Insufficient coolant.
y The water hose and jacket are clogged. Coolant is leaking
y Fan motor malfunction. y The water pump mechanical seal does not
y The filler cap of the radiator malfunction. function properly.
y The O ring is deteriorated.
y The water hose is broken or aged.

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12. COOLING SYSTEM

Trouble Diagnosis for Cooling System

The temperature indicated is too high

A. Stop and waiting for the

engine is completely A1.Refill the radiator with
N coolant then check for any Y
cooled down, open cap to Water leaking problem
check the capacity of leakage?
coolant in radiator.
N
Y

B. Turn on main switch and

check the water N B-1. Measure thermo unit to N
Replace thermo unit
temperature indicator confirm voltage 6V↑?
back to zero?

Y
Y
B-2. Inspect the circuits of
water temperature have Y Short or earth handle
short or earth?

N
Meter problem

C. Open radiator cap and C-1. Eng. stop and remove

softly throttle, inspect
N water pump cover, start
N
Water pump repair
coolant have circulated? the motor to inspect pump
its rotation?

Y
Y Water hose clogged

D. Close radiator cap,

measure thermo unit to N
confirm voltage reduced Replace thermo unit
comply with temperature
rise?

Y
Next page

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12. COOLING SYSTEM

Preceding page

E. Keep eng. 3000~4000 rpm E-1. Measure thermal switch to

and inspect cooling fan was
N confirm voltage be
N
Replace thermal switch
operating after the changed (12→0V)?
temperature gauge over 3
checks?
Y
Y
E-2. Connect cooling fan
F. Confirm the cooling fan was terminals with N
convulsion? Replace cooling fan
battery(12V) directly to
inspect its operation?
Y
Meter unusual Y

E-3. Keep eng. 3000~4000

rpm and inspect coolant
If circuit connect reverse flow into reserve tank
cooling fan will forward, after the temperature
correct and check again. gauge over 3 checks?

Y
E-4. Remove thermostat from
holder then heats it by N
Replace thermostat
water directly to check its
operation?

Y Refill with coolant then

check again

For bleed the air bubbles

completely, open radiator cap Notice the water hose
and start engine while engine can’t any unsuitable
is cool then press water hose bend or twist and
softly by hand to bleeding. bleed the air bubbles
Turn the throttle repeatedly completely.
until the coolant surface
becomes stable.

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12. COOLING SYSTEM

System Test
Test on the filler cap
Hermetically seal the filler cap, apply water and
pressure to the filler cap. Replace it with new one
if found failing to maintain the specified pressure
within a given time limit, or the opening pressure is
too high or too low. The specified pressure shall
be maintained at least for 6 seconds in the test
Relief pressure for the filler cap: 0.75-1.05
kg/cm2 Pressure tester
Apply pressure to the radiator, engine and water Filler cap
hose to check for any leakage
Caution
Radiator cap
Pressure which is too high may damage the
radiator. Never use pressure which exceeds
1.05 kg/cm2.
If the system fails to maintain the specified
pressure for at least 6 seconds, repair or replace
parts.
Change of coolant
Warning
Never attempt to carry out service work on the
cooling system unless the engine is completely
cooled down, otherwise, you may get scalded.
Remove the front cover, and then remove filler
cap.
Place a water pan under the water pump, loosen
the drain bolt to drain out the coolant.
Reinstall the drain bolt.

Refilling system with coolant and bleeding the air

bubbles.
y Run the engine, and remove by-pass pipe.
y Check by-pass hole whether has the air bubble
to emit.
y If emits without the air bubble, only has the
coolant to flow out, then backflow pipe joint on, Drain bolt
engine flameout.
y Remove radiator filler cap.
y Starts the engine, inspects does not have the air
bubble in the radiator coolant, also the coolant
liquid level is stable.
y Stop the engine. Add coolant to proper level if
necessary.
y Screw and tighten up the radiator filler cap.

Caution
In order to avoid the water tank rusting, please do
not use the unclear trade mark refrigerant.
Coolant recommended: SYM Bramax radiator
agent. By-pass pipe
Concentration: 50%

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12. COOLING SYSTEM

Check reserve tank

y Remove the front cover, and then remove
reserve tank filler cap.
y Check the liquid level in the reservoir. Add
coolant to proper level if too low.
y Reinstall the reserve tank filler cap.

Caution
The reserve tank liquid level coca too is not high,
after avoids the water temperature elevating, in
the cooling system the refrigerant backflow
floods. Viewing window

Radiator
Check
Remove the front cover, check for any leakage
from weld seam.
Blow radiator clean using compressed air. If the
radiator is blocked by dirt, use low pressure water
jet to clean it.
Care shall be taken when straightening the sink
fan.

Removal
Coolant leakage
Sets at a vessel underneath the water pump,
dismantles the drain bolt to leak off in the cooling
system refrigerant.

Drain bolt

Remove front cover. 2 bolts Coolant inlet pipe

Disconnect the couplers for the thermo switch and
fan motor.
Remove coolant inlet pipe.
Loosen the radiator 2 bolts.

Thermo switch
coupler

Cooling fan coupler

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12. COOLING SYSTEM
Remove coolant outlet pipe and reserve tank pipe, Reserve tank pipe
and then remove radiator and cooling fan.

Coolant outlet pipe

Disassembly
Loosen the 4 bolts from the fan duct, and then
remove the fan duct and radiator plate.
Cooling fan
Loosen the 4 bolts from the fan and remove the bolts x3
fan.
Loosen 3 screws from the fan motor, and take off
the fan motor.
Remove nut to remove the fan from fan motor.

Cooling fan bolts x4

Assembly Radiator plate Cooling fan duct

Install fan motor onto fan shroud and insert the fan
into the motor shaft.
Apply a coat of the adhesive to the shaft thread of
the motor, and then install the washer and the lock
nut.
Tighten the fan shroud onto the radiator with four
bolts. Please refer to chapter 17 for the inspection
of the thermo switch.
Caution
Liquid packing must be applied to the thermo Thermo switch
switch before installing to avoid damaging the
radiator.

Installation
Install the removed parts in the reverse order of
removal.
Install radiator in the reverse order of removal.
Upon completion, check for any leakage.

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12. COOLING SYSTEM

Water Pump
Check water pump seal / cooling
system divulges inspection
y Disassembles the refrigerant drain bolt,
overflows little buckles the N actually fluid,
confirmed overflows the refrigerant whether has
the greasy dirt.
y Turns on lathe the engine oil gauge rule, the
inspection engine oil whether does have
bleaches situation of the emulsified.
If has the above two kind of interior to divulge the
Drain bolt
phenomenon, possibly for the water pump inner
two seal damages, the engine cooling system
damages or the cylinder and the cylinder head
gasket damages, please first dismantles the right
crank case to say A confirms the replacement
water pump seal, if does not have the question to
take apart for overhaul cooling system of system
again the cylinder head, the cylinder.

Removal of water pump

Loosen the drain bolt to drain out the coolant.
Remove the water hose.
Loosen three bolts and remove the pump cover.
Loosen 9 bolts and remove the right cover.
Take off the gasket and dowel pin.

Turn pump rotor clockwise and remove.

Caution
The rotor is provided with left turn thread.

Remove the circlip from the right crankcase cover.

Remove the water pump shaft and the inner
bearing.
Remove the outside bearing by inner bearing
puller.
Rotate the inner ring of bearing, the bearing shall
move smoothly and quietly.
If the bearing does not rotate smoothly or
produces a noise, replace it with new one.

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 To this chapter contents
12. COOLING SYSTEM
Check any wear and damage of the mechanical Mechanical seal
seal and inside seal.
Caution
The mechanical seal and inside seal must be
replaced as a unit.

Replacement of Mechanical Seal Water pump bearing

Remove the inside bearing by inner bearing puller. driver
Drive the mechanical seal and inner seal out of the
right crankcase.
Special tools:
Inner bearing puller
Water pump bearing driver
Caution
Replace a new mechanical seal after removing
it.

Mechanical seal
Apply a coat of sealant to the mating surfaces of
the right crankcase before installing the new
mechanical seal.

Install the mechanical seal onto the right

crankcase.
Special tools: Water pump mechanical
Water pump mechanical seal driver seal driver

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12. COOLING SYSTEM
Install the new inner seal onto the right crankcase.
Water pump oil seal
Special tools: driver (inner)
Water pump oil seal driver (inner)

Install a new outside bearing to the right

Water pump bearing
crankcase cover. driver (6901)
Special tools:
Water pump bearing driver (6901)
Caution
Do not reuse old bearing. It must be replaced
with a new one once it has been removed.

Mount the water pump shaft and the inner bearing Inner bearing
to the right crankcase cover.

Water pump shaft

Install the circlip to hold the inner bearing.

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12. COOLING SYSTEM

Install the seal washer into the rotor.
Caution
Washer must be replaced together with the
mechanical seal.

Install the rotor onto the water pump shaft and Water pump rotor
tighten.
Torque Value: 1.0~1.4kgf-m
Caution
The rotor is left thread.

Install the dowel pin and right cover gasket.

The rotation water pump rotor, causes the water
pump drive shaft scoop channel, aligns the oil
pump drive shaft flange, install the right crank case.
(bolts × 9)

Install the dowel pin and new gasket.

Install the water pump cover with 4 bolts.

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12. COOLING SYSTEM

Thermostat By-pass pipe Temperature sensor

Please refer to chapter 17 for inspection of
temperature sensor.

Removal
Remove the luggage box and body cover.
Drain out the coolant.
Disconnect the cable of temperature sensor.
Disconnect the by-pass pipe.
Remove the thermostat set. (1 bolt)
Bolt
Installation
Apply a coat of sealant or equivalent to the thread
of temperature sensor and install it on the holder. Temperature sensor
Connect the cable to the temperature sensor.
Refill the coolant and bleed out the air bubble
(Page 12-5).
Install the luggage box and body cover.

Disassembly
Remove the temperature sensor and O-ring from
the thermostat body.

O-ring

Remove 2 bolts and separate the thermostat body 2 bolts

from the cover.

Remove the thermostat.

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12. COOLING SYSTEM

Inspection
Visually inspect thermostat for any damage.

Place the thermostat into heated water to check its

operation.
Caution
Whenever the thermostat and the thermometer
are in contact to the wall of heated water
container, the reading displayed is incorrect. If
the valve of the thermostat remains open at
room temperature or the valve operation is not
corresponding to the temperature change, then
it must be replaced.

Technical Data
Valve begins to open 71 ~ 80℃
Valve stroke 3.5 ~ 4.5 mm at 80℃

Assembly
Install in reverse order of removal.
Caution
Always use a new O-ring and apply a coat of
grease on it before installing.

Refill the specified coolant as necessary.

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12. COOLING SYSTEM

Notes:

12-14
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13. BODY COVER

Mechanism Diagram ····················· 13-1 Rear carrier·····································13-9

Maintenance··································· 13-2 Body cover ·····································13-10
Front cover····································· 13-3 Inner box·········································13-11
Handle front cover························· 13-4 Floor panel ·····································13-12
Handle rear cover ·························· 13-5 Front fender····································13-13
Side cover ······································ 13-6 Rear fender·····································13-15
Front under spoiler ······················· 13-7 Center fender ·································13-15
Luggage box ·································· 13-8

Mechanism Diagram
Seat

Rear carrier

Luggage box
Handle rear cover

Right body
Right side cover cover Rear fender

Inner box 13

Handle front cover Center cover

Left body cover

Center fender

Floor panel

Front cover

Right front fender B Left side cover

Front under spoiler

Under cover

Left front fender B

Front fender

13-1
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13. BODY COVER

Maintenance
Body covers disassemble sequence:

Handle front cover Front cover Seat & Luggage box

Handle rear cover Front under spoiler Rear carrier

Inner box Body cover

Right front fender B

Left front fender B

Rear fender

Front fender
Center cover

Center cover Floor panel

Center fender Under cover

Under cover

y Be careful not to damage various covers in assembly or disassembly operation.

y Never injure hooks molded on the body covers.
y Align the buckles on the guards with slot on the covers.
y Make sure that each hook is properly installed during the assembly.
y Never compact forcefully or hammer the guard and the covers during assembly.

13-2
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13. BODY COVER

Front cover
Remove
Loosen 8 screw frome the front cover.

8 screws

Loosen 2 screw bottom of front handle cover.

2 screws

Remove headlight coupler, and then remove front

cover.

electric cord coupling

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Handle front cover

Disassembly
Loosen 2 screws from handle rear cover rear side.

2 Screws

Loosen 1 screw from front handle cover.

Screw×1

Coupler
Remove front winker light cord coupler.

Remove the handle front cover.

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13. BODY COVER

Handle rear cover Speedometer cable

Remover
Remove front cover.
Remove speedometer cable.
Disconnect each switch connectors.

Each switch connectors

Remove electric line coupler from the radiator.

Coupler

2 Screws
Loosen 2 screws from the handle rear cover.

Loosen 1 screw from backside of the handle rear

cover.
Remove handle rear cover.

2 screws

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13. BODY COVER

Side cover
Remove
Loosen 2 screws from the lift side cover.

2 screws

Loosen 2 screws from the right side cover.

2 screws

Remove the right & left side cover.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Front under spoiler

Remove
Remove front cover.
Loosen 4 screw of the inner box side.

4 screws

Loosen 2 screws from front side of the front under

spoiler.

2 bolts

Remove the front under spoiler.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Luggage box 4 nuts

Remove
Open seat.
Loosen 4 nuts & 2 bolt of the luggage box.

2 bolts

Loosen 1 screw from front side of the body cover.

1 screw

Remove the luggage box.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Rear carrier
Remove
Loosen 4 bolts from the rear carrier.

4 bolts

Remove the rear carrier.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Body cover Rubber

Remove
Remove luggage box and rear carrier.
Remove the fuel tank cap and rubber.

Fuel tank cap

Loosen 2 bolts from the taillight underneath.

2 bolts

Loosen 1 screw from the center cover.

1 screw

Remove electric line coupler from the taillight and

seat look cable.
Remove right and left body covers.

Installation
Install in reverse order of removal procedures.
Taillight coupler

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13. BODY COVER

Inner box Main switch cover

Remove
Remove the front cover.
Loosen 1 bolt from the setting at hook and remove
the hook.
Remove main switch cover.

1 bolt

Loosen 2 screws from the under spoiler.

2 bolts

Remove the inner box.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Floor panel
Remove
Loosen 4 screws from the right & left step bar.
Remove the right & left step bar covers.

4 screws

2 bolts
Loosen 2 screws from the right & left step bar, and
then remove step bars.

Remove the battery and CDI.

Loosen 4 bolts from the floor panel.

4 bolts

CDI

Remove the floor panel.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Front fender
Remove
Remove right & left front fender B. (4 bolts)

4 bolts

Upward pushes, after causes the tenon to fall off

front, again takes out the front fender B.

Caution
y When disassemble age must pay attention,
whether the tenon is separated from.
y Cannot hardly pull out, is easy to create the
tenon to break off.

Remove speedometer cable. (1 screw)

1 screw

From front fender left side remove brake pipe clip.

Brake pipe position

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13. BODY COVER

Use T flex socket wrench, remove front fender in

upside bolt. (3 bolts)

3 bolts

Downward presses the front fender, will cause it to

be separated from the front cushion, and then take
down to front.

Installation
Install in reverse order of removal procedures.

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13. BODY COVER

Rear fender
Remove luggage box and seat.
Remove rear carrier.
Remove body cover.
Remove fuel tank.
Remove rear fender upper side bolts. (2 bolts)

2 bolts

Remove rear fender.

Installation
Install in reverse order of removal procedures.

Center fender
Remove air cleaner.
Remove center fender left side bolt. (1 bolt)

2 bolts

Remove center fender right side bolts, and then

remove center fender. (2 bolts)

Installation
Install in reverse order of removal procedures.

2 bolts

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13. BODY COVER

Note:

13-16
 Home page Contents
14. BRAKE

Mechanism Diagram-Front Disk Brake 14-1 Brake fluid replacement / Air-bleed···· 14-7
Mechanism Diagram-Rear Drum Brake 14-2 Disk Brake-Caliper ······························· 14-8
Maintenance Description ······················ 14-3 Brake Disk ············································ 14-9
Trouble Diagnosis ································· 14-4 Disk Brake - Master Cylinder ·············· 14-9
Disk Brake System Inspection ············· 14-5 Rear Drum Brake·································· 14-12
Adding Brake Fluid································ 14-6

Mechanism Diagram-Front Disk Brake

0.5~0.6kgf-m 3.0~4.0kgf-m
0.8~1.2kgf-m

14

4.0~4.5kgf-m

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14. BRAKE

Mechanism Diagram-Rear Drum Brake

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14. BRAKE

Maintenance Description
Operational precautions
Caution
Inhaling asbestos may cause disorders of respiration system or cancer, therefore, never use air hose or
dry brush to clean brake parts. Use vacuum cleaner or other authorized tool instead.

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

Specifications
Item Standard (mm) Limit (mm)
The thickness of front and rear brake disk 4.000 2.500

Front and rear brake disk eccentricity < 0.100 0.300

Master cylinder inner diameter 11.000 - 11.043 11.055

Master cylinder outer diameter 10.957 - 10.984 10.945

Diameter of front disk 220.000 -

Diameter of rear brake drum 130.000 -

Thickness of front brake lining 5.100 2.000

Thickness of rear brake lining 5.100 2.000

Torque values
Front brake hose bolts 3.0~4.0kgf-m
Bolt for front brake caliper 3.0~3.5kgf-m
Bolts for the front brake disk 4.0~4.5kgf-m
Brake lever nut 0.8~1.2kgf-m
Nut for the rear brake arm 0.5~0.6kgf-m
Air-bleed valve 0.5~0.6kgf-m

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14. BRAKE

Trouble Diagnosis
Disk Brake
Soft brake lever Uneven brake
1. Air inside the hydraulic system 1. Dirty brake lining/disk
2. Hydraulic system leaking 2. Poor wheel alignment
3. Worn master piston 3. Clogged brake hose
4. Worn brake pad 4. Deformed or warped brake disk
5. Poor brake caliper 5. Restricted brake hose and fittings
6. Worn brake lining/disk
7. Low brake fluid
8. Blocked brake hose
9. Warp/bent brake disk Tight brake
10. Bent brake lever 1. Dirty brake lining/disk
2. Poor wheel alignment
3. Deformed or warped brake disk

Hard operation of brake lever

1. Blocked brake system
2. Poor brake caliper
Brake noise
3. Blocked brake pipe 1. Dirty lining
4. Seized/worn master cylinder piston 2. Deformed brake disk
5. Bent brake lever 3. Poor brake caliper installation
4. Imbalance brake disk or wheel

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

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14. BRAKE

Disk Brake System Inspection

Inspection
By visual examination whether divulges or the
damage, with spanner inspection brake tube seam
whether becomes less crowded, and the
inspection handle bar turn right or turn left, or
pressure the cushion, whether besides the
pipeline protection department, whether there is
interferes, contacts other parts of.

Check the brake from behind the brake caliper. Brake caliper
The brake pad must be replaced with new lining
when the brake pad wear limit reaches the brake
disk. Brake lining wear
limit grooves

Brake disk

Park the motorcycle on a level ground, and check

if fluid level is under the “LOWER” mark.
Recommended Brake Fluid: WELL RUN BRAKE
OIL (DOT 3).
Caution
y The vehicles inclined or just stop, the survey oil
level could not be accurate, had to settle the
3~5 minute.
y In order to prevent has the chemical change,
please do not use counterfeiting or other
unclear trade marks brake fluid.
y Uses by all means must with the trade mark
brake fluid, guarantees the ghost vehicle
efficiency.

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14. BRAKE

Adding Brake Fluid

Master cylinder
Before the brake fluid reservoir is removed, turn
the handle so that the brake fluid reservoir
becomes horizontal, and then remove the brake
fluid reservoir.
When maintenance brake system, will be
supposed to paint the surface or the rubber parts
catches up by the rags.
Caution
Supplement brake fluid please do not surpass the
upper limit, spilled brake fluid on painted
surfaces, plastic or rubber components may
result in their damages.
Screw

Master cylinder cap

Remove the master cylinder cap and diaphragm.
Increases the high quality brake fluid, uses by all Diaphragm plate
means must with the trade mark brake fluid joins Upper
level Diaphragm
in the master cylinder.
Clean the dirty brake disk.
Caution
y The dirty brake lining or disk will reduce the
brake performance.
y To mixed non-compatible brake fluid will Lower level
reduce brake performance.
y Foreign materials will block the system
causing brake performance to be reduced or
totally lost.

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14. BRAKE

Brake fluid replacement / Air-bleed Air-bleed valve

Connect drain hose to air-bleed valve.

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

Connect one end of transparent hose to the drain

valve, and put the other end into a container.
Air-bleed valve
Open the drain valve around 1/4 turns, and at the Bubble
same time hold the brake lever until the there is no
air bubble in the drain hose and also feeling
resistance on the brake lever.
Close the drain valve when finishing the brake
system refilling fluid procedure, and operate the
brake lever to check whether air bubble is in
brake system or not.

If brake is still soft, please bleed the system as

described below:
1. Tightly hold the brake lever and open the drain Transparent hose
valve around 1/4 turns, and then close the
valve.

Caution
y Do not release the brake lever before the
drain valve is closed.
y Always check the brake fluid level when
carrying out the air bleeding procedure to
avoid air enter into the system.
2. Slowly release the brake lever, and wait for a
few seconds until it reaches its top position.
3. Repeat the steps 1 and 2 until there is no air
bubble at the end of the hose.
4. Tightly close the drain valve.
5. Make sure the brake fluid is in the UPPER level
of the master cylinder, and refill the fluid if
necessary.
6. Cover the cap.

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14. BRAKE

Disk Brake - Caliper

Removal
Place a container under the brake caliper, and
loosen the brake hose bolt and finally remove the
brake hose.
Caution
Do not spill brake fluid on painted surfaces.

Brake hose bolt

Remove two caliper bolts and the caliper.

Disassembly
Make sure the brake lining condition. Replace
the lining if the brake lining wear limitation groove Caliper bolts
close to the brake disk.
Brake lining replacement
Compress the caliper and let the brake lining out
of the caliper mounting plate. Brake lining
Compress the brake lining locking spring. wear limitation
groove
Remove the inner brake lining firstly and then
remove the outer brake lining.
Compress the brake caliper at first as installation.
Install the inner brake lining firstly, and then install
the outer brake lining.

Installation
Install the brake caliper and tighten the attaching Locking spring
Brake lining
bolts securely.
Torque: 3.3kgf-m
Caliper plate
Brake lining
Caution
y Use M8 x 35 mm flange bolt only.
y Long bolt will impair the operation of brake
disk.

Use two seal washers and hose bolts to lock the

hose and brake caliper in place.
Torque: 3.5kgf-m Brake caliper
Refill up the brake fluid to the reservoir and make
necessary air bleeding. Brake piston
Locking spring

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14. BRAKE

Brake Disk Brake disk

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

Micrometer

Remove the brake disk from wheel.

Check the disk for deformation and bend.
Allowable limit: 0.30 mm
Caution
y The dirty brake lining or disk will reduce the
brake performance.
y Brake lining includes the asbestos ingredient,
cannot use the air-gun to be clean, the
operator should dress the mouthpiece and
the glove, use vacuum cleaner clean it.

Disk Brake - Master Cylinder

Master Cylinder Removal
Caution
Do not let foreign materials enter into the
cylinder.

Caution
The whole set of master cylinder, piston, spring,
diaphragm and cir clip should be replaced as a
set.
2 bolts

Remove the front and rear handlebar guards.

Remove the leads of brake lamp switch.
Drain out the brake fluid.
Remove the brake lever from the brake master Cir clip
Rubber boot
cylinder.
Remove the brake hose.
Piston
Remove the master cylinder bolts and the master
cylinder.
Piston cup
Remove the rubber pad.
Remove the cir clip. Spring
Remove the piston and the spring.
Clean the master cylinder with recommended
brake fluid.
Master cylinder

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14. BRAKE

Master Cylinder Inspection

Check the master cylinder for damage or scratch.
Replace it if necessary.
Measure the cylinder inner diameter at several
points along both X and Y directions.
Replace the cylinder if the measured values
exceed allowable limit.
Allowable limit: 12.550 mm

缸規

Measure the outer diameter of the piston.

Replace the piston if its measured value exceeds 活塞
allowable limit.
Allowable limit: 12.654 mm

分厘卡

Master Cylinder Assembly

Cir clip
Caution Rubber boot

y It is necessary to replace the whole set

Piston
comprising piston, spring, piston cup, and cir
clip.
Piston cup
y Make sure there is no dust on all
components before assembling. Spring

Apply clean brake fluid to the piston cup, and then

install the cup onto the piston.
Install the larger end of the spring onto the master Master cylinder

cylinder.
The master cup’s cavity should be face inside of
master cylinder when installing the master cup.
Install the cir clip.
Caution
y Never install cup lip in the opposite direction.
y Make sure the cir clip is seated securely in
the groove.

Install the rubber pad into groove properly.

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14. BRAKE

Master Cylinder Install

Install the rubber pad into the groove correctly.
Place the master cylinder onto handlebar, and
install the bolts.
Install the brake lever, and connect leads to brake
light switch.

2 bolts

Connect brake hoses with 2 new washers. Washer

Tighten the brake hose bolt to the specified torque
value.
Make sure the hose is installed correctly.
Install all wires, hoses, and components carefully
so avoid to twisting them together.
Caution
Improper routing may damage leads, hoses or Brake light
pipes. switch

Brake hose

Caution
Kink of brake leads, hose or pipe may reduce
brake performance.

Add specified brake fluid and bleed the system.

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14. BRAKE

Rear Drum Brake

Remove brake drum
Remove wheel and brake drum.
To use vacuum cleaner or other alternatives to
avoid danger caused from dusts.
Caution
y Inhaling brake lining ashes may cause
disorders of respiration system, therefore,
never use compressed air or dry brush to
clean brake parts.
Brake drum
y Brake performance will be reduced by grease
on brake lining.

Inspection brake drum

Check brake drum for damage or wear out, and
replace it if necessary.
Measure the inner diameter of brake drum and
record the max. value.
Allowable limit: 131.0mm
Caution
y Clean the rust onto the brake drum with
#120 sand-paper.
y Measure the inner diameter of brake drum
with micrometer.
Brake lining

Brake lining inspection

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

Remove brake lining Brake cam

To both hands pulls open brake lining, remove
brake lining from brake.
Caution Spring

Brake linings must be replaced as a shoes.

Lock pin
Brake lining

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14. BRAKE

Install brake lining

Apply with a thin coat of grease to the brake cam Brake cam
and the anchor pin.
Install brake cam.
Never allow brake linings to be contaminated by
oil or grease.
Wipe off the excessive grease from brake cam Lock pin
and the anchor pin.
Caution
Brake efficiency will be reduced if brake linings Spring
is contaminated by oil or grease. Brake lining

Rear brake panel

Apply a thin cost of grease between the oil seals
Brake cam
on the brake cam shaft.
O-ring
Install the brake cam and arm after aligning it with
the punched point.

Brake arm

Tighten the bolts and nuts to specified torque:

Torque value: 0.5~0.6kgf-m Brake arm
Hook on the return spring.
Brake cam

Bolt

Return spring

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14. BRAKE

Notes:

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Mechanism Diagram ··························15-1 Front Wheel ········································ 15-5

Operational Precautions ····················15-2 Front Cushion ···································· 15-8
Trouble Diagnosis ······························15-2 Steering Stem····································· 15-9
Steering Handle ··································15-3

Mechanism Diagram

4.0~5.0kgf-m

1.0~2.0kgf-m

0.2~0.3kgf-m

2.4~3.0kgf-m

15
4.0~4.5kgf-m

5.0~7.0kgf-m

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Operational Precautions
General
Please refer to the Maintenance Manual of tubeless tire in respect to the removal, repair and installation of
the tire.

Torque Values
Nut for the front wheel axle 5.0 ~ 7.0kgf-m
Nut for the steering handle 4.0 ~ 5.0kgf-m
Lock nut for the steering handle stem 1.0 ~ 2.0kgf-m
Top crown for the steering handle stem 0.2 ~ 0.3kgf-m
Locating screw for the speedometer cable 0.15 ~0.3kgf-m
Front cushion upper lock bolt 2.4 ~ 3.0kgf-m

Special Tools
Steering handle top thread wrench SYM-5320000
Inner bearing puller SYM-6204020
Steering nut wrench SYM-6204010
Driver 32*35mm
Driver 42*47mm

Trouble Diagnosis
Hard to steer The front wheel rim run-out
y The steering handle stem nut is too tight. y The rim is bent.
y The ball and the top crown of the steering y The wheel axle nut is not tightened enough.
handle stem are damaged. y Side-worn or poor tire.
y Insufficient tire pressure. y The bearing clearance of the wheel axle is too
large.

The steering handlebar is tilted

y Uneven arrangement of the front cushion. Soft front cushion
y The front fork is bent. y The front cushion spring is worn out.
y The front wheel axle is bent. y The oil seal of the front cushion is leaking.

Noise in front cushion

y Front cushion is warped.
y The joint of the front cushion gets loose.

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Steering Handle Holder

Removal
Remove the handle front cover, handle rear cover
and front cover. (Refer to chapter 13)
Loosen the lock bolts for the master cylinder of the
front brake.
Caution
Do not let foreign materials enter into the cylinder.

Master cylinder 2 bolts

Remove throttle holder, cap, cable and grip after

mounting screw removed.

Screw

Remove rear brake lever mounting nut and bolt, Bracket holder bolt
and then remove brake lever and cable.
Remove rear brake lever bracket after mounting
bolt removed.

Brake lever nut

Brake lever screw

Brake cable

Loosen handle mounting nut.

Remove handle mounting bolt, and then remove
the handle. Bolt

Nut

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Installation
Install handle and align with bolt hole.
Install bolt and nut and then tighten it. Bolt
Torque value: 4.5kgf-m

Nut

Apply with grease onto throttle cable and the

sliding surface of handle.
Align the lock pin of the throttle bracket with the
hole on the handle, and then install the throttle
bracket.
Caution
When installs the throttle cable, first spreads the Screw
grease in the terminal to receive the throttle grip
again.
y After installs the handle, inspects the throttle
grip, whether may change to in the direction the
handle time the free position, the freedom does
moves.

Install the lock bolts for the master cylinder of the Holder
front brake.

Master cylinder 2 bolts

Align the lock pin with the hole on the handle and Brake holder bolt
also install brake lever bracket. Then, tighten the
brake lever bracket bolt.
Install brake cable, lever on to bracket, and then
tighten lever screw and nut.

After the installment completes, carries on the

following inspection and the adjustment: Brake lever nut
y Throttle grip operation. Brake lever screw
y All electric appliances, the meter function.

Brake cable

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Front Wheel
Remove
First by the bracket strut frame base, causes the
front wheel to float off.
Remove the speedometer cable.
Turn loose the axle nut.

Speedometer cable Shaft nut

Pull out the front wheel axle.

Remove the front wheel.
Caution
Care shall be taken not to push the brake lever
to avoid the brake pad being squeezed out. In
case that the brake pad is accidentally squeezed
out, use a screwdriver to force it back to the
place.

Wheel axle

Inspection
Wheel axle
Place the wheel axle on a V block, measure its run
out.
Service limit: 0.2 mm

Wheel axle

Bearing
Use finger to move the inner ring of each bearing,
it shall move smoothly and quietly. Check the Free play
outer ring is securely attached on the wheel hub. Free play
If the motion of the inner ring of the bearing is not
smooth, or noisy and loose when being moved,
remove and discard it.
Caution
The bearing shall be replaced in pair.

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

Disassembly
Remove 5 bolts and brake disk.
Remove dust seal, bearing and dist collar from left
side.
Remove dust seal, bearing and retainer hear box
from right side.
Special tools:
Inner bearing puller (SYM-6204020)

Assembly
Fill out the block of bearing by grease.
Drive the left bearing, dust seal and install the dist. Speedometer gear box
collar. Dist collar

Install the right side bearing.

Caution
y Carefully install the bearing in correct and
evenly. Dust seal
y Bearing outer face should be faced up as
bearing installation.
Retainer hear box
Install the brake disk and then tighten the bolts
Torque value: 4.5kgf-m
Bearing Dust seal

Install right side dust seal.

Lubricate the retainer with grease and install into
the wheel hub.
Align the flange part on the speedometer gear with
the slot of wheel hub.
Caution
Contaminated brake lining will reduce brake
performance so the brake lining, brake drum
and disc must be free of grease.

Apply with grease onto the left side dust seal.

Install the dust seal and side collar.

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Installation
Open out brake lining with brake caliper.
Place the front wheel between the front cushion.

Wheel axle

Caution
Gear box groove
Align the gear box groove with the stopper
flange.
Insert the wheel axle into the wheel and the install
the wheel axle nut.

Front fork stopper

Tighten the nut.

Torque value: 5.0~7.0kgf-m

Connect the speedometer cable to the

speedometer gear box.

Speedometer cable Shaft nut

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Front Cushion
Remove
Remove front cover, front under spoiler and front
fender.
Remove front brake caliper.
Remove front wheel.

Remove front cushion upper mounting bolts, and

then remove front cushion.

4 bolts

Installation
Align the cover flange with upper level of the
cushion clamp, and then tighten bolts.
Torque value: 2.7kgf-m

Install the removed components in reverse order

of removal procedures.

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15. STEERING / FRONT WHEEL / FRONT CUSHION

Steering Stem
Remove Steering lock nut
Remove handle, front wheel and front cushion.
Remove the steering stem mounting nut.
Remove top cone race and front fork.
Caution
Place the steel ball onto a parts container to
prevent from missing.

Top cone-race

Slightly tap the top and bottom ball bearing seats

with a plastic hammer to remove the seats.
Remove bottom cone race body with a punch.
Caution
Do not damage the steering stem.

Installation Steering stem mounting nut

Install a new bottom cone race onto the steering
Top cone race
stem.
Push the cone race until to mounted position. Top ball
bearing seat
Caution
Do not tilt the ball bearing seats as installation. Bottom ball
bearing seat

Apply with grease onto the ball bearing seats, and

install steel balls onto the seats. Steel balls
(Top: 26 balls, bottom: 29 balls)
Bottom cone race

Lubricate the top cone race seat with grease. Steering lock nut
Screw the cone race in to top ball bearing seat till
touching, and then screw out the cane race
1/4~3/8 turns. Return 1/2 turns
Torque value: 0.25kgf-m
Caution
Check the steering stem that should be rotated
freely and no clearance in vertical direction. Locking to
1/4~3/8 turns

Top cone-race

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15. STEERING / FRONT WHEEL / FRONT CUSHION
Install the steering stem mounting nut and tighten
the nut by means of holding the top cone race
body.
Torque value: 1.0~2.0kgf-m
Steering lock nut

Install in reverse order of removal procedures.

Top cone-race

Shake steering handle up & down, left & right, and

front & rear to check if it is loosen, has too much
resistance and pulls to one side.
Check steering handle if it is being pulled too tight
by the brake cables.

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Mechanism Diagram ··························· 16-1 Muffler ················································· 16-3

Operational Precaution ······················· 16-2 Rear Wheel ········································· 16-3
Trouble Diagnosis ······························· 16-2 Rear Cushion······································ 16-5

Mechanism Diagram

3.5~4.5kgf-m

2.4~3.0kgf-m

1.0~1.2kgf-m

4.0~5.0kgf-m

10.0~12.0kgf-m 16

3.2~3.8kgf-m

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Operational Precaution
General
Please refer to the Maintenance Manual for tubeless tire in respect to the removal, repair and installation
of the tires.

Service data Unit: mm

Item Standard Allowable Limit
Radial - 2.0
Run-out of rear rim
Axial - 2.0
Thickness of rear brake lining 5.1 2.0
Sustaining stroke of rear cushion 72 -

Torque Value
Rear wheel shaft nut 10.0~12.0kgf-m
Rear cushion upper bolt 3.5~4.5kgf-m
Rear cushion under bolt 2.4~3.0kgf-m
Rear fork mounting bolt 4.0~5.0kgf-m
Exhaust muffler mounting nut 1.0~1.2kgf-m
Exhaust muffler mounting bolt 3.2~3.8kgf-m

Trouble Diagnosis
Run-out of rear wheel Poor Performance of Brake
y Deformed or bent wheel hub. y Improperly adjusted brake.
y Improper tires. y Contaminated brake disc.
y Loose wheel shaft. y Worn brake lining.
y Air inside brake fluid pipe.
y Grease on brake disc.
Soft Cushion y The brake fluid piping is clogged.
y The spring is too weak. y The brake fluid pipe is deformed or bent.
y Insufficient amount of brake fluid in the
reservoir.
Noisy Brake
y Worn brake lining.
y Offset brake disc.
y Improper assembly of brake caliper.
y Brake disc or wheel imbalance.

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Muffler
Removal
Loosen the 2 nuts from exhaust muffler front side.

2 nuts

Loosen the 3 mounting bolts by exhaust muffler

right side.
Remove the exhaust muffler.

Installation
Install in reverse order of removal procedures.
Caution
Replace the front side muffler pipe gasket if worn
or deformed.
Torque Value
For mounting bolt: 3.2 ~ 3.8kgf-m
For mounting nut: 1.0 ~ 1.2kgf-m 3 bolts

Rear Wheel Cushion under bolt

Removal
Remove the exhaust muffler.
Remove the lower bolt of the right side rear
cushion.
Remove 2 bolts of the rear fork.
Remove 1 nut of the rear wheel shaft, and then Fork bolts
remove outside collar.

Wheel shaft nut

Remove the rear fork, fork inside collar, and then

remove the rear wheel.

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Inspection
Rear wheel rim
Place the wheel rim on a rotational support.
Rotate it by hand and measure the run-out with a
dial indicator.
Run-out limit: 2.0 mm

Rear fork bearing

Rotate the inner ring of the bearing with a finger. Free play

The bearing should move smoothly and quietly. Free play

Check the fit of the bearing and rim.
Replace the bearing if its motion is not smooth or
noisy.

Replacement of rear fork bearing

Dust seal
Remove the outside dust seal of the rear fork.
Use inner cir clip plier to remove the bearing lock
clip.
Pull off the rear fork bearing by means of the inner
bearing puller.
Inside collar
Remove the inside dust seal.
Caution Clip

Never reuse the old dust seal on the bearing. Bearing

Outside collar

Dust seal

Press in the bearing into the rear fork by bearing Clip

driver.
Install the oil bearing lock clip.
Install new dust seals into rear fork two side.

Outside collar

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Installation
Install the rear wheel.
Install the inside collar on the rear fork.
Install the rear fork onto the rear wheel shaft.
Mount the outside collar on the rear fork.
Tighten the rear wheel shaft nut.

Install the rear fork mounting bolts and tighten the

bolts.
Align the rear cushion with the rear fork hole;
tighten the cushion with bolts.
Install the exhaust muffler, first tighten front side
mounting nuts, and then tighten the mounting
bolts.
Torque Value Cushion under bolt
Rear wheel shaft nut: 10.0~12.0kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Rear fork mounting bolt: 4.0~5.0kgf-m
Exhaust muffler mounting nut: 1.0~1.2kgf-m
Exhaust muffler mounting bolt: 3.2~3.8kgf-m
Caution Fork bolts

Attention must be paid to their direction when

rear fork collars are installed. The small ends of
inner and outer collars must face to rear fork
bearing.
Wheel shaft nut

Rear Cushion
Removal
Remove the luggage box, rear carrier and body
covers.
Loosen the mounting bolts of the air cleaner (2
bolts).
Remove the exhaust muffler (3 bolts, 2 nuts).
Remove the under bolts by left / right rear
cushions.
Remove the upper bolts by left / right rear
cushions, and then remove the cushion.

Installation Upper bolt

Install in reverse order of removal procedures.
Caution
The rear cushion must be replaced as a unit.
Never disassemble the rear cushion as that
would damage the structure.

Torque Value
Rear cushion upper bolt: 3.5~4.5kgf-m
Rear cushion under bolt: 2.4~3.0kgf-m
Under bolt

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16. REAR WHEEL / REAR FORK / REAR CUSHION

Notes:

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17. ELECTRICAL SYSTEM

Mechanism Diagram ··························17-1 Meters················································17-11

Maintenance Data·······························17-2 Light / Bulb········································17-12
Technical Specification······················17-2 Switch / Horn·····································17-14
Trouble Diagnosis ······························17-3 Fuel Unit ············································17-17
Battery ·················································17-4 Cooling Fan Thermo Switch ············17-18
Charging System ································17-5 Thermo Unit ······································17-19
Ignition System···································17-8 Water Temperature Meter ················17-19
Starting System ··································17-10

Mechanism Diagram

Horn
Winker relay

Main switch
Dimmer & winker & horn switch

Start switch & light switch

C.D.I. unit
Battery

Spark plug AC. Generator

Starter relay

Ignition coil Fuse box

Regulator rectifier

Headlight relay

Fuel unit 17

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17. ELECTRICAL SYSTEM

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

Technical Specification
Charging system
Description Specification

Capacity 12V8Ah
Battery
0.9A / 5 hours (standard)
Charging rate
4A / 1 hour (fast charging)
Leak current < 1 mA

Charging current 1.2 A / 2000 rpm

Control voltage in charging 14.5 + 0.5 V / 2000 rpm

Ignition system
Description Specification

Model NGK CR8E (Recommended)

Spark plug
Gap 0.6 - 0.7 mm

Primary winding 0.17 ± 10% Ω

Ignition coil and
Without cap: 3.1 ± 10 KΩ
resistance Secondary winding
With cap:8.1 ± 10 KΩ

13° TDC / 1000 rpm

Ignition timing “F” mark
27°TDC / 6000 rpm

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17. ELECTRICAL SYSTEM

Trouble Diagnosis
No voltage Charging system does not operate
y Battery discharged properly
y The cable disconnected y Burnt fuse
y The fuse is blown y Poor contact, open or short circuit
y Improper operation of the main switch y Poor regulator
y Poor ACG

Low voltage
y The battery is not fully charged Engine does not crank smoothly
y Poor contact y Primary winding circuit
y Poor charging system - Poor ignition coil
y Poor voltage regulator - Poor connection of cable and connectors
- Poor main switch
y Secondary winding circuit
No spark produced by spark plug - Poor ignition coil
y The spark plug is out of work - Poor spark plug
y The cable is poorly connected, open or - Poor ignition coil cable
short-circuited - Current leakage in the spark plug
- Between AC.G. and C.D.I. y Incorrect ignition timing
y Poor connection between C.D.I. and ignition - Poor AC.G.
coil - Improper installation of the pulse sensor
- Poor connection between C.D.I. and the - Poor C.D.I.
main switch
y Poor main switch
y Poor C.D.I. Weak starter motor
y AC.G. is out of work y Poor charging system
y The battery is not fully charged
y Poor connection in the windings
Starter motor does not work y The motor gear is jammed by foreign material
y The fuse is blown
y The battery is not fully charge
y Poor main switch Starter motor is working, but engine does
y Poor starter switch
not crank
y The front and rear brake switches do not
y Poor starter motor pinion
operate correctly
y The starter motor run in reverse direction
y Starter relay is out of work
y Poor battery
y The ignition coil is poorly connected, open or
short-circuited
y The starter motor is out of work

Intermittent power supply

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

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17. ELECTRICAL SYSTEM

Battery
Removal
Loosen 5 screws and remove the battery cover.
Disconnect the negative cable terminal first, then
the positive cable terminal.
Remove the battery from the motorcycle.

5 screws

Voltage Check
Use the digital voltmeter to check the voltage of
the battery.
Voltage:
Fully charged: 13.0~13.2 V at 20℃
Undercharged: Below 12.3 V at 20℃

Charging
Connect the positive terminal (+) of the charger to
the battery positive terminal (+).
Connect the negative terminal (-) of the charger to
the battery negative terminal (-).
Standard Maximum

Charging current 0.9A 4.0A

Charging time 5H 1H

Warning
y Keep flames away while recharging.
y Charging is completely controlled by the
ON/OFF switch on the charger, not by
battery cables.

Caution
y Never rapid charge the battery unless in
emergency.
y Verify the battery is recharged with current
and duration prescribed above.
y Large current and fast time to charge will
render damage to the battery.

When installing the battery, coat the cable terminal with grease.

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17. ELECTRICAL SYSTEM

Charging System
Charging circuit

Main switch
Green Red
Black
Yellow Yellow
Fuse 20A Yellow

Battery Yellow

Regulator rectifier

Auto by-starter
AC. Generator

Current Leakage Inspection

Turn the main switch to OFF position, and remove
the negative cable terminal (-) from the battery.
Connect an ammeter between the negative cable
terminal and the battery negative terminal. Battery negative terminal

Caution
y In the current leakage test, set the current
range at the largest scale, then gradually
decrease to the lower scale as the test
process goes to avoid possible damage to
the ammeter and the fuse.
y Do not turn the main switch to ON position
during test.
If the leaked current exceeds the specified value, it
may indicate a short circuit.
Allowable current leakage: Less than 1mA
Disconnect each cable one by one and take
measurement of the current of each cable to
locate the short circuit.

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17. ELECTRICAL SYSTEM

Inspection on Charging Voltage Connect a tachometer.

Turn on the headlight to high beam and start the
Voltmeter engine.
Accelerate the engine to the specified revolution
Ammeter per minute and measure the charging voltage.
Specified Charging Current:
1.2 A / 6000 rpm
Control Charging Voltage:
14.5 + 0.5 V / 2000 rpm

Caution
To replace the old battery, use a new battery with
the same current and voltage.
Fuse connector

The following problems are related to the charging

Caution system, follow the instructions provided in the
checking list to correct it if any one of the problems
y Before conducting the inspection, be sure that
takes place.
the battery is fully charged. If undercharged,
(1) The charging voltage can not exceed the
the current changes dramatically.
voltage between two battery terminals and
y Use a fully charged battery having a voltage
the charging current is in the discharging
larger than 13.0 V
direction.
y While starting the engine, the starter motor
(2) The charging voltage and current are too
draws large amount of current from the
much higher than the standard values.
battery.
The following problems are not related to the
After the engine is warmed up, replace original charging system; correct it if any by following
battery with a fully charged battery. steps indicate in the checking list.
Connect a digital voltmeter to the battery (1) The standard charging voltage and current
terminals. can only reach when the revolution of the
Connect an ammeter between both ends of the engine exceeds the specified rpm.
main fuse. - Bulbs used exceed their rate and
consume too much power.
Caution - The replacement battery is aged and
When the probe is reversibly connected, use a does not have enough capacity.
voltmeter having an indication that the current (2) The charging voltage is normal, but the
flows from the positive or the negative direction current is not.
and the measurement should be at zero, - The replacement battery is aged and
ammeter at one direction only. does not have enough capacity.
- Battery used do not have enough
Caution electricity or is over charged.
- The fuse of the ammeter is blown.
y Do not use short-circuit cable.
- The ammeter is improperly connected.
y It is possible to measure the current by
(3) The charging current is normal, but the
connecting an ammeter between the battery
voltage is not.
positive terminal and the cable position
- The fuse of the voltmeter is blown.
terminal, however, while the starter motor is
activated, the surge current the motor draws
from the battery may damage the ammeter.
Use the kick starter to start the engine.
y The main switch shall be turned to OFF
position during the process of inspection.
Never tamper with the ammeter and the cable
while there is current flowing through. It may
damage the ammeter.

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17. ELECTRICAL SYSTEM

Inspection on regulator rectifier

Remove the luggage box, rear carrier and body
covers.
Disconnect two 3 pin couplers of the regulator
rectifier.
Inspection the rectifier coupler to the wire harness
passes the condition.
Item Check Points Standard Value
Main switch Battery voltage
R–B
connection (ON)
Battery
R–G Battery voltage
connection
Charging coil Y–Y 0.17 ~ 0.8Ω

If the readings measured are not normal, check

parts in the circuit.
If the parts are normal, then trouble is in the wiring.
If there is nothing wrong with parts and wiring,
replace the regulator rectifier.

Regulator rectifier

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17. ELECTRICAL SYSTEM

Ignition System
Ignition circuit diagram

CDI. Unit

Green/white
Green

Black/yellow
Black/white

Black/red

Ignition
coil

Blue/Yellow
Main switch
Spark plug

Green

Pulse generator

Exciting coil

C.D.I unit
Disconnect connectors of the C.D.I unit.
Check the following connectors as indicated in the table at the harness side.
Item Points to check Result

Main switch Black/white ~ green -

Exciting coil Black/red ~ green 100~200Ω

Pulse generator Green/White ~ Blue/yellow 50~170Ω

Primary circuit Black/yellow ~ green 0.17±10%Ω

Ignition coil Black/yellow ~ with no cap 3.6±10%Ω

Secondary circuit
Black/yellow ~ with cap 7.3~11KΩ

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17. ELECTRICAL SYSTEM

Inspection on Ignition Coil

Remove the luggage box.
Disengage the connector of the ignition coil and
the spark plug cap.
Measure the resistance between the terminals of
the primary winding.
Standard resistance: 0.17Ω ± 10%
Remove the cap from the spark plug and measure
the resistance between the spark plug and the
primary winding.
Standard resistance:
With no cap: 3.6Ω ± 10%
With cap: 7.3~11 KΩ

Ignition coil
Replacement
Loosen the lock bolt and replace the ignition coil if
necessary.

Spark plug

Inspection on Exciting Coil Exciting coil coupler

Caution
The test can be carried out without removing the
exciting coil from the engine.

Remove the luggage box, rear carrier and body

covers.
Disconnect coupler of the exciting coil.
Measure the resistance between the black/red
terminal and the earth.
Standard resistance: 100~200Ω
Please refer to the Section 10 for disassembly of
coil.

Inspection of Pulse Generator

Disconnect the coupler of the pulse generator and
measure the resistance between the terminals of
green/white and blue/yellow.
Standard resistance: 50~170Ω

Pulse generator coupler

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17. ELECTRICAL SYSTEM

Starting System
Starting circuit diagram

Main switch
Main fuse 20A Battery

Red

Fuse 10A

Starter relay
Brake switch Starter motor

Yellow/red Green/yellow

Starter switch

Inspection on starter relay

Open the main switch.
Press the brake.
Push down the starter switch.
If a sound of “Looh Looh” is heard, it indicates the
relay function normally.

Remove the luggage box.

Disconnect the negative cable terminal of the
battery.
Disconnect the cable positive terminal from the
relay.
Disconnect the positive cable of the starter motor.
Disconnect the coupler of the relay.
Connect an ohmmeter to the large terminal end.
Connect the yellow/red cable to the battery
positive terminal and the green/yellow cable to the
battery negative terminal.
Check the continuity of the large terminal end.
If there is no continuity, replace the relay.

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17. ELECTRICAL SYSTEM

Removal of Starter motor

Remove the battery cover (5 screws).
Disconnect the cable negative terminal (-), then
the cable positive terminal (+).
Remove the luggage box.
Remove the air cleaner.

Loosen the lock bolts and remove the starter 2 Bolts

motor.

Installation of Starter motor

Install in reverse order of removal procedures.

Meters
Removal
Remove handle front cover.
Remove the front cover, and then remove meter
coupler and handle switch coupler.
Remove speedometer cable.

Meter cable

Remove handle rear cover and speedometer.

Loosen 3 screws, and then remove speedometer
from handle rear cover.

Installation of Starter motor

Install in reverse order of removal procedures.

3 screws

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17. ELECTRICAL SYSTEM

Light / Bulb
Replacing bulb for headlight
Remove the front cover.

Headlight adjustment screw

Disconnect the terminal coupler and the rubber Headlight Position light
sleeve from the headlight.

Headlight Position light

Remove the bulb spring holder and the bulb.
Replace with new bulb if necessary.

Caution
y Never touch the bulb with finger, which will
create a heat point.
y Clean the fingerprint left on the bulb with
alcohol.

Holder Bulb

Install the bulb of the headlight in reverse order of Headlight Position light
removal.
Upon completion of replacement, turn on the main
switch to ensure the headlight works well.
Adjust the beam and distance of the headlight if
necessary.

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17. ELECTRICAL SYSTEM

Replacing the Front winker light Bulb

Loosen fixing screws and remove the handle front
cover (screw x 3).

Replace with new front winker light bulb.

Replacing Bulb of taillight

Remove the taillight lens (2 screws).

2 Screws

Replace taillight or winker light bulb.

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17. ELECTRICAL SYSTEM

Switch / Horn
Main Switch
Inspection
Remove the front cover.
Disconnect the main switch coupler.
Check the continuity between two points as
indicted below:
Pin
BAT1 BAT2 I E
Position
LOCK
Main switch
OFF

ON
Black /
Wire Color Red Black Green
White
Replacement of main switch
Disconnect the coupler of the main switch and
loosen the lock bolts (bolt x 2).
Remove the main switch.
Install the new main switch and tighten the lock
bolts (bolt x 2).
Install the main switch coupler.

2 bolts
Handle switch
Remove the handle front cover and rear cover.
Disconnect the coupler of handle. Headlight switch
Check the continuity between two points as
indicated in the table below.

Start Switch / Headlight Switch

Pin
ST BAT2
Position
FREE

Yellow
Wire Color Green Start switch
/ Red

Headlight Switch
Pin
BAT3 TL HL
Position Headlight switch

White Blue
Wire color Brown
/ Green / White
Start switch

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17. ELECTRICAL SYSTEM

Dimmer and Passing switch Dimmer and passing switch

Pin
HL LO HI PASS
Position

PASSING
Winker switch Horn switch

Wire color Brown White Blue

White /
Dimmer and passing switch
/ White Green

Winker switch
Pin
R WR L
Position

FROM R
Winker switch
N PUSH OFF
Horn switch

FROM L

Light
Wire color Gray Orange
green

Horn switch
Pin
BAT3 HO
Position

FREE

Wire Color White/ Green Light green

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17. ELECTRICAL SYSTEM

Brake Switch
While grasp the brake lever firmly, the terminals of
white/green and green/yellow of the brake should
have continuity.
Replace the switch if damaged.

Brake switch

Horn
Remove the front cover.

喇叭

Apply 12 V power source to two terminals of the

horn, the horn should sound.
Replace the horn if necessary.

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17. ELECTRICAL SYSTEM

Fuel Unit Fuel unit

Open the seat.

Remove the luggage box.
Remove the rear carrier.
Remove the body cover.
Disconnect the coupler of the fuel unit.

Fuel unit coupler

Remove the fuel unit (screw x 4).

Caution
y Great care shall be taken not to damage or
bend the float arm of the gauge.

When the float arm shifts to the F position or the E

position, the resistance measured shall be as
follows:
Position Resistance Full

E (Empty) 97.5~107.5 Ω

F (Full) 4~10 Ω
Connect the wiring to the fuel unit and the
ohmmeter as shown.
Empty
Connect the fuel unit coupler to the wire harness.
Turn on the main switch.
Move the float arm to verify the proper position the
fuel gauge needle indicates.

Arm Position Needle Position

Up (Full) F (Full)
Down (Empty) E (Empty)

Caution
While conducting the test, turn on the direction
indication lamp to make sure that the battery is in
serviceable condition.

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17. ELECTRICAL SYSTEM

Cooling Fan Thermo Switch

The thermo switch mounted on the radiator
controls the operation of the cooling fan motor.
In case that the fan motor fails to work, disconnect
the green and black/blue leads and connect jump
wires to the terminals, then, turn on the main
switch, the fan motor should operate.
If the fan motor still fails to run, measure battery
voltage between the green and black/blue leads.
If there is no voltage, check for blown fuse, loose
connection or short-circuit.
If the fan motor runs, check the thermo switch in Thermo switch
the manner as described below:
Hang the thermo switch on the bowl filled with
coolant to check the switch’s opening and closing
temperatures, confirm the switch is open circuited
at room temperature, increase the coolant
temperature gradually. The switch should have a
continuity at 98-102℃.
Caution
y Keep the coolant at a constant temperature at
least for three minutes. Sudden increase the
coolant temperature will cause the
thermometer and the tester to indicate wrong Thermometer
readings.
y Never let the thermometer and the thermo
switch contact the wall of the bowl, which may
result in wrong readings.
y The thermo switch shall be placed in the
coolant until the teeth are completely
submerged.

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17. ELECTRICAL SYSTEM

Thermo unit
Remove the thermo unit.
Hang the thermo unit in an oil heater, heat the oil
and measure the resistance at each temperature.
Temperature 50°C 80°C 100°C 120°C

Standard (Ω) 134~149 47.5~57.0 26~29 14.8~17.2

Thermo unit
Caution
y Wear gloves and goggles when performing
this test.

Caution
y Engine oil should be used as a heating
medium as the test temperature must be
higher than 100℃.
y Contacting the container wall by the
thermometer and the thermo unit may result in
wrong readings.

Thermo unit

Water Temperature Meter

Disconnect the water temperature meter and
connect it to engine ground.
Turn on the main switch.
The needle of the meter should move to other end,
H position.
Caution
y Do not ground the water temperature more
than 5 seconds, or the meter will be damaged.

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17. ELECTRICAL SYSTEM

Notes:

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18. ELECTRICAL DIAGRAM

HD125 / 200 ELECTRICAL DIAGRAM

18

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18. ELECTRICAL DIAGRAM

Notes:

18-2