GT125 250 Manual

HYOSUNG MOTORS & MACHINERY INC.
SERVICE MANUAL
SERVICE MANUAL
99000-94710
GROUP INDEX
FOREWORD
This manual contains an introductory description on
HYOSUNG
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL SYSTEM
and proce-
CHASSIS
latest specification at the time of publication.

If modification has been made since then,
difference may exist between the content of this
manual and the actual vehicle.
Illustrations in this manual are used to show the
ELECTRICAL SYSTEM
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This manual has been prepared on the basis of the
dures for its inspection/service and overhaul of its main

components.
Other information considered as generally known is not
included.
Read GENERAL INFORMATION section to familiarize
yourself with outline of the vehicle and MAINTENANCE
and other sections to use as a guide for proper inspection and service.
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service.
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basic principles of operation and work procedures.

They may not represent the actual vehicle exactly
in detail.
SERVICING INFORMATION
WARNING
This manual is intended for those who have

enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2002.
HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE
LOOKING FOR:
1. The text of this manual is divided into sections.

2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you are looking for.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. On the first page of each section, its contents are listed. Find
the item and page you need.
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COMPONENT PARTS
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Example: Front wheel
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing and
meaning associated with them respectively.
DEFINITION
SYMBOL
DEFINITION
Apply THREAD LOCK1324.
Apply oil. Use engine oil unless otherwise

specified.
Apply or use brake fluid.
Apply SUPER GREASEA.
Measure in voltage range.
Apply SUPER GREASEC.
Measure in resistance range.
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Apply MOLY PASTE.
Measure in current range.
Apply SILICONE GREASE.
Torque control required.

Data beside it indicates specified torque.
Apply BOND1215.
SYMBOL
Use special tool.
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NOTE
Difference between photographs and actual motorcycles depends on the markets.
GENERAL INFORMATION
1
CONTENTS
1-1
GENERAL PRECAUTIONS
1-1
SERIAL NUMBER LOCATION
1-3
FUEL AND OIL RECOMMENDATIONS
1-4
BREAK-IN PROCEDURES
1-5
CYLINDER CLASSIFICATION
1-5
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SPECIFICATIONS
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EXTERIOR ILLUSTRATION
INFORMATION LABELS
1-6
1-8
1-1 GENERAL INFORMATION
WARNING / CAUTION / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages
highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
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NOTE
Indicates a potential hazard that could result in vehicle damage.
Indicates special information to make maintenance easier or instructions cleaner.
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Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
WARNING
Proper service and repair procedures are important for the safety of the service machanic and the safety and reliability of the vehicle.
When 2 or more persons work together, pay attention to the safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
When working with toxic or flammable materials, make sure that the area you work in is well-ventilated and that you follow all off the material manufacturers instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a
while after engine operation.
After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system
for leaks.
GENERAL INFORMATION 1-2
WARNING
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If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they may
be reinstalled in the proper order and orientation.
Be sure to use special tools when instructed.
Make sure that all parts used in reassembly are clean, and also lubricated when specified.
When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
When removing the battery, disconnect the negative cable first and then positive cable. When
reconnecting the battery, connect the positive cable first and then negative cable, and replace the terminal
cover on the positive terminal.
When performing service to electrical parts, if the service procedures do not require use of
battery power, diconnect the negative cable at the battery.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips,
and certain other parts as specified, be sure to replace them with new ones. Also, before installing
these new parts, be sure to remove any left over material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
Do not use self-locking nuts a few times over.
Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or
oil if a thread is smeared with them.
After reassembly, check parts for tightness and operation.
WARNING
To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
To protect Earths natural resouces, properly dispose of used vehicles and parts.
SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the steering head tube. The engine serial number is located on the left upside of crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.
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FRAME SERIAL NUMBER
ENGINE SERIAL NUMBER
FUEL AND OIL RECOMMENDATION

FUEL
Gasoline used should be graded 85~95 octane (Research Method) or higher. An unleaded gasoline type is
recommended.
ENGINE OIL
ENGINE OIL SPECIFICATION
Classification system
Grade
API
Over SG
SAE
10W/30 or 10W/40
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Use a premium quality 4-stroke motor oil to ensure

longer service life of your motorcycle.
If an SAE 10W/30 or 10W/40 motor oil is not available,

select an alternative according to the following chart.
WARNING
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Don
t mix the unrecommended oil. It could damage the engine.
When refilling the oil tank, don
t allow the dust to get inside.
Mop the oil spilt.
Don
t put the patch on the cap. It could disturb the oil to be provided and damage the engine.
BRAKE FLUID
Specification and classification: DOT3 or DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
FRONT FORK OIL

Use fork oil : TELLUS #22
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts toBREAK-INbefore subjecting the engine to maximum
stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its
early life. The general rules are as follows:
Keep to these break-in procedures:
Initial 800km
Less than 1/2 throttle
Up to 1,600km
Less than 3/4 throttle
CYLINDER CLASSIFICATION
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Upon reaching an odometer reading of 1,600 km you can subject the motorcycle to full throttle operation.
Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
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The engine of
/
is composed of the two cylinder, is classified into the front cylinder and
rear cylinder as basis of the motorcycle ahead.
Front cylinder
Rear cylinder
FRONT
760
315
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180
795
960
1,045
1,120
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395
800
890
795
895
890
795
635
(
1,455
2,080
325
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(
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
2,080 mm (81.9 in)
Overall width
760 mm (29.9 in)
Overall height
1,120 mm (44.1 in)
Wheelbase
1,455 mm (53.7 in)
Ground clearance
180 mm (7.1 in)
Unladen mass
170 kg (375 lbs)
Type
Four-stroke, DOHC, air-cooled and oil-cooled
Number of cylinder
V-2 cylinder
Bore
57.0 mm (2.24 in)
44.0 mm (1.73 in)
Stroke
48.8 mm (1.92 in)
41.0 mm (1.61 in)
167 kg (368 lbs)
Carburetor
249 (15.2 in )
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Piston displacement
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ENGINE
124.7 (7.6 in3 )
BDS 26TYPE (DOUBLE)
Starter system
Wet sump
Lubrication system
Electric starter
TRANSMISSION
Clutch
Wet multi-plate type
Transmission
5-speed constant mesh
Gearshift pattern
1-down, 4-up
Final reduction
3.286
3.714
Gear ratio, 1st
2.462
2.750
2nd
1.556
1.786
3rd
1.190
1.350
4th
0.957
1.091
5th
0.840
0.913
520 HO 112 links
428 HO 136 links
Drive chain
CHASSIS
Telescopic type
Rear suspension
Swingarm type
Steering angle
33(right & left)
Caster
25.5
Trail
85 mm (3.35 in)
Front brake
Disk brake
Rear brake
Disk brake
Front tire size
110/70 - 17 54H
Rear tire size
150/70 - 17 69H
Front fork stroke
120 mm (4.72 in)
76 mm (2.29 in)
Front suspension
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ELECTRICAL
CDItype
Ignition type
13B.T.D.C.at 2,000 rpm and
Ignition timing
30B.T.D.C.at 6,000 rpm
Spark plug
CR8E
12V 12Ah
Fuse
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Battery
15 A
Head lamp
Turn signal lamp
Brake / Tail lamp
Speedometer lamp
HI : 60 W
HI : 35 W
LO : 55 W
LO : 35 W
10 W
21 / 5 W
1.7 W3
High beam indicator lamp
1.7 W
Turn signal indicator lamp(right & left)
1.7 W2
License plate lamp
5W
Neutral indicator lamp
1.7 W
CAPACITIES
Fuel tank
17.0
Engine oil, oil change
1,450
with filter change
1,500
overhaul
1,800
1,650
400 2.5 cc
262 cc
Front fork oil (One side)
NOTE
The specifications are subject to change without notice.
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE
2- 1
PERIODIC MAINTENANCE CHART
2- 1
LUBRICATION POINTS
2- 2
MAINTENANCE PROCEDURES
2- 3
2- 3
SPARK PLUG
2- 5
VALVE CLEARANCE
2- 5
AIR CLEANER
2- 6
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EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLTS
CARBURETOR
FUEL HOSE
2- 8
2- 8
2- 9
ENGINE OIL FILTER
2-10
DRIVE CHAIN
2-11
BRAKE SYSTEM
2-13
ENGINE OIL
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CLUTCH
2- 7
2-17
STEERING
FRONT FORK
2-17
REAR SUSPENSION
2-17
TIRE
2-18
CHASSIS BOLTS AND NUTS
2-18
COMPRESSION PRESSURE
2-19
OIL PRESSURE
2-20
2-1 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the
motorcycle operating at peak performance and economy.
CAUTION
More frequent servicing should be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

ENGINE
Air cleaner element

Exhaust pipe nuts and
muffler mounting bolts
Tighten
CHASSIS
Interval
Brake hose
Brake fluid
Tires
Steering
Front forks
Rear suspension
Chassis bolts and nuts
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Tighten
Inspect
Tighten
Remove carbon
Replace
Clean
Inspect
Replace every 4 years
page
2- 6
2-5
2- 3
3-48
3-22
2- 5
2- 8
Replace
Replace
Inspect
Inspect
Inspect
Replace
Replace
Inspect
Inspect
Inspect
2-10
2- 9
2- 7
2- 7
2- 8
Initial 1,000 km
Every 4,000 km
Every 8,000 km
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Engine oil filter

Engine oil
Throttle cable
Idle speed
Clutch
Every 8,000 km
Replace every 12,000 km
Inspect
Tighten
Clean
Inspect
Fuel hose
Drive chain
Brake
Every 4,000 km
Clean every 3,000 km
Valve clearance adjust

Cylinder head nut
Cylinder head & Cylinder
Spark plug
Item
Initial 1,000 km
Interval
Item
Clean and lubricate every 1,000km

Inspect
Inspect
Inspect
Inspect

Inspect
Inspect
Inspect
Inspect
Tighten

Inspect
Inspect
Inspect
Inspect
Tighten
2-11
2-13
2-13
2-13
2-18
2-17
2-17
2-17
2-18
CAUTION
Using poor quality replacement parts can cause your motorcycle to wear more quickly and shorten its useful life.
Use only genuine Hyoung replacement parts or their equivalent.
PERIODIC MAINTENANCE 2-2
LUBRICATION POINT
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Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Clutch lever holder

Drive chain
Side stand pivot and spring hook
Speedometer gear box
Front brake lever holder

Throttle cable
Rear brake pedal pivot
O - Motor oil, G - Grease
NOTE
Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy condition.
MAINTENANCE PROCEDURE
This section describes the service procedure for
each section of the periodic maintenance.
VALVE CLEARANCE
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km.
CAUTION
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The valve clearance specification is different for

intake and exhause valves.
Valve clearance adjustment must be checked and
adjusted, 1) at the time of periodic inspection, 2)
when the valve mechanism is serviced, and 3)
when the camshaft is disturbed by removing it for
servicing.
Remove the spark plug. (Refer to page 2-5)
Remove the fuel tank. (Refer to page 4-1)
Remove the cylinder head cover and .
Remove the magneto cover plug and the timing
inspection plug .
The clearance specification is for COLD state.
Rotate the magneto rotor to set the front cylinders

piston at TDC (Top Dead Center) of the compression
stroke.
(Rotate the rotor untilFline on the rotor is aligned
with the center of hole on the crankcase.)
To inspect the front cylinders valve clearance, insert

the thickness gauge to the clearance between the
camshaft and the tappet.
Valve clearance (when cold)
IN.
0.1 0.2 mm (0.004~0.008 in)
EX.
0.2 0.3 mm (0.008~0.012 in)
Thickness gauge : 09900-20806
[ FRONT CYLINDER ]
[ REAR CYLINDER ]
If the clearance is out of specification, first remove the

cam chain tensioner, camshaft housing, camshaft.
To install the tappet shim at original position, record
the shim NO. and clearance withA,B,C,D
mark on the cylinder head as the illustration.
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Adjust valve timing, install the camshaft housing and the

tensioner.
After the crankshaft rotate about 10 times, measure the
valve clearance.
If the clearance be not agree, adjust the standard clearance as the same manner above.
In case that valve adjustment which there is no the
tappet shim selection chart, please follow instructions
of example in the below.
For example, the intake clearance is 0.4 and the shim
is 170 (1.70 mm), select 195 (1.95 mm) of the shim
which 170 (1.70 mm) of the shim add up the excess
clearance 0.25 mm when adjust with the standard
0.15 as the intake standard clearance 0.10.2 mm.
Select the tappet that agree with tappet clearance

(vertical line) and shim NO.(horizontal line) as refer to the
tappet shim selection chart. (Refer to page 7-3334)
CAUTION
Valve clearance should be checked when the

engine is cold.
If you don
t rotate the crankshaft about 10
times before measuring the valve clearance,
there is no meaning of valve clearance.
Rotate the magneto rotor to set the rear cylinders

piston at TDC(Top Dead Center) of the compression
stroke.
(Rotate the rotor 285counter-clockwise from the
Fline, and until theRline on the rotor is
aligned with the center of hole on the crankcase.)
Inspect the rear cylinders valve clearance with the

same manner of the front cylinder.
SPARK PLUG
Inspect Interval
Clean Initial 1,000 km and Every 4,000 km,
Replace Every 8,000 km.
SPARK PLUG SPECIFICATION
Hot type
CR7E
Standard type
CR8E
Cold type
CR9E
Remove the carbon deposite with wire or pin and adjust

the spark plug gap to 0.70.8 mm, measuring with a
thickness gauge.
Spark plug gap
0.70.8 mm (0.028~0.032 in)
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Check to see the worn or burnt condition of the electrodes.

If it is extremly worn or burnt, replace the plug.
And also replace the plug if it has a broken insulator,
damaged thread, etc.
Install the spark plug, and then tighten it to specified
torque.
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Disconnect the spark plug caps.

Remove the spark plugs.
Spark plug : 20~25 Nm (2.0~2.5 kgm)
0.7 ~ 0.8mm
(0.028 ~ 0.032 in)
EXHAUSE PIPE NUTS AND MUFFLER

MOUNTING BOLTS
Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km.
Tighten the exhaust pipe nuts , and muffler mounting bolts to the specified torque.
Exhaust pipe nut
: 18~28 Nm (1.8~2.8 kgm)
Muffler mounting bolt
: 20~30 Nm (2.0~3.0 kgm)
[ Front Cylinder ]
[ Rear Cylinder ]
AIR CLEANER
Inspect Interval
Clean Every 3,000 km,

Replace Every 12,000 km.
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The air cleaner is located under the fuel tank.

Remove the fuel tank.
Remove the four screw .
Pull up the air cleaner cover and the air cleaner element .
Clean the air cleaner element for the following:

When the air cleaner element clean with the air gun,
necessarily blow at the inside by compressed air.
Carefully examine the air cleaner element for tears during
cleaning. Replace it with a new one if it is torn.
Assemble the element completely or damage severely
the engine.
Be careful not to allow water to go inside the air cleaner element.
CAUTION
More frequent servicing may be performed on motorcycles that are used under severe conditions, also clean the air cleaner element when
replacing the oil to prevent damage of the engine.
CARBURETOR
Inspect Interval
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IDLE SPEED
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Make this inspection when the engine is hot.
CAUTION
1,4501,550 rpm
Engine idle speed
Connect an engine tachometer to the high tension

cord.
Start up the engine and set its speed at anywhere
1,450 and 1,550 rpm by turning throttle stop screw .
Engine tachometer : 09900-26006
THROTTLE CABLE PLAY

There should be 0.51.0 mm play on the throttle cable.
To adjust the throttle cable play.
Tug on the throttle cable to check the amount of play.
Loosen the lock nut and turn the adjuster in or
out until the specified play is obtained.
Secure the lock nuts while holding the adjuster in
place.
Throttle cable play
0.51.0 mm (0.02~0.04 in)
FUEL HOSE
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km,
Replace every 4 years.
Remove the front and rear seat. (Refer to page 6-1)
Inspect the fuel hoses for damage and fuel leakage. If
any defects are found, the fuel hoses must be replaced.
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CLUTCH
Inspect Interval
Clutch play should be 4 mm as measured at the clutch lever

holder before the clutch begins to disengage. If the play in
the clutch is incorrect, adjust it in the following way :
Loosen the lock nut and screw the adjuster on
the clutch lever holder all the way in.
Loosen clutch cable adjuster lock nut .
Turn the clutch cable adjuster in or out to acquire
the specified play.
Tighten lock nut while holding the adjuster in position.
The clutch cable should be lubricated with a light
weight oil whenever it is adjusted.
Clutch cable play
4 mm (0.16 in)
GEARSHIFT LEVER HEIGHT ADJUSTMENT

Loosen the lock nut .
With the link rod turned, adjust the gearshift lever
height.
ENGINE OIL
Inspect Interval
Replace Initial 1,000 km and Every 4,000 km.
Oil change
1,450
Filter change
1,500
Overhaul engine
1,800
1,450
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Necessary amount of engine oil
1,500
1,650
SAE 10W/30 or 10W/40

API Over SG
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Engine oil type
Oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be
together with the engine oil change.
Keep the motorcycle upright.
Place an oil pan below the engine, and drain the oil
by removing the filler cap and drain plug .
Tighten the drain plug to the specified torque, and
pour fresh oil through the oil filler. Use an API classification of Over SG oil with SAE 10W/30 or 10W/40
viscosity.
Oil drain plug : 18~20 Nm (1.8~2.0 kgm)
Start up the engine and allow it to run for several

minutes at idling speed.
Turn off the engine and wait about three minutes,
then check the oil level through the inspection window. If the level is below markF, add oil toFlevel.
If the level is above markF, drain oil toFlevel.
CAUTION
Never operate the motorcycle if the engine oil level
is below theLower line mark(L)in the inspection window. Never fill the engine oil above the
Upper line mark(F).
Engine oil level being most suitable about 1mm under
theUpper line mark(F)of the engine oil lens. In
case of the engine oil pouring in excessively, the
engine output being made insufficient.
Be careful not to pouring in the engine oil excessively.
CAUTION
CAUTION
ENGINE OIL FILTER

Inspect Interval
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More frequent servicing may be performed on motorcycles that are used under severe conditions.
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Necessarily, confirm and clean the oil strainer

when replace the engine oil (specially, when first
replacement).
Replace Initial 1,000 km and Every 4,000 km.
Drain the engine oil as described in the engine oil

replacement procedure.
Remove the oil filter cap .
Remove the oil filter.
Install the new O-ring .
Install the new oil filter.

Install the new O-ring and spring to the oil filter
cap.
Install the oil filter cap.
CAUTION
Before installing the oil filter cap, apply engine
oil lightly to the new O-ring .
OIL FILTER INSTALLATION

INSERTION
DIRECTION
CAUTION
LUSTER MATERIAL
When install the oil filter, necessarily,HYOSUNG

character and16510H05240parts NO. install toward the outside, otherwise can damage the engine.
HYOSUNG
WARNING
16510H05240
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CAUTION
Add new engine oil and check the oil level as

described in the engine oil replacement procedure.
Engine oil and exhaust pipes can be hot enough to

burn you.
Wait until the oil drain plug and exhaust pipes are
cool enough to touch with bare hands before draining oil.
Use HYOSUNG MOTORCYCLE GENUINE OIL FILTER only, since the other make
s genuine filters
and after-market parts may differ filtering performance and durability, which could cause engine
damage or oil leaks. Hyosung motors genuine oil
filter is also not usable for the motocycles.
DRIVE CHAIN
Inspect Interval
Clean and Lubricate Every 1,000 km.
Visually check the drive chain for the possible defects
listed below. (Support the motorcycle by the jack or
block, turn the rear wheel slowly by hand with the transmission shifted to Neutral.)
Loose pins
Excessive wear
Damaged rollers
Improper chain adjustment
Dry or rusted links
Kinked or binding links
If any defects are found, the drive chain must be
replaced.
OUTSIDE
NOTE
When replacing the drive chain, replace the
drive chain and sprocket as a set.
Loose the axle nut .
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Tense the drive chain fully by turning both chain

adjusters , .
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Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be
replaced.
Service limit
20pitch length
Drive chain
319.4 mm
256.5 mm
(12.58 in)
(10.10 in)
Loosen or tighten both chain adjusters , until the

chain has 20 30 mm of slack in the middle
between the engine and rear sprockets. The marks
, on both chain adjusters must be at the same
position on the scale to ensure that the front and rear
wheels are correctly aligned.
Drive chain slack
20 30 mm (0.79 ~ 1.18 in)
Place the motorcycle on jack or block for accurate

adjustment.
After adjusting the drive chain, tighten the axle nut
to the specified torque.
Tighten both chain adjusters , securely.
Rear axle nut : 90~140 Nm (9.0~14.0 kgm)
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Recheck the drive chain slack after tightening the

axle nut.
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20~30mm
(0.79~1.18 in)
Wash the drive chain with kerosine. If the drive chain

tends to rust quickly, the intervals must be shortened.
After washing and drying the chain, oil it with a
engine oil or chain lubricating oil.
CAUTION
The drive chain for this motorcycle is made of the

special material.
The chain should be replaced with a 520HO for
and 428SO for

.
Use of another chain may lead to premature
chain failure.
BRAKE SYSTEM
Inspect Interval
[ BRAKE ]
[ BRAKE HOSE & BRAKE FLUID ]
Replace the brake hoses Every 4 years,
Replace the brake fluid Every 2 years.
BRAKE FLUID LEVEL CHECK

Keep the motorcycle upright and place the handlebars straight.
Check the brake fluid level by observing the lower
limit line (LOWER) on the front brake fluid reservoir.
When the level is below the lower limit line (LOWER),
replenish with brake fluid that meets the following
specification.
LOWERLIMIT LINE
Specification and Classification : DOT 3 or DOT 4
CAUTION
CAUTION
[ Front Brake ]
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The brake system of this motorcycle is filled with

a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based or
petroleum-based. Do not use any brake fluid
taken from old, used or unsealed containers.
Never re-use brake fluid left over from the last
servicing or stored for a long period.
BRAKE PAD WEAR
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Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces.
Check the brake hoses and hose joints for cracks
and oil leakage before riding.
[ Rear Brake ]
The extend of brake pad wear can be checked by

observing the grooved limit on the pad. When the
wear exceeds the grooved limit, replace the pads with
new ones.
CAUTION
Replace the brake pad as a set, otherwise braking

performance will be adversely affected.
FRONT AND REAR BRAKE PAD REPLACEMENT

Remove the brake caliper.
Remove the brake pads.
To reassmble, reverse the above sequence.
Front brake caliper mounting bolt
: 18~28 Nm (1.8~2.8 kgm)
Rear brake caliper mounting bolt
: 18~28 Nm (1.8~2.8 kgm)
[ Front Brake ]
FRONT AND REAR BRAKE FLUID REPLACEMENT

Place the motorcycle on a level surface and keep the
handlebars straight.
Remove the master cylinder reservoir cap and diaphragm.
Suck up the old brake fluid as much as possible.
Fill the reservoir with new brake fluid.
Specification and Classification
: DOT 3 or DOT 4
Connect a clear hose to the air bleeder valve and
insert the other end of the hose into a receptacle.
[ Rear Brake ]
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Loosen the air bleeder valve and pump the brake

lever until the old brake fluid is completely out of the
brake system.
Close the air bleeder valve and disconnect the clear

hose. Fill the reservoir with new brake fluid to the
upper line.
Replace the rear brake
s fluid with the same manner
of the front brake.
Front brake caliper air bleeder valve
:6~9 Nm (0.6~0.9 kgm)
Rear brake caliper air bleeder valve
:6~9 Nm (0.6~0.9 kgm)
NOTE
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Air trapped in the brake fluid circuit acts like a cushion to

absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of
air is indicated bysponginessof the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider,
it is essential that, after remounting the brake and
restoring the brake system to the normal condition, the
brake fluid circuit be purged of air in the following manner :
Fill the master cylider reservoir to top of the inspection window. Replace the reservoir cap to prevent dirt
from entering it.
Attach a hose to the air bleeder valve, and insert the
free end of the hose into a receptacle.
Bleed air from the brake system.
Squeeze and release the brake lever several times in
rapid succession and sqeeze the lever fully without
releasing it. Loosen the bleeder valve by turning it a
quarter of a turn so that the brake fluid runs into the
receptacle, this will remove the tension of the brake
lever causing it to touch the handlebar grip. Then,
close the air bleeder valve, pump and squeeze the
brake lever, and open the valve. Repeat this process
until the fluid flowing into the receptacle no longer
contains air bubbles.
AIR BLEEDING OF THE BRAKE FLUID

CIRCUIT
While bleeding the brake system, replenish the

brake fluid in the reservoir as necessary. Make
sure that there is always some fluid visible in
the reservoir.
Close the air bleeder valve, and disconnect the hose.

Fill the reservoir with brake fluid to the upper line.
Bleed the rear brakes air with the same manner of
front brake.
Front brake caliper air bleeder valve
: 6~9 Nm (0.6~0.9 kgm)
Rear brake caliper air bleeder valve
: 6~9 Nm (0.6~0.9 kgm)
CAUTION
Handle brake fluid with care : the fluid reacts
chemically with paint, plastics, rubber materials, etc.
FRONT BRAKE LAMP SWITCH

The front brake lamp switch is located beneath the front
brake lever. Loosen the switch fitting screws and adjust the
timing by moving the switch body forward or backward.
REAR BRAKE LAMP SWITCH

Adjust the rear brake lamp switch so that the brake lamp
will come on just before pressure is felt when the brake
pedal is depressed.
STEERING
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Steering should be adjusted properly for smooth turning

of handlebars and safe running. Overtight steering prevents smooth turning of the handlebars and too loose
steering will cause poor stability. Check that there is no
play in the steering stem while grasping the lower fork
tubes by supporting the machine so that the front wheel
is off the ground, with the wheel straight ahead, and pull
forward. If play is found, perform steering bearing
adjustment as described in page 6-29 of this manual.
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Inspect Interval
Inspect Interval
Inspect Every 4,000 km.
FRONT FORK
Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any
defective parts, if necessary.
REAR SUSPENSION
Inspect Interval
Inspect Every 4,000 km.
Inspect the rear shock absorber for oil leakage and
mounting rubbers including engine mounting for wear
and damage. Replace any defective parts, if necessary.(Refer to page 6-36)
TIRE
Tire wear indicator
Inspect Interval
TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will
decrease riding stability and can lead to loss of control.
Inspect shortage of tire thread
s depth by the tire
wear indicator .
Replace the front and rear tires at once when appear
the tire wear indicator .
Tire wear indicator mark
TIRE PRESSURE
The standard tire on
is 110/70-17 54H for front and

150/70-17 69H for rear.
The use of tires other than those specified
may cause instability. It is highly recommended to
use a HYOSUNG Genuine Tire.
COLD INFLATION SOLD RIDING DUAL RIDING

TIRE PRESSURE KPa kgf/cm2 psi KPa kgf/cm2 psi
CAUTION
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If the tire pressure is too high or too low, steering will be

adversely affected and tire wear increased. Therefore,
maintain the correct tire pressure for good roadability or
shorter tire life will result. Cold inflation tire pressure is
as follows.
196 2.00 29.0 196 2.00 29.0
Rear
221 2.25 32.0 245 2.50 36.0
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Front
CHASSIS BOLTS AND NUTS
Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km.
Check that all chassis bolts and nuts are tightened to

their specified torque.(Refer to page 7-12)
COMPRESSION PRESSURE
The compression of a cylinder is a good indicator of its
internal condition.
The decision to overhaul the cylinder is often based on
the results of a compression test. Periodic maintenance
records kept at your dealership should include compression reading for each maintenance service.
Compression pressure
14~16 kg/cm (at 500 rpm)
Standard
11~13 kg/cm2 (at 500 rpm)
Service limit
12 kg/cm2 (at 500 rpm)
Service limit
10 kg/cm2 (at 500 rpm)
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Low compression pressure can indicate any of the following conditions :

Excessively worn cylinder wall
Worn-down piston or piston rings
Piston rings stuck in grooves
Poor seating of valves
Ruptured or otherwise defective cylinder head gasket
Standard
COMPRESSION TEST PROCEDURE
NOTE
Before testing the engine for compression

pressure, make sure that the cylinder head
bolts are tightened to the specified torque
values and valves are properly adjusted.
Have the engine warmed up by idling before testing.
Be sure that the battery used is in fullycharged condition.
Remove the parts concerned and test the compression

pressure in the following manner.
Loosen the oil cooler mounting bolts from the frame.
Remove all the spark plug.
Fit the compression gauge in one of the plug holes,
while taking care that the connection is tight.
Keep the throttle grip in full-open position.
Crank the engine a few seconds with the starter, and
record the maximum gauge reading as the compression of that cylinder.
Compression gauge : 09915-64510
OIL PRESSURE
Check the oil pressure periodically. This will give a good indication of the condition of the moving parts.
Standard
Standard
Oil pressure
Oil pressure
2.0 0.5 /
(at 65 3,000 rpm)
0.9 ~1.1 /
(at 65 3,000 rpm)
If the oil pressure is lower or higher than the specification, the following causes may be considered.
LOW OIL PRESSURE
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Oil leakage from the oil passage

Damaged O-ring
Defective oil pump
Combination of above items
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Engine oil viscosity is too high

Clogged oil passage
Combination of the above items
HIGH OIL PRESSURE
OIL PRESSURE TEST PROCEDURE
Check the oil pressure in the following manner.

Remove the oil check plug and install the adapter of oil
pressure gauge at the removed position.
Connect an engine tachometer.
Warm up the engine as follows :
Summer : 10 min. at 2,000 rpm.
Winter : 20 min. at 2,000 rpm.
After warming up, increase the engine speed to
3,000 rpm. (with the engine tachometer), and read
the oil pressure gauge.
Oil pressure gauge : 09915-74510
Engine tachometer : 09900-26006
C
G
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ENGINE
CONTENTS
ENGINE REMOVAL AND REINSTALLATION
3- 1
ENGINE REMOVAL
3- 1
ENGINE REINSTALLATION
3- 5
3- 7
STARTER MOTER
3- 7
ENGINE DISASSEMBLY
MAGNETO COVER
MAGNETO ROTOR
CLUTCH COVER
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CLUTCH
PISTON
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CYLINDER HEAD COVER
3- 8
3-12
3-13
3-13
3-14
3-15
PRIMARY DRIVE GEAR
3-16
OIL PUMP
3-16
GEARSHIFT SHAFT
3-17
3-19
ENGINE REASSEMBLY
3-36
ENGINE COMPONENT INSPECTION AND SERVICE
CAUTION
Mark an identification of assembly location on each removed part so that each will be restored
to the original position during reassembly.
Wash clean and dry the removed parts before inspecting and measuring.
Oil the rotating or sliding parts before assembly.
Make sure to use the correct type of lubricant where specified.
Check that each rotating or sliding part moves or operates smoothly after assembly.
Make sure to follow the bolt tightening order where specified.
If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the bolts
and check that the tightening margin is equal in each bolt.
3-1 ENGINE
ENGINE REMOVAL AND

REINSTALLATION
ENGINE REMOVAL
NOTE
If the engine is dirtied, wash the machine
with a suitable cleaner before removing the
engine.
Remove the front seat.(Refer to page 6-1)

Remove the fuel tank.(Refer to page 4-1)
Drain the engine oil.(Refer to page 2-9)
Disconnect the battery lead wire .
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CAUTION
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First, disconnect the lead wire.
AIR CLEANER
With the two screw loosened, remove the air

cleaner case.
Loosen the clamp screw.
CARBURETOR
Remove the carburetor after removed the intake pipes.
(Refer to page 4-5)
Disconnect the vacuum hoses .
(
)
ENGINE 3-2
CLUTCH CABLE
Disconnect the clutch cable end out of clutch lever.
Disconnect the clutch cable end out of clutch release
arm.
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[ Front Cylinder ]
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With the exhaust pipe bolts and muffler mounting

bolts removed, remove the exhaust pipes and mufflers.
EXHAUST PIPE AND MUFFLER
[ Rear Cylinder ]
3-3 ENGINE
ELECTRIC PARTS
With take out the spark plug caps, remove the spark
plug.
[ Front Cylinder ]
[ Rear Cylinder ]
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Remove the starter motor lead wire.
Remove the engine ground lead wire .
Disconnect the magneto coupler .
ENGINE 3-4
ENGINE SPROCKET
Remove the engine sprocket cover.
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Remove the breather hose.
Loosen the bolt and remove the link rod.

Flatten the lock washer.
Remove the engine sprocket nut and washer.
NOTE
When loosening the engine sprocket nut,

depress the brake pedal.
Remove the engine sprocket.
NOTE
If it is difficult to remove the engine

s p r o c k e t , loosen the rear axle nut, c h a i n
adjusters to provide additional chain
slack.(Refer to page 2-11)
3-5 ENGINE
Remove the oil cooler.
CAUTION
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Remove the carburetor when removing or

installing the engine necessarily.
When removing the carburetor , loosen the
intake pipe mounting bolts at the same time.
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Support the engine using an engine jack.

Remove the engine mounting nuts and bolts.
Remove the engine from the frame.
ENGINE REINSTALLATION
Reinstall the engine in the reverse order of engine
removal.
Install the engine mounting bolts and nuts.
Tighten the engine mounting bolts and nuts to the
specified torque.
Engine mounting bolt
60 N
m (4.0
6.0 kg
m)
: 40
ENGINE 3-6
ENGINE SPOCKET
Loosen the rear axle nut and chain adjusters, left
and right.
Install the engine sprocket.
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Engine sprocket nut

: 80~100 Nm (8.0~10.0 kgm)
Tighten the engine sprocket nut to the specified

torque.
NOTE
When tightening the engine sprocket nut,

depress the rear brake pedal.
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Bend the lock washer securely.
Install the gearshift arm and adjust the gearshift lever

height.(Refer to page 2-9)
Connect each electric part and its couplers.(Refer to

page 7-23~30)
Install the exhaust pipes and mufflers.
Install the carburetor and air cleaner.
After remounting the engine, the following adjustments are necessary.

Engine idling speed
Throttle cable play
Clutch cable play
Drive chain
Gearshift lever height
Engine oil level
Refer to page 2-7

Refer to page 2-7
Refer to page 2-8
Refer to page 2-11
Refer to page 2-9
Refer to page 2-9
3-7 ENGINE
ENGINE DISASSEMBLY
STARTER MOTOR
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Remove the starter motor.
Remove the gear position switch.

Remove the contacts and springs .
Remove the three union bolts.
ENGINE 3-8
CYLINDER HEAD COVER

Remove the cylinder head cover.
To set the piston at TDC(Top Dead Center).
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Align the index mark on the magneto rotor with

the index mark on the magneto cover as turn the
crankshaft counter-clockwise.
To set piston at TDC(Top Dead Center) of the
compression stroke as align theFmark for
front cylinder and theRmark for rear cylinder.
CAUTION
Remove the cam chain tensioner.
[ Front Cylinder ]
[ Rear Cylinder ]
3-9 ENGINE
With the three bolts removed, remove the cam chain

guide NO.2.
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Remove the camshaft housing.
Remove the camshaft (IN.EX.).
Remove the C-ring.
ENGINE 3-10
Loosen the two cylinder head base cover nuts.
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Loosen the three cylinder head base nuts.
Loosen the four cylinder head stud bolts.
Remove the chain guide NO.1 and cylinder head.
3-11 ENGINE
Remove the tappet and the shim.
CAUTION
Draw out the tappet and shim with the strong
magnet not to be scratched.
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The tappet and shim should be lined so that each

will be restored to the original position during
reassembly.
CAUTION
Compress the valve spring by using the special tool.
Valve spring compressor : 09916-14510

Valve spring compressor attachment
: 09916H35C00
(
)
: 09916H5100
(
Take out the valve cotter from the valve stem.

Remove the valve spring retainer.
Pull out valve from the other side.
ENGINE 3-12
Remove the two cylinder base nuts and cylinder.
CAUTION
If tapping with the plastic hammer is necessary,
pay attention to break the fins.
Remove the rear cylinder head and cylinder with the

same manner of the front cylinder head and cylinder
removal.
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Rear Cylinder
PISTION
Place a clean rag over the cylinder base to prevent

piston pin circlips from dropping into crankcase.
Remove the piston pin circlips with long-nose pliers.
Remove the piston pin by using the special tool.

Piston pin puller : 09910-34510
NOTE
Make an identification on each piston head so
that confirmed the cylinder.
Front Cylinder
3-13 ENGINE
MAGNETO COVER
Remove the magneto cover.
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Remove in the order of spacer , shaft , starter

idle gear .
MAGNETO ROTOR
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With the magneto rotor held immovable using the

special tool, loosen the rotor nut.
Conrod holder : 09910-20115
Remove the magneto rotor by using the special tool.

Rotor remover
(
)
: 09930-30164
Rotor remover
(
)
: 09930-30162
Rotor remove sliding shaft

: 09930-30102
ENGINE 3-14
Remove the key .

Remove the starter driven gear .
Remove the cam chain tensioner and cam chain

.
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CLUTCH COVER
Remove the clutch release arm .
Remove the clutch cover bolts.

Remove the clutch cover.
3-15 ENGINE
CLUTCH
With the primary drive gear held immovable, remove
the clutch spring mounting bolts diagonally.
Remove the disk pressure .
Flatten the lock washer .
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Remove the clutch drive and driven plates.
With the clutch sleeve hub held immovable using

special tool, remove the clutch sleeve hub nut.
Clutch sleeve hub holder : 09920-53710
ENGINE 3-16
Remove the clutch sleeve hub and primary driven

gear assembly .
PRIMARY DRIVE GEAR
CAUTION
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This bolt has left-hand thread. If turning it

counter-clockwise(
), it may cause damage.
Pay attention at the primary drive gear with two
washer.
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With the magneto rotor held immovable using special

tool, remove the primary drive gear nut.
Remove the key and cam chain .

Remove the cam chain tensioner .
OIL PUMP
Remove the circlip and oil pump driven gear.
3-17 ENGINE
Remove the pin .

With the three screws loosened, remove the oil pump
.
GEARSHIFT SHAFT
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Draw out the gearshift shaft .
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With the cam guide screws loosened, draw out the

guide and lifter.
Remove the cam driven gear.
CAUTION
Pay attention to not lost the gearshift pawl, pin,

spring with the cam driven gear removal.
With the neutral cam stopper plug loosened, remove

the washer, spring, stopper.
ENGINE 3-18
Remove the crankcase securing bolts.

Separate the crankcase into 2 parts, right and left,
with a special tool.
Crankcase separator : 09920-13120
CAUTION
When separating the crankcase , necessarily,
remove it after installed the special tool (Crankcase
separator) on the side of clutch.
In case separate oppositely, the gearshift cam stopper will be damaged in the side of magneto.
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Fit the crankcase separater, so that the tool

arms parallel the side of the crankcase.
NOTE
Remove the gearshift fork shaft and gearshift fork

.
Remove the gearshift cam .
Remove the driveshaft assembly , countershaft
assembly .
Remove the oil pump idle gearshaft .
Remove the crankshaft by using the special tool.

Crankcase separator : 09920-13120
3-19 ENGINE
ENGINE COMPONENT INSPECTION AND SERVICE
CAUTION
Be sure to identify each removed part as to its location, and lay the parts out in groups designated as
Front cylinder,Rear cylinder,Exhaust,
Intake, so that each will be restored to the original location during assembly.
Service limit
Cylinder head
distortion
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0.05 mm (0.002 in)
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Decarbonate in combustion chamber.

Check the gasketed surface of the cylinder head for distortion with a straightedage and thickness gauge, taking
a clearance reading at several places as indicated. If the
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder head.
CYLINDER HEAD DISTORTION
VALVE FACE WEAR
Visually inspect each valve face for wear. Replace any

valve with an abnormally worn face. The thickness of
the valve face decreases as the face wears. Measure
the valve head . If it is out of specification, replace the
valve with a new one.
Valve head thickness
Service limit
0.5 mm (0.02 in)
Vernier calipers : 09900-20101
VALVE STEM RUNOUT

Check the valve stem for abnormal wear or bend.
Place the valve on V-blocks and measure runout.
If the service limit is exceeded or abnormal condition
exists, replace the valve.
Valve stem runout
(T.D.C)
(B.T.D.C)
Intake open
19 32
(A.T.D.C)
Exhaust close
Service limit
0.05 mm (0.002 in)
Dial gauge : 09900-20606

Magnetic stand : 09900-20701
V-block : 09900-21304
(A.B.D.C)
Intake close
57
38
(B.B.D.C)
Exhaust open
(B.D.C)
Valve timing diagram
ENGINE 3-20
CAMSHAFT
(T.D.C)
(B.T.D.C)
Intake open
The camshaft should be checked for runout and also for

wear of cams and journals if the engine has been noted
to produce abnormal noise or vibration or a lack of output power. Any of these abnormality could be caused by
a worn camshaft.
(A.T.D.C)
Exhaust close
1745
14
(A.B.D.C)
Intake close
48
(B.B.D.C)
Exhaust open
(B.D.C)
Valve timing diagram
34.170 mm (1.345 in)
Exhaust cam
34.120 mm (1.343 in)
Micrometer((25~50 mm)) : 09900-20202
Tappet & shim wear
When measuring the valve clearance, the clearance

should be within the standard range.
0.1~0.2 mm
Intake valve
Standard(When cold)
Valve clearance
Exhaust valve
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Intake cam
Service limit
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Cam height
(0.004~0.008 in)
0.2~0.3 mm
(0.008~0.012 in)
Inspect the tappet for wear and scratch.

If modification or scratch is present, replace the tappet.
The shim has various size.
Replace the thin shim to valve clearance is narrow, or
the thick shim to valve clearance is wide as that shim
thickness was installed with standard at present.
(Refer to page 7-3334)
SHIM KIND
There are 41 kinds of shim which thickness is increased

by each 0.025 mm from 1.20 mm to 2.20 mm.
CAMSHAFT WEAR
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power.
The limit of cam wear is specified for both intake and
exhaust cams in terms of cam height , which is to be
measured with a micrometer. Replace camshafts if
found it worn down to the limit.
3-21 ENGINE
VALVE HEAD RADIAL RUNOUT

Place a dial gauge as shown and measure valve head
radial runout.
If the service limit is exceeded, replace the valve.
Valve head radial
runout
Service limit
0.03 mm (0.0012 in)
Dial gauge : 09900-20606

V-block : 09900-21304
Valve guide-valve stem clearance
Standard
0.010~0.037 mm
IN.
(0.0004~0.0015 in)
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Measure the clearance in the valve guide-valve stem, by

rigging up the dial gauge as shown. If the clearance
is measured exceeds the limit specified below, then
determine whether the valve or the guide should be
replaced to reduce the clearance to within the standard
range:
VALVE GUIDE-VALVE STEM CLEARANCE
0.030~0.057 mm
EX.
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(0.0012~0.0022 in)
Dial gauge : 09900-20606

VALVE STEM DIAMETER
Valve stem diameter

IN.
EX.
Measure the valve stem outside diameter.

If the diameter measured exceeds the standard, replace
the valve.
Standard
4.475~4.490 mm 3.975~3.990 mm
(0.1762~0.1768 in) (0.1565~0.1571 in)
4.455~4.470 mm 3.955~3.970 mm
(0.1754~0.1760 in) (0.1557~0.1563 in)
Micrometer(0~25 mm) : 09900-20201
VALVE SPRING
The force of the coil spring keeps the valve seat tight. A
weakened spring results in reduced engine power output and often accounts for the chattering noise coming
from the valve mechanism.
Check the valve springs for proper strength by measur
ing their free length and also by the force required
to compress them. If the spring length is less than the
service limit or if the force required to compress the
spring does not fall within the specified range, replace
both the inner and outer springs as a set.
ENGINE 3-22
Service limit
Valve spring free

length(IN. & EX.)
37.64 mm
37.80 mm
(1.482 in)
(1.488 in)
Venier calipers : 09900-20101

Standard
Valve spring
tension
(IN. & EX.)
12.0~13.9 kgf
30.0 kgf
(26.7~30.6 lbs)
(66.1 lbs)
at length 33.7 mm (1.33 in) at length 27.95 mm (1.10 in)
Service limit
Cylinder distortion
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0.05 mm (0.002 in)
Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a
clearance reading at several places as indicated.
If the largest reading at any position of the
straightedge exceeds the limit, replace the cylinder.
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CYLINDER DISTORTION
CYLINDER BORE
Measure the cylinder bore diameter at six place. If any

one of the measurements exceeds the limit, overhaul
the cylinder and replace the piston with an oversize, or
replace the cylinder.
Standard
Service limit
Cylinder bore 57.000~57.015 mm
57.080 mm
(2.2441~2.2447 in)
(2.2473 in)
Standard
Service limit
Cylinder bore 44.000~44.015 mm
44.080 mm
(1.7323~1.7329 in)
(1.7354 in)
Cylinder gauge set : 09900-20508
CAM CHAIN TENSION ADJUSTER

Check that the push rod slides smoothly with the lock
shaft handle clockwise.
If it does not slide smoothly, replace the cam chain tension adjuster with a new one.
3-23 ENGINE
CAM CHAIN TENSIONER

Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
PISTON DIAMETER INSPECTION
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Measure the outside diameter of piston in the direction perpendicular to the piston pin axis at the height from the skirt
as shown in the illustration using a micrometer.
If the measurement is found less than the service
limit, replace the piston.
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Check the cam chain for wear, damage and kinked or binding links. If any defects are found, replace it with a new
one.
Check the cam chain guide for wear and damage. If it is
found to be damaged, replace it with a new one.
CAM CHAIN AND CAM CHAIN GUIDE
Service limit
56.880 mm
43.890 mm
(2.2394 in)
(1.7280 in)
Piston diameter
Piston oversize
0.5, 1.0 mm (0.02, 0.04 in)

(0.6 in)
Micrometer(50~75 mm) : 09900-20203

Micrometer(25~50 mm) : 09900-20202
PISTON-TO-CYLINDER CLEARANCE
To determine the piston-to-cylinder clearance, calculate
the difference between the cylinder bore and outside
diameter of the piston.
Standard
Piston-to-cylin0.05~0.06 mm
der clearance
(0.0020~0.0024 in)
Service limit
0.120 mm
(0.0047 in)
Standard
Piston-to-cylin0.03~0.04 mm
der clearance
(0.0012~0.0016 in)
Service limit
0.1 mm
(0.0040 in)
ENGINE 3-24
PISTON PIN HOLE BORE

Using a dial calipers, measure the piston pin hole bore
both in the vertical and horizontal directions.
If the measurement exceeds the service limit, replace
the piston.
Service limit
Piston pin hole
bore
15.030 mm (0.5917 in) 13.030 mm (0.513 in)
Dial calipers : 09900-20605
PISTON PIN DIAMETER INSPECTION
14.980 mm(0.5898 in) 13.980 mm(0.550 in)

Micrometer(0~25 mm) : 09900-20201
PISTON RING FREE END GAP

INSPECTION
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Before installing piston rings, measure the free end gap

of each ring using vernier calipers. If the gap is less than
the service limit, replace the ring.
Piston ring free
end gap
Standard
7.2 mm (0.284 in) 5.0 mm (0.197 in)
2nd
5.8 mm (0.228 in) 6.0 mm (0.236 in)
Piston ring free
Service limit
1st
end gap
1st
5.7 mm (0.224 in) 4.0 mm (0.158 in)
2nd
4.6 mm (0.181 in) 4.8 mm (0.189 in)
PISTON RING END GAP INSPECTION

Insert the piston ring squarely into the cylinder using the
piston head.
Measure the end gap with a thickness gauge.
If the gap exceeds the service limit, replace the piston ring.
Piston ring end gap
Standard
(Assembly condition)
1st
2nd
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Service limit
Piston pin
diameter
Using a micrometer, measure the piston pin outside

diameter at three position, both the ends and the center.
If any of the measurements is founds less than the service limit, replace the pin.
0.20~0.32 mm
0.10~0.25 mm
(0.008~0.013 in) (0.004~0.010 in)

0.20~0.32 mm
0.25~0.40 mm
(0.008~0.013 in) (0.010~0.016 in)
3-25 ENGINE
Piston ring end gap(Assembly condition)
Service limit
1st
0.5 mm (0.02 in)
2nd
0.5 mm (0.02 in)
PISTON RING-TO-GROOVE CLEARANCE INSPECTION
1st
0.180 mm (0.007 in)
2nd
0.150 mm (0.006 in)
Piston ring-groove width
Standard
1st
1.01~1.03 mm
(0.040~0.041 in)
2nd
1.01~1.03 mm
(0.040~0.041 in)
Oil
2.01~2.03 mm
(0.079~0.080 in)
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Piston ring thickness
Standard
0.970~0.990 mm
1st
(0.0382~0.0390 in)
2nd
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Service limit
Piston ring-groove clearance
Remove carbon deposit both from the piston ring and its
groove.
Fit the piston ring into the groove. With the ring compressed and lifted up, measure the clearance on the
bottom side of the ring using a thickness gauge.
0.970~0.990 mm
(0.0382~0.0390 in)

Micrometer(0~25 mm) : 09900-20201
OVERSIZE RINGS
Oversize piston ring
The following two types of oversize piston ring are used.
They bear the following identification numbers.
Oversize piston ring
1st
2nd
0.5 mm
05
05
1.0 mm
10
10
Oversize oil ring

The following two types of oversize oil ring are used.
They bear the following identification marks.
Oversize oil ring
Color classification
0.5 mm
Painted red
1.0 mm
Painted yellow
ENGINE 3-26
CONROD SMALL END INSIDE DIAMETER INSPECTION

Using a dial calipers, measure the conrod small end
inside diameter both in vertical and horizontal directions.
If any of the measurements exceeds the service limit,
replace the conrod.
Standard
Conrod small
15.006~15.014 mm
end I.D.
(0.5908~0.5911 in)
15.040 mm
(0.5921 in)
Standard
Conrod small
13.006~13.014 mm
end I.D.
(0.5121~0.5124 in)
Service limit
13.040 mm
Service limit
(0.5134 in)
Dial calipers : 09900-20605
CONROD DEFLECTION INSPECTION
Conrod deflection
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Move the small end sideways while holding the big end
immovable in thrust direction.
Measure the amount of deflection.
Turn the conrod and see if it moves smoothly without
play and noise. This method can check the extent of
wear on the parts of the conrods big end.
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Service limit
3.0mm (0.12 in)
CONROD BIG END SIDE CLEARANCE

INSPECTION
Using a thickness gauge, measure the side clearance at

the conrod big end. If the measurement is out of standard value, measure the conrod big end and the crank
pin widths individually to determine which one is to be
replaced.
Standard
Conrod big end
0.40~0.85 mm
side clearance
(0.016~0.034 in)
Service limit
1.0 mm
(0.040 in)
Standard
Conrod big end
0.15~0.40 mm
side clearance
(0.006~0.016 in)
Service limit
1.0 mm
(0.040 in)
CRANKSHAFT RUNOUT INSPECTION

With the right and left crank journals supported with Vblock, turn the crankshaft slowly. At this time, measure
the crankshaft end runout using a dial gauge. If the
runout exceeds the service limit, replace the crankshaft.
3-27 ENGINE
Service limit
Crankshaft runout
0.05 mm (0.002 in)

Dial gauge : 09900-20606
V-block : 09900-21304
CRANKSHAFT REASSEBLY
Measure the width between the webs referring to the figure below when rebuilding the crankshaft.
720.1mm
(2.840.004 in)
Standard
Width between webs
720.1 mm
(2.840.004 in)
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MAGNETO COVER
STARTER CLUTCH
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MAGNETO INSPECTION(Refer to page 5-4)

DISASSEMBLY
Remove the stator .
Install the starter driven gear onto the starter clutch and
turn the starter driven gear by hand(the gear turns in
only one direction). The starter driven gear should
turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter
clutch. Also, inspect the surface of the starter driven
gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the
defective parts.
DISASSEMBLY
Hold the magneto rotor with the rotor holder and
remove the starter clutch bolts.
Rotor holder : 09930-44510
ENGINE 3-28
REASSEMBLY
Apply a small quantity of THREAD LOCK1324to
the starter clutch bolts and tighten them to the specified torque while holding the rotor with the rotor
holder.
Thread Lock1324
Rotor holder : 09930-44510
Starter clutch bolt
: 15~20 Nm(1.5~2.0 kgm)
STARTER DRIVEN GEAR
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STARTER DRIVEN GEAR BUSHING

Install the starter driven gear bushing and gear
onto the crankshaft and turn the starter driven
gear by hand. Inspect the starter driven gear bushing
for smooth rotation and any abnormal noise. If the
bushing does not turn smoothly or there is any abnormal noise, replace it.
DISASSEMBLY
Remove the bushing using the special tool.
Bearing remover(20~35 mm)

: 09923-74510
CLUTCH COVER
OIL FILTER REPLACEMENT(Refer to page 2-10)
DISASSEMBLY
Remove the circlip and right crankshaft oil seal.
Oil seal remover : 09913-50121
3-29 ENGINE
REASSEMBLY
Drive in the oil seal using the special tool.
Bearing installer : 09913-75820
Install the circlip.
Standard
Clutch drive plate

thickness
2.9~3.1 mm (0.114~0.122 in)

Service limit
2.6 mm (0.102 in)
Clutch drive plate
Standard
claw width
11.8~12.0 mm (0.465~0.472 in)
Clutch drive plate
Service limit
claw width
11.0 mm (0.433 in)
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Clutch drive plate

thickness
CLUTCH DRIVEN PLATES

Measure each clutch driven plate for distortion using
the thickness gauge. If a clutch driven plate is not within
the service limit, replace the clutch plates as a set.
Clutch driven plate
distortion
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Measure the thickness and claw width of the clutch drive

plates using vernier calipers. If a clutch drive plate is not
within the service limit, replace the clutch plates as a
set.
CLUTCH DRIVE PLATES
Service limit
0.1 mm (0.004 in)
ENGINE 3-30
CLUTCH SPRING FREE LENGTH

Measure the free length of each clutch spring using
vernier calipers. If any spring is not within the service
limit, replace all of the spring.
Service limit
Clutch spring
free length
36.2 mm (1.43 in) 29.5 mm (1.16 in)
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Inspect the clutch release bearing for any abnormality,

especially cracks. When removing the bearing from the
clutch, decide whether it can be reused or if it should be
replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
CLUTCH RELEASE BEARING
PRIMARY DRIVEN GEAR
Inspect the primary driven gear bearing for any damage.

If any abnormal condition are found, replace the primary
driven gear.
OIL PUMP
Turn the oil pump shaft and check that rotation is
smooth. If any abnormal condition is found, replace the
oil pump with new one.
3-31 ENGINE
GEARSHIFT SHAFT
Disassemble and reassemble the gearshift shaft as
shown in right picture.
TRANSMISSION
INSPECTION
GEAR-SHIFTING FORK
Service limit
0.10~0.30 mm
0.5 mm
(0.004~0.012 in)
(0.020 in)

Shift fork groove
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width
Standard
5.0~5.1 mm
5.0~5.1 mm
(0.197~0.201 in) (0.197~0.201 in)
NO.3
5.0~5.1 mm
5.5~5.6 mm
(0.197~0.201 in) (0.217~0.221 in)
Shift fork
Standard
NO.1 & NO.2

NO.3
NO.1 & NO.2
thickness
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Standard
Shift fork-groove
clearance
Using a thickness gauge, check the clearance between

in the groove of its gear and shifting fork.
The clearance for each of the three shifting forks plays
an important role in the smoothness and positiveness of
shifting action.
If the clearance checked is noted to exceed the limit
specified, replace the fork or its gear, or both.
4.8~4.9 mm
4.8~4.9 mm
(0.189~0.193 in) (0.189~0.193 in)

4.8~4.9 mm
5.3~5.4 mm
(0.189~0.193 in) (0.209~0.213 in)
REASSEMBLY
Assemble the countershaft and drive shaft in the reverse
order of disassembly. Pay attention to following points :
NOTE
Before installing the gears, coat lightly engine oil
to the driveshaft and countershaft.
ENGINE 3-32
CAUTION
Never reuse a circlip. After a circlip has been
removed from a shaft, it should be discarded
and a new circlip must be installed.
When installing a new circlip, care must be
taken not to expand the end gap larger than
required to slip the circlip over the shaft.
After installing a circlip, always ensure that it
is completely seated in its groove and securely
fitted.
Thrust
When installing a new circlip, pay attention to the

direction of the circlip. Fit it to the side where the
thrust is as shown in figure.
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Thickness for washers, circlips and spacers

1.0mm 1.0mm
1.2mm 1.0mm
0.5mm
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TRANSMISSION GEARS AND RELATED PARTS
3-33 ENGINE
Thickness for washers, circlips and spacers

1.2mm 6.0mm
0.5mm 1.0mm
1.0mm
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CRANKCASE
BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for
abnormal play, noise and smooth rotation while the
bearings are in the crankcase.
Replace the bearing in the following procedure if there is
anything unusual.
play
play
ENGINE 3-34
DISASSEMBLY
RIGHT CRANKCASE BEARING
Remove the bearing retainer.
Remove the bearings and .
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Bearing remover(17 mm) : 09923-73210

Bearing remover(20~35 mm) : 09923-74510
Remove the bearing .

CAUTION
The removed bearing should be replace with a

new one.
LEFT CRANKCASE BEARING
Remove the oil seals and .

3-35 ENGINE
Remove the bearing retainer.
Remove the bearings , and .
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Bearing remover(17 mm) : 09923-73210

Bearing remover(20~35 mm) : 09923-74510
REASSEMBLY
RIGHT CRANKCASE BEARING
Drive in the bearings , and .

LEFT CRANKCASE BEARING
Drive in the bearings , and .

ENGINE 3-36
Install the oil seals and .

Apply SUPER GREASEAon the lip of oil seal.
SUPER GREASEA
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Make sure to coat the rotating and sliding sections with engine oil.
CAUTION
CRANKSHAFT
Using the special tool, press in the crankshaft into the

left crankcase.
Crankshaft installer : 09910-32812

CAUTION
Never fit the crankshaft into crankcase by striking it with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.
TRANSMISSION
Install the transmission.
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The engine reassembly can be performed in the reverse

order of disassembly procedures. However, the following points must be observed in the reassembly operation.
ENGINE REASSEMBLY
3-37 ENGINE
GEARSHIFT CAM AND GEARSHIFT

FORKS
Install the gearshift fork NO.1 , NO.2 , and NO.3
.
Install the gearshift cam , and gearshift fork shaft
, .
Install the oil pump idle gear shaft .
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Install the dowel pins .

Before assembling the crankcase, apply the engine
oil to each gear and bearing.
Apply BOND1215to the right crankcase.

BOND1215
CAUTION
Application of BOND1215must be performed within a short period of time.

Take extreme care not to let BOND1215
enter into the oil hole or bearing.
Install the crankcase.

Install the crankcase bolts.
Crankcase bolt
: 8~12 Nm(0.8~1.2 kgm)
ENGINE 3-38
NOTE
After the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly.
If these shafts do not rotate smoothly, try to
free it by tapping with a plastic hammer.
Install the oil seal retainer.
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SUPER GREASEA
Apply the SUPER GREASEAto the driveshaft Oring and oil seal lip.
Install the driveshaft spacer.
GEARSHIFT CAM DRIVEN GEAR

When installing the gearshift into the cam driven
gear, the big shoulder face toward outside as
shown in figure.
Install the cam guide and pawl lifter.
When installed, apply the THREAD LOCK1324to
the securing screw.
THREAD LOCK1324
A
A
A
A
3-39 ENGINE
GEARSHIFT SHAFT
Install the gear shifting shaft. Match the center teeth of
the gear on the shifting shaft with the center teeth on the
shifting driven gear as shown.
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After the cam driven gear, cam guide, gear shift

shaft and neutral cam stopper have been fitted,
confirm that gear change is normal while turning,
the countshaft and driveshaft. If gear change is
not obtained, it means that assembly of gears or
installation of gear shifting fork is incorrect. In
this case, disassemble and trace the mistake.
CAUTION
OIL PUMP
Before installing the oil pump, apply the engine oil to

the contact face of case, outer rotor, inner rotor and
shaft.
Apply a small quantity THREAD LOCK1324to the
oil pump securing screws.
THREAD LOCK1324
Tighten the oil pump securing screws.

Install the oil pump pin.
Put in the oil pump driven gear, and install the circlip.
5th
4th
3rd
2nd
N
1st
ENGINE 3-40
CAUTION
When installing the oil pump to the crankcase,
turn the pump gear and check that rotation is
smooth by the hand.
CAM CHAIN TENSIONER

Install the washer and cam chain tensioner ,
tighten the cam chain tensioner bolt.
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Cam chain tensioner bolt

: 6~8 Nm(0.6~0.8 kgm)
Install the cam chain and key.
Install the primary drive gear and NO.2 gear to the

crankshaft, put in the key to the key groove.
Align the key groove and

mark.
CAUTION
When installing the NO.2 gear, install so that the
mark on the gear align the key groove as shown
in figure.
No.2 Gear
3-41 ENGINE
CAUTION
Pay attention to the two washer to lower end of the
primary drive gear nut in times of assemblage.
With the magneto rotor held immovable using special

tool, tighten the primary drive gear nut.
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Primary drive gear nut

: 40~60 Nm(4.0~6.0 kgm)
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PRIMARY DIRVEN GEAR
NOTE
Valve clearance should be checked when the

engine is cold.
Both the intake and exhaust valves must be
checked and adjusted when the piston is at TopDead-Center (TDC) of the compression stroke.
Install the primary driven gear assembly.
CLUTCH
Install the clutch sleeve hub , lock washer .
ENGINE 3-42
Install the clutch sleeve hub nut, and tighten it to the

specified torque using the special tool.
Clutch sleeve hub holder : 09920-53710
Clutch sleeve hub nut
: 30~50 Nm(3.0~5.0 kgm)
Bend the lock washer securely.
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Install the clutch drive plates and driven plates.
Install the clutch release rack , bearing and

washer .
3-43 ENGINE
Install the clutch pressure plate , clutch springs

and clutch spring mounting bolts.
Hold the primary drive gear nut and tighten the clutch
spring mounting bolts in a crisscross pattern.
NOTE
Make sure that the clutch pressure plate is
installed correctly.
CLUTCH COVER
Install the two dowel pins and new gasket .
Apply engine oil to each gears, bearings and clutch
plates.
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Install the clutch cover, and tighten the clutch cover

bolts securely.
Install the clutch release arm as following:

Turn the clutch release shaft toward(This time,
mark on the shaft align outside contact line the
stopper screw) the right.
Install that the cable connecting center line of the
clutch release arm align matching mark rightside of
the case as shown in the right figure.
Stopper screw
Clutch release
arm bolt
Release camshaft
notch mark
Clutch release
arm
Crankcase
matching mark
ENGINE 3-44
NEUTRAL CAM STOPPER

Put in the neutral cam stopper, spring and washer,
tighten the cam stopper plug to the specified torque.
Neutral cam stopper plug
: 20~25 Nm(2.0~2.5 kgm)
OIL DRAIN PLUG

Tighten the oil drain plug to the specified torque.
Engine oil drain plug
: 18~20 Nm(1.8~2.0 kgm)
STATOR
STARTER CLUTCH
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THREAD LOCK1324

the threaded parts of screws.
When installing the starter clutch and rotor, apply the

THREAD LOCK1324to the bolts and tighten to
the specified torque.
THREAD LOCK1324
Starter clutch bolt

: 15~20 Nm(1.5~2.0 kgm)
MAGNETO ROTOR
Fit the key in the key slot on the crankshaft.
With the magneto rotor, install the starter clutch
on the crankshaft.
the threaded parts of crankshaft.
THREAD LOCK1324
3-45 ENGINE
Tighten the magneto rotor nut to the specified torque.

Magneto rotor nut
: 50~60 Nm(5.0~6.0 kgm)
STARTER IDLE GEAR AND MOTOR
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Install the starter idle gear, shaft and spacer.
Install the starter motor.
MAGNETO COVER
Install the new gasket and dowel pin.
Apply oil to the each gear, bearing and starter clutch.
ENGINE 3-46
Install the magneto cover and tighten the magneto

cover bolts.
Magneto cover bolt
: 8~12 Nm (0.8~1.2 kgm)
PISTON RING
Install the piston ring in order of oil ring, 2nd ring and
1st ring at first at the front cylinder.
CAUTION
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When all the piston rings have been assembled, check that each can turn smoothly.
To minimize compression and oil leaks, locate each
piston ring end gap in the position as shown in the
right illustration
2nd ring / side rail(Upper side)
Side rail(Lower side)
1st ring / spacer
Be careful not to cause scratch on the piston

when inserting the piston ring to the piston.
Also, do not expand the piston ring more than
necessary as the ring can break.
PISTON
Apply the MOLY PASTE to the piston pin.
MOLY PASTE
When installing the piston, turn the mark on the

piston head to exhaust side.
After the piston pin has been inserted through the
conrod, install the circlip .
CAUTION
Replace the circlip with a new one.
Place a piece of rag under the piston when
installing the circlip to prevent it from falling
into the crankcase.
CAUTION
is equipped with the two cylinder

engine, which is composed of the two piston for
the front and rear.
The classification isFfor the front andRfor
the rear.
Front
tire side
Rear
tire side
Exhaust
pipe
installation
side
Exhaust
pipe
installation
side
[Front piston]
[Rear piston]
3-47 ENGINE
CYLINDER
Apply BOND1215to the parting line of crankcase.
BOND1215
Place the dowel pin and new gasket on the

crankcase.
CAUTION
VALVE AND SPRING
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Insert the valve, with their stems coated with MOLY

PASTE.
Apply the oil to the lip of the stem seal.
The narrow pitch side of each spring face to the head
when the valve spring install. The pitch of inside
spring and outside spring is changed. The pitch of
spring is decreased from the upper side to the lower
side.
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Apply the engine oil to the conrod big end, piston and
the piston rings.
Coat the cylinder wall with oil.
Install the cylinder.
This cylinder is different from the front and rear.
With the cam chain groove of cylinder face the left side,
it is the front cylinder when the cam chain tension adjuster
be existed at the back.
Make sure to replace the gasket with a new one.
Valve spring compressor : 09916-14510

: 09916H35C00
(

: 09916H5100
(
CYLINDER HEAD
Put in the valve spring and retainer, install the cotter

with compressed the spring by using the valve spring
compressor.
CAUTION
After installing the valve cotter, tap the valve
stem end by using the plastic hammer at 2~3
times for assembly of the valve and cotter.
Fit the cylinder head and tighten the stud bolts.
CAUTION
Pay caution to prevent the cam chain from dropping into the crankcase.
Cylinder head stud bolt
: 21~25 Nm (2.1~2.5 kgm)
Broad pitch part
Head direction
Narrow pitch part
ENGINE 3-48
Tighten the cylinder head base nuts.

Cylinder head base nut
(
)
: 7~11 Nm (0.7~1.1 kgm)
(
)
: 15~20 Nm (1.5~2.0 kgm)
Tighten the two cylinder base cover nuts.
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Install the tappet and shim.
CAUTION
CAUTION
With fit the tappet, it should be replaced if turn

not smoothly by the hand.
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The tappet and shim should be installed at the

original position when removed.
If otherwise, it is difficult to adjust the valve clearance.
Fit the chain guide.
[ Front Cylinder ]
[ Rear Cylinder ]
Fit the C-ring.
Tappet
Shim
3-49 ENGINE
CAMSHAFT ASSEMBLY
Distinguish theEXmark for the exhaust camshaft,
theINmark for the intake camshaft.
Be distinguished always each camshaft what has
notch at the rightside end and leftside end of it.
When installing the camshaft and cam sprocket,
apply a small quantity THREAD LOCK1324to the
bolts and tighten with the specified torque.
EX
IN
EX
IN
THREAD LOCK1324
Camshaft sprocket bolt

: 10~12 Nm (1.0~1.2 kgm)
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Apply the engine oil to the camshaft bearings.
With pull up the camshaft drive chain, align theF

mark of magneto rotor into the punching mark of magneto cover to turn the crankshaft.(Front cylinder)
CAUTION
When adjusting the rear cylinder, align theR

mark of magneto rotor into turn counter-clockwise 285at the postion of front cylinder.
CAUTION
If turn the crankshaft without pulling up the camshaft
drive chain, the chain may be fallen off between the
crankcase and cam chain drive sprocket.
The front cylinder head install first the exhaust

camshaft, following the intake camshaft.
The rear cylinder head install first the intake as the
cam chain tension adjuster exist exhaust side.
ENGINE 3-50
The notch markof exhaust camshaft should be

aligned with the plane of cylinder head.
At that time, the2arrow of exhaust camshaft sprocket should be in a vertical position to the plane of
cylinder head when exhaust camshaft sprocket was
geared into camchain.
The notch markof intake camshaft should be
toward the outside and aligned with the plane of
cylinder head. At that time, the3arrow of intake
camshaft sprocket should be in a vertical position to
the plane of cylinder head when the intake camshaft
sprocket was geared into the camchain.
Gear into the chain at the3arrow of intake sprocket that count the 16th of chain roller pin from the
roller pin on the 2arrow of exhaust sprocket to the
intake camshaft.
CAUTION
Notch mark
The rear cylinder gear into that count the 16th of

chain roller pin from the 3 arrow of intake
sprocket to the2arrow of exhaust sprocket.
Intake
16Pin
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Exhaust
IN
EX
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Notch mark
Install the 3arrow punching mark of intake

camshaft sprocket with the surface of cylinder head
vertically.
The camshaft sprocket use the intake and exhaust (the
front and rear is different) in common, but use to distinguish according as installation with the camshaft.
Pin installation
For example,
Front exhaust : Camshaft exhaust + Front sprocket
(Install the camshaft pin at the E marking hole.)
Rear intake : Camshaft intake + Rear sprocket
(Install the camshaft pin at the RI marking hole.)
Exhaust
Intake
[ Front Cylinder ]
Exhaust
Pin installation
[ Rear Cylinder ]
Intake
3-51 ENGINE
CAUTION
The cam chain is installed to the all of three sprocket.
Be sure to lie the crankshaft until the four holder and cam chain tension adjuster are installed completely.
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16 Pin
Intake
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Exhaust
Notch mark
[Front cylinder]
16 Pin
Notch mark
Exhaust
Intake
[Rear cylinder]
NOTE
The camshaft housing should be installed in the same manner with the front engine.
ENGINE 3-52
Each camshaft housing is punched withA

B
C
D.
Put on the housingAto theAof head surface,
the housingBto theB, the housingCto the
Cand the housingDto theDas thatA
BC
Dis punched also to the cylinder head
upper surface.
Fix the four camshaft bearing holder and cam chain
guide by tightening of the bolt in order.
Install each bolt diagonally by using the wrench
pulling the shaft down.
Tighten the bolt of each camshaft bearing holder with
the same torque.
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If get damaged the head or surface of camshaft

bearing housing thrust, produce an result that the
bearing housing not was tightened.
CAUTION
Tighten the camshaft housing bolt with the specified

torque.
CAUTION
The camshaft housing bolt is made of the special

material.
This bolt is superior at the degree of hardness
more than the different high tension bolt.
Pay special caution that the different type of bolt
should not be used.
This bolt head is punched the 9mark.
Camshaft housing bolt
: 8~12 Nm(0.8~1.2 kgm)
If turn the lock shaft handle in clockwise ( )
direction, the pushrod is inserted in.
Turn the mechanial spring continually until the handle
is turned to the end.
Fix the adjuster into the cylinder block.
Lock shaft handle
3-53 ENGINE
IN.
0.1~0.2 mm
EX.
0.2~0.3 mm
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Standard
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Valve clearance
Turn the crankshaft about 10 times counter-clockwise ( ) on the basis of the magneto rotor.
If the valve clearance is within standard after measured
the valve clearance, begin the next operation.
If it is out of stanadard, adjust the valve clearance
within standard limit after disassembled the camshaft
and replaced the proper shim.
Get out the pushrod for the front to turn the lock shaft
handle in counter-clockwise ( ).
Adjust the valve clearance of rear cylinder with the

same manner of the front cylinder.(Refer to page 2-3)
CAUTION
If you don
t turn the crankshaft about 10 times
before measured the valve clearance, there is no
meaning in valve clearance.
Apply BOND1215to the surface of cylinder head

cover packing block.
BOND1215
Tighten the cylinder head cover bolts with the specified torque.
Cylinder head cover bolt
: 12~16 Nm(1.2~1.6 kgm)
ENGINE 3-54
SPARK PLUG
Install the spark plug.(Refer to page 2-5)
Install the rear cylinder head and cylinder with the

same manner which installed the front cylinder head
and cylinder.
Front Cylinder
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Rear Cylinder
GEAR POSITION SWITCH
Install the spring and contact .

Apply SUPER GREASEAto the O-ring and install
the gear postion switch.
SUPER GREASEA
FUEL SYSTEM
CONTENTS
FUEL TANK / FUEL COCK
4- 1
FUEL PUMP
4- 2
CARBURETOR
4- 4
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CAUTION
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Gasoline must be handled carefully in an area well ventilated and away from fire or sparks.
4-1 FUEL SYSTEM
FUEL TANK / FUEL COCK

REMOVAL
WARNING
Gasoline is very explosive. Extreme care must be
taken.
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Remove the front seat. (Refer to page 6-1)

Remove the fuel tank mounting bolt, and take off
the hooks.
Disconnect the fuel hose and remove the fuel
tank.
Remove the fuel cock.
FUEL SYSTEM 4-2
FUEL PUMP
(
REMOVAL
Remove the front seat and fuel tank.
Turn the fuel cock toOFF.
Disconnect the fuel hoses , .
Remove the fuel pump mounting bolts.
Remove the fuel pump lead wire coupler .
INSPECTION
WARNING
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Disconnect the fuel hose , connect the suitable

hose and insert the free end of the hose into a receptacle.
Check the fuel flow when starting the engine for few
seconds by pressing the starter switch.
If the fuel flow is not found, check the fuel cock.
If the fuel cock and hoses are not fault, replace the fuel
pump. (Refer to page 5-21)
Gasolin is very explosive. Extreme care must be

taken.
REASSEMBLY
Carry out the assembly procedure in the reverse order

of disassembly.
Connect the fuel pump lead wire coupler.
Tighten the fuel pump mounting bolts.
Connect the fuel hoses , securely.
FUEL HOSE ROUTING :

Fuel hose (To fuel cock)
Fuel hose (To carburetor)
FUEL PUMP RELAY
Remove the fuel pump relay mounting bolts and coupler.

Disconnect the fuel hose , and check the fuel
flow when starting the engine for few seconds by
pressing the starter switch.
If the fuel pump are not fault, check the fuel pump relay.
(Refer to page 5-21)
4-3 FUEL SYSTEM
FUEL PUMP
(
REMOVAL

Turn the fuel cock toOFF.
Disconnect the fuel hoses , and vacuum hose
.
INSPECTION
WARNING
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Disconnect the fuel hose , connect the suitable

hose and insert the free end of the hose into a receptacle.
Check the fuel flow when starting the engine for few
seconds by pressing the starter switch.
If the fuel flow is not found, check the fuel cock.
If the fuel cock and hoses are not fault, replace the fuel
pump.
Gasolin is very explosive. Extreme care must be

taken.
REASSEMBLY
Carry out the assembly procedure in the reverse order

of disassembly.
Tighten the fuel pump mounting bolts.
Connect the fuel hoses , and vacuum hose
securely.
FUEL HOSE ROUTING :
Fuel hose (To fuel cock)
Fuel hose (To carburetor)
Vacuum hose (To intake pipe).
FUEL SYSTEM 4-4
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CARBURETOR
4-5 FUEL SYSTEM
LOCATION OF CARBURETOR I.D.

NO.
The carburetor I.D. is stamped on the location on the
carburetor as shown in the right photo.
REMOVAL
Remove the fuel tank. (Refer to page 4-1)
Remove the fuel hose.
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Remove the throttle cables and choke cable .

Loosen the clamp screw and remove the carburetor.
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DISASSEMBLY
Remove the diaphragm cover .
Remove the spring and piston valve along with

diaphragm .
FUEL SYSTEM 4-6
Remove the jet needle cap , spring , retainer

, and jet needle .
Remove the float chamber body .
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Remove the float assembly along with the needle

valve by removing the pin.
Remove the valve seat .

Remove the main jet , jet holder and pilot jet .
4-7 FUEL SYSTEM
Remove the throttle cable bracket .
NOTE
Record the number of turn for the pilot screw

when install to confer.
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Remove the pilot screw with count and tighten the

number of turn.
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INSPECTION
Check for
stopped wear
Check the following parts for damage and clogging.

Pilot jet
Piston valve
Main jet
Starter jet
Main air jet
Gaskets and O-rings
Pilot air jet
Pilot outlet and bypass
Needle jet holder
Float
Needle valve
Jet needle
Valve seat
Foreign
substance
If any abnormal condition is found, wash the part clean.

If damage or clogging is found, replace the part with a
new one.
CLEANING
Clean all jets by using compressed air.
After cleaning, reassemble the carburetor with new
seals and gaskets.
Needle valve
FUEL SYSTEM 4-8
FLOAT HEIGHT ADJUSTMENT

To check the float height, turn the carburetor upside
down. Measure the float height while the float arm is
just contacting the needle valve using vernier calipers.
Float height
17mm (0.67 in)
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Bend the float arm as necessary to bring the

height to the specified level.
After adjustment, check the float height and the fuel
level again.
REASSEMBLY
Carburetor reassembly can be performed in the reverse

order of disassembly. When reassembling, carefully
observe the following instructions.
After cleaning, reinstall the pilot screw to the original

number of turn that is recorded during disassembly.
Fit the seal rings securely to the float chamber and

install the float chamber to the carburetor body.
Install the eight screw .
4-9 FUEL SYSTEM
Install the jet needle with the pin on the spacer

securely engaged with the hole on the piston
valve.
Align the hole of the diaphragm with passage way

on the carburetor body.
Install the eight screw .
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CAUTION
Never adjustCO adjust screw of the carburetor. If adjust at discretion, have a bad influence
upon output of the engine as the two carburetor
is disharmonious.
After the assembly and installation on the engine

have been completed, perform the following adjusment.
Throttle cable adjustment. (Refer to page 2-7)
Idle speed adjustment. (Refer to page 2-7)
ELECTRICAL SYSTEM
CONTENTS
5- 1
IGNITION SYSTEM
5- 3
CHARGING SYSTEM
5- 7
STARTER SYSTEM AND

SIDE STAND IGNITION INTERLOCK SYSTEM
5- 11
SWITCHES
5- 15
LAMP
BATTERY
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FUEL SYSTEM(
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LOCATION OF ELECTRICAL COMPONENTS
5- 16
5- 18
5- 21
5-1 ELECTRICAL SYSTEM
LOCATION OF ELECTRICAL COMPONENTS
Front brake lamp switch
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Battery
Turn signal relay
Head lamp relay
C.D.I Unit
Rear brake lamp switch
Side stand switch
Starter motor
ELECTRICAL SYSTEM 5-2
Regulator / Rectifier
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Ignition coil (NO.1 & NO.2)
Magneto
Gear position switch
Fuse
Fuel pump relay
(
IGNITION SYSTEM
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/
is started as the battery discharged ignition system without a contact point. The battery ignition system is composed a rotor with five rotor tip, the D.C CDI, the ignition coil and battery. This system ignites after get
signal from ignition timing of pick-up with the electric energy of this battery and occur the 1st electric current. Therefore, a
high voltage current is induced in the secondary winding of the ignition coil and results in strong spark between spark plug
gap.
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C.D.I Unit
Magneto
RELAY
ENGINE STOP SWITCH
REAR
IGNITION
COIL
FRONT
IGNITION
COIL
C.D.I UNIT
MAGNETO
IG.
SWITCH
FUSE
Ignition coil & Spark plug
INSPECTION
MAGNETO
Using the pocket tester, measure the resistance
between the lead wires in the following table.
Pick-up coil
G - L Approx 90110
Charging coil
Y - Y Approx 0.60.9
Pocket Tester : 09900-25002
CAUTION
G
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WIRE COLOR
L
: Blue
G
: Green
BY : Black with Yellow tracer
OB : Orange with Black tracer
Br
: Brown
BW : Black with White tracer
WL : White with Blue tracer
YG : Yellow with Green tracer
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THREAD LOCK1324
When mounting the stator on the magneto cover,

apply a small quantity of THREAD LOCK1324
to the threaded parts of screws.
CDI UNIT
Using the pocket tester(R 1 range), measure the
resistance between the terminal in the following table.
Pocket Tester : 09900-25002
Unit : k
CAUTION
Numberical value may differ a little according

to the tester.
Please remind that there may be a defect
which can not be identified even though the
measurement by using the tester indicates a
low voltage.
The range of measurement adjust a [ X 1 ]
unit.
CAUTION
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IGNITION COIL
Pull out the spark plug.
Place it on the cylinder head after installing it at the
plug cap to obtain ground.
Push in the electric starter switch to rotate the starter
motor, to have the test of sparking performance.
If not emited spark or the spark bring out the orange
color, replace the ignition coil.
Rear cylinder ignition coil
Front cylinder ignition coil
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The ignition coil is marked theFfor front, and

theRfor rear.
If otherwise, it may occure severe damage to the
engine.
B/R
IGNITION COIL (Checking with Pocket Tester)

A pocket tester or an ohm meter may be used,
instead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary windings. Exact ohmic readings are
not necessary, but, if the windings are in sound
condition, their continuity will be noted with approximate ohmic values.
Ignition coil resistance
Primary
0.190.24 Tester knob indication 1 range
Secondary 5.46.6
Tester knob indication 1 range
Check to attached plug cap

Pocket tester : 09900-25002
Ground
Plug cap
SPARK PLUG
Clean the plug with a wire brush and pin. Use the pin to
remove carbon, taking care not to damage the porcelain.
Check the gap with a thickness gauge.

0.7 0.8 mm
(0.028 0.032 in)
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Spark plug gap
0.7 0.8 mm
(0.028 0.032 in)
CHARGING SYSTEM
The circuit of the charging system is indicated in figure, which is composed of the AC generator, regulator / rectifier unit and battery. The AC current generated from the AC generator is converted by the rectifier and is
turned into the DC current, then it charges the battery.
IG. switch
Battery
Control
unit
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A. C generator
L
O
A
D
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FUNCTION OF REGULATOR
While the engine rpm is low and the generated current of the AC generator is lower than the adjusted voltage of
the regulator, the regulator does not function, incidentally the generated current charges the battery directly.
IG. switch
Battery
Control
unit
A. C generator
L
O
A
D
When the engine rpm become higher, the generated voltage of the AC generator also becomes higher and the
voltage between points and of the regulator according becomes high, and when it reaches the adjusted
voltage of the control unit, consequently the control unit becomesONcondition. On theONcondition of the
control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will becomeONcondition. Then
the SCR becomes conductive to the direction from point to point . Namely at the state of this, the current
generated from the AC generator gets through SCR without charging the battery and returns to the AC generator
again. At the end of this state, since the AC current generated from the AC generator flows into the point , reverse
current tends to flow to SCR, then the circuit of SCR turns toOFFmode and begins to charge the battery again.
Thus these repetitions maintain charging constant voltage to the battry and protect it from overcharging.
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IG. switch
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A. C generator
Control
unit
Battery
L
O
A
D
INSPECTION
CHARGING OUTPUT CHECK
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the DC voltage
between the battery terminal and .
If the tester reads under 14.0 V or over 15.0 V, check
the magneto no-load performance and regulator /
rectifier.
CAUTION
When making this test, be sure that the battery is
full-charged condition.
IG. switch
14.015.0 V (at 5,000 rpm)
Regulator
Rectifier
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Standard charge
MAGNETO NO-LOAD PERFORMANCE

Disconnect the three lead wires from the magneto
terminal.
Start the engine and keep it running at 5,000 rpm.
Using the pocket tester, measure the AC voltage
between the three lead wires.
If the tester reads under 67 V or over 99 V the magneto
is faulty.
Standard NO-load perfor6799 V (at 5,000 rpm)
mance of magneto
Battery
DCV
REGULATOR / RECTIFIER
Disconnect the coupler.
Using the multi-tester ( 1 range), measure the
resistance between the terminals in the following
table.
If the resistance checked is incorrect, replace the regu
lator / rectifier.
Unit :
0.82 0.82 0.82 3055
0.82
0.82
0.82
0.82
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3055 0.82 0.82 0.82
0.82
0.82
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Probe of tester
Probe of tester
STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM

STARTER SYSTEM DESCRIPTION
The starter system consists of the following components : the starter motor, starter relay, clutch lever position
switch, C.D.I unit, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery.
Pressing the starter switch (on the right handlebar switch) energizes the starter relay, causing the contact
points to close, thus completing the circuit from the starter motor to the battery.
START RELAY
CLUTCH LEVER
SWITCH
FUSE
ENGINE STOP
SWITCH
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START
SWITCH
MAIN SWITCH
SIDE STAND
SWITCH
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NEUTRAL
SWITCH
BATTERY
SIDE STAND / IGNITION INTERLOCK SYSTEM DESCRIPTION
This side stand / ignition interlock system prevents the motorcycle from being started with side stand down.
The system is operated by an electric circuit provided between the battery and ignition coil.
The circuit consists of the C.D.I unit, neutral indicator light and switches.
The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side stand is either up or down.
The gear position and side stand switches work together in this system.
The ignition coil work only in two situations as follows.
FUSE
IGNITION
SWITCH
ENGINE STOP
SWITCH
IGNITION COIL
NEUTRAL
INDICATOR LIGHT
CDI
Unit
BATTERY
GEAR
POSITION
SWITCH
SIDE STAND SWITCH

DOWN POSITION
TRANSMISSION : Neutral -ON

Side stand - Down
( OFF)
IGNITION SWITCH
ON
IGNITION COIL
BATTERY
NEUTRAL
INDICATOR LIGHT
CDI
Unit
SIDE STAND SWITCH

DOWN POSITION
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IGNITION SWITCH
TRANSMISSION : Neutral -OFF

Side stand - Up
( ON)
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GEAR POSITION
SWITCHON
ON
BATTERY
IGNITION COIL
CDI
Unit
NEUTRAL
INDICATOR LIGHT
SIDE STAND SWITCH

GEAR POSITION
UP POSITION
SWITCHOFF
/
is equipped with the side stand ignition interlock system.
1. If the transmission is in neutral, you can start the engine regardless of clutch lever and side stand.
2. If the transmission is not in neutral, you can only start the engine with pulling in clutch lever and side stand up.
No Neutral switch Clutch lever
Side stand
Engine Start
NOTE
Possible
Possible
On or Up.
Impossible
Off or Down
Impossible
STARTER MOTOR REMOVAL AND

DISASSEMBLY
Disconnect the starter motor lead wire .
With loosen the bolt , remove the starter motor.
Disassemble the starter motor.
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CARBON BRUSH
Inspect the brushes for abnormal wear, crack
or smoothness in the brush holder.
If the brush has failed, replace the brush sub assy.
STARTER MOTOR INSPECTION
COMMUTATOR
Inspect the commutator for discoloration, abnormal
wear or undercut .
If the commutator is abnomally worn, replace the
armature.
When surface is discolored, polish it with #400
sand paper and clean it with dry cloth.
ARMATURE COIL INSPECTION

Check for continuity between each segment.
Check for continuity between each segment and
the armature shaft.
If there is no continuity between the segments or
there is continuity between the segment and shaft,
replace the starter motor with a new one.
Segment
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STARTER MOTOR REASSEMBLY

Reassemble the starter motor. Pay attention to the following points :
Reassembly the starter motor as shown in the illustration.
Align the mark on the housing with the line

on the housing end.
Apply SUPER GREASE Ato the O-ring

and remount the starter motor.
SUPER GREASEA
SWITCHES
Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch
assemblies with new ones.
IGNITION SWITCH
O
BR
OB
OFF
LOCK
BW
ON
ENGINE STOP SWITCH
STARTER SWITCH
Gr
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LIGHT SWITCH
ON
OB
YG
OFF
HI
LO
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YW
TURN SIGNAL SWITCH
PUSH
R
Sb
Lg
HORN SWITCH
DIMMER SWITCH
ON
BW
OFF
FRONT/REAR BRAKE LAMP SWITCH
ON
OFF
WB
LAMP
HEADLAMP
&
Rear
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TURN SIGNAL LAMP
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TAIL / BRAKE LAMP
Front
COMBINATION METER
CAUTION
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INSPECTION
Using the pocket tester, check the continuity between
lead wires in the following illustration.
If the continuity measured incorrect, replace the respective part.
Remove the combination meter.

Disassemble the combination meter as shown in the
illustration.
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When making this test, it is not necessary to

remove the combination meter.
BATTERY
CAUTION OF BATTERY TREATMENT
The battery needs attention generally as it occur flammability gas.
If you dont follow the instruction in the below, there may be a explosion and severe accident.
Therefore, please pay attention to the following points.
Prohibit positively battery from contacting to short, spark or firearms.
The recharge of battery should be done in the wide place where the wind is well ventilated.
Please dont recharge it at the sight of wind-proof.
CAUTION OF BATTERY ELECTROLYTE TREATMENT
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Pay attention for the battery electrolyte not to stains the chassis or the humanbody.
If stains the chassis or the humanbody, at once wash a vast quantity of water.
When it be stained, clothes should come into being a hole or painting should take off.
Be cured from a doctor.
When the battery electrolyte was dropped to the surface of land, wash a vast quantity of water.
Neutralize by hydroxide, bicarbonate of soda and so on.
CAUTION OF MAINTENANCE FREE

BATTERY TREATMENT
Do not remove the aluminum tape to seal the battery

electrolyte filler hole untill use as battery of completely
seal type.
Do not use it except the battery electrolyte.
When pour into the battery electrolyte, necessarily
use the electrolyte of the specified capacity.
Do not open the sealing cap after recharge the battery eletrolyte.
Filling electrolyte.
Put the battery on even land and remove the aluminum tape sealing.
Remove the cap at the electrolyte container.
CAUTION
Do not remove the seal of the electrolyte
container, not prick with sharp thing.
Aluminum tape
Filler holes
CAUTION
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The pouring of electrolyte may not be done if

the electrolyte container is pushed slopely.
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Pouring of battery electrolyte

When insert the nozzles of the electrolyte container into
the batterys electrolyte filler holes, holding the container
firmly so that it does not fall.
Take precaution not to allow any fluid to spill.
Cap
Confirmation of pour
Make sure that air bubbles are coming up each
electrolyte container, and keep this position for more
than about 20 minutes.
CAUTION
If no air bubbles are coming up from a filler
port, tap the buttom of the two or three times.
Air bubble
Seal
Separation of electrolyte container

After confirming that you entered the electrolyte into battery completely, remove the electrolyte containers from
the battery.
CAUTION
Draw the empty receptacle out slowly because
there may be a chance which remaining electrolyte vaporize.
Insert of the caps

Insert the cap into the filler holes, pressing it firmly so
that the top of the caps do not protrude above the up per
surface of the batterystop cover.
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Visually inspect the surface of the battery container. If

any signs of cracking or electrolyte leakage from the
sides of the battery have occurred, replace the battery
with a new one. If the battery terminals are found to be
coated with rust or an acidic white powdery substance,
then this can be cleaned away with sandpaper.
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Insert the caps firmly
SERVICING
RECHARGING OPERATION
Using the pocket tester, check the battery voltage. If

the voltage reading is less than the 12.0V (DC),
recharge the battery with a battery charger.
CAUTION
When recharging the battery, remove the battery

from the motorcycle.
NOTE
Do not remove the caps on the battery top while

recharging.
CAUTION
Be careful not to permit the charging current to
exceed 3A at any time.
After recharging, wait for more than 30 minutes and
check the battery voltage with a pocket tester.
If the battery voltage is less than the 12.5V, recharge
the battery again.
If battery voltage is still less than 12.5V, after
recharging, replace the battery with a new one.
When the motorcycle is not used for a long period,
check the battery every 1 month to prevent the battery discharge.
How to charge
Standard
1.4 A 10 hours
Fast
6 A 30 minutes
FUEL SYSTEM (
FUEL PUMP
Remove the fuel pump lead wire coupler.
Using the pocket tester (X 1 range), measure the
table.
If the resistance checked is incorrect, replace the
fuel pump.
Fuel pump resistance
4.5 ~ 10.0 (BW-BL)
FUEL PUMP RELAY
Remove the fuel pump relay coupler.

Using the pocket tester (X 1 range), measure the
table.
If the resistance checked is incorrect, replace the
fuel pump relay.
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Unit :
700~950
700~950
Probe of tester
Probe of tester
CHASSIS
CONTENTS
EXTERIOR PARTS
6- 1
FRONT WHEEL
6- 2
FRONT BRAKE
6- 6
HANDLEBARS
6- 12
6- 14
FRONT FORK
(
6- 20
REAR WHEEL
REAR BRAKE
REAR SHOCK ABSORBER
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STEERING
FRONT FORK
(
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SWING ARM
6- 27
6- 30
6- 34
6- 36
6- 37
6-1 CHASSIS
EXTERIOR PARTS
FRONT FENDER
With the bolts removed, remove the front fender.
REAR SEAT
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Remove the rear seat with the ignition key.
FRONT SEAT
To remove the front seat, pull the knob located under

the rear seat.
CHASSIS 6-2
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FRONT WHEEL
REMOVAL
Loosen the axle pinch bolt , right and left.
Loosen the front axle .
Raise the front wheel off the ground with a block
or jack.
CAUTION
When using a jack, take care not to cause
scratches on the chassis.
Remove the front wheel by removing the front axle
.
6-3 CHASSIS
Remove the brake disc.
INSPECTION AND DISASSEMBLY

TIRE
For inspection of the tire : Refer to page 2-18.
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Service limit
Axle shaft runout
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0.25 mm (0.01 in)
Dial gauge : 09900-20606

V-block : 09900-21304
FRONT AXLE
Measure the front axle runout using the dial gauge. If
the runout exceeds the limit, replace the front axle.
WHEEL
Make sure that the wheel runout (axial and radial) does
not exceed the service limit when checked as shown.
An excessive amount of runout is usually due to worn or
loose wheel bearings and can be corrected by replacing
the bearings. If bearing replacement fails to reduce the
wheel.
Wheel runout
Service limit
(axial and radial)
2.0 mm (0.08 in)
WHEEL BEARING
Inspect the play of the wheel bearings by finger while
they are in the wheel. Rotate the inner race by finger to
inspect for abnormal noise and smooth rotation.
Replace the bearing in the following procedure if there is
anything unusual.
CHASSIS 6-4
WHEEL BEARING REMOVAL

Remove the wheel bearing by using the special tool.
Wheel bearing remover : 09941-50111
CAUTION
The removed bearing should be replaced with
new ones.
WHEEL BEARING
Apply SUPER GREASEAto the wheel bearings.
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SUPER GREASEA
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Reassemble the front wheel in the reverse order of

removal and disassembly.
Pay attention to the following points :
REASSEMBLY
Install the wheel bearings as follows by using the

special tools.
Steering race installer : 09941-34513
CAUTION
First install the right wheel bearing, then install

the left wheel bearing.
BRAKE DISC
Make sure that the brake disc is clean and free of any
greasy matter.
Apply THREAD LOCK1324to the disc mounting
bolts and tighten them to the specified torque.
Brake disc bolt
: 18~28 Nm (1.8 ~2.8 kgm)
THREAD LOCK1324
6-5 CHASSIS
Tighten the front axle bolt and axle pinch bolt to

Front axle bolt : 50~80 Nm (5.0 ~8.0 kgm)
Front axle pinch bolt
: 15~25 Nm (1.5 ~2.5 kgm)
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CHASSIS 6-6
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FRONT BRAKE
WARNING
Do not mix with brake fluid of different brand.
Do not use a brake fluid kept in an open container or stored for long period of time.
To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of
children.
When filling brake fluid, take care not to allow water or dirt to enter the system.
To wash the brake system parts, use brake fluid and not any other material.
Do not allow dirt and fluid to contact the brake disc or pad.
6-7 CHASSIS
CAUTION
Do not allow brake fluid to contact the paint surface, plastic or rubber parts, or its chemical reaction can cause
discoloration or crack.
BRAKE FLUID REPLACEMENT

For replacing procedure of brake fluid : Refer to page 2-15
BRAKE PAD REPLACEMENT

For replacing procedure of brake pad : Refer to page 2-14
Drain brake fluid. (Refer to page 2-15)
CAUTION
To prevent brake fluid from splashing on the

parts nearby, cover the parts with cloth.
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CALIPER DISASSEMBLY
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Remove the union bolt and caliper mounting bolts

.
Remove the brake pad. (Refer to page 2-14)
Remove the brake caliper holder .
Using an air gun, push out the caliper piston.
WARNING
Place a rag over the piston to prevent it from
popping out and flying and keeping hand off
the piston.
Be careful of brake fluid which can possibly
splash.
Do not use high pressure air but increase the
pressure gradually.
CHASSIS 6-8
Remove the dust seal and piston seal .
CAUTION
Care not to cause scratch on the cylinder bore.
Do not reuse the piston seal and dust seal that
have been removed.
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Inspect the caliper cylinder wall and piston surface for

scratch, corrosion or other damages.
If any abnormal condition is noted, replace the caliper.
CALIPER INSPECTION
CALIPER REASSEMBLY
Reassemble the caliper in the reverse order of disassembly procedures and observe the following points.
CAUTION
Wash the caliper components with fresh brake

fluid before reassembly. Do not wipe off brake
fluid after washing the components.
Replace the piston seal and dust seal with new
ones with brake fluid applied.
Brake fluid specification and classification
: DOT 3 or DOT 4
Install the brake pad spring.
6-9 CHASSIS
Apply SILICONE GREASE to the brake caliper holder.

SILICONE GREASE
Install the brake pads. (Refer to page 2-14)
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Fill the system with brake fluid and bleed air. (Refer to
page 2-16)
Inspection after reassembly : Refer to page 2-14
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Front brake caliper mounting bolts

:18~28 Nm (1.8~2.8 kgm)
Front brake hose union bolts
:20~25 Nm (2.0~2.5 kgm)
Tighten the caliper mounting bolts .

With the hose end seated to the stopper, tighten the
union bolt
BRAKE DISC INSPECTION
Check the brake disc for damage or cracks. Measure the

thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if damage is found.
Micrometer (025 mm) : 09900-20201

Brake disc thickness
Service limit
3.0 mm (0.12 in)
Measure the runout using the dial gauge.

Replace the brake disc if the runout exceeds the service
limit.
Dial gauge : 09900-20606
Brake disc runout
Service limit
0.3 mm (0.012 in)
If either measurement exceeds the service limit,

replace the brake disc. (Refer to page 6-3)
CHASSIS 6-10
MASTER CYLINDER DISASSEMBLY

Drain brake fluid the master cylinder.
Disconnect the brake lamp switch lead wire coupler.
Remove the union bolt .
CAUTION
Place a rag under the union bolt so that brake
fluid can not contact the parts.
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Remove the two clamp bolts and take off the master
cylinder.
Remove the two fitting screws and separate the cap

and diaphragm.
Detach the dust seal boot and remove the circlip.

Pull out the piston/cup set and spring .
6-11 CHASSIS
MASTER CYLINDER INSPECTION

Inspect the master cylinder bore for any scratches or
other damage.
Inspect the piston surface for any scratches or other
damage.
MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse order of
disassembly.
Specification and Classification

: DOT 3 or DOT 4
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Wash the master cylider components with new

brake fluid before reassembly.
When washing the components, use the specified brake fluid. Never use different types of
fluid or cleaning solvents such as gasoline,
kerosine, etc.
CAUTION
NOTE
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When installing the circlip, make sure that the sharp

edge of the circlip faces outside.
Master Cylinder
When remounting the master cylinder to the

handlebars, first tighten the clamp bolts for
upside as shown.
WARNING
Up
Bleed air from the brake fluid circuit after

reassembling master cylinder.(See page 2-16)
Handlebar
Clearance
CHASSIS 6-12
HANDLEBARS
HANDLEBARS RIGHT SIDE PARTS
REMOVAL
Remove the right handlebar switches.

Disconnect the brake lamp switch lead wires and
remove the master cylinder. (Refer to page 6-10)
Remove the handlebar balancer and grip .
HANDLEBARS LEFT SIDE PARTS

REMOVAL
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Remove the left handlebar switches.

Remove the handlebar balancer and grip .
Remove the clutch lever holder.
Remove the clamp bolts and detach the handlebar

holders.
Remove the handlebar.
REMOUNTING
Perform the remounting work in the reverse order of the
removal procedures while observing the following
instructions.
Install the handlebars with the punch mark aligned
with the handlebar clamp as shown.
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolts
: 18~28 Nm (1.8 ~2.8 kgm)
6-13 CHASSIS
NOTE
The gap between the handlebar clamp and
holder should be even.
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SUPER GREASEA
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Align the mating face of clutch lever holders with the

respective punch marks and tighten the bolt.
Install the brake master cylinder. (Refer to page 611).
Apply SUPER GREASEAto the throttle cables
and assemble them.
CHASSIS 6-14
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FRONT FORK
(
6-15 CHASSIS
REMOVAL AND DISASSEMBLY
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Loosen the front fork upper and lower clamp

bolts.
Remove the front brake hose clamp.
Pull down right and left front forks.
Take off the front wheel. (See page 6-2)
Remove the front fork cap, O-ring , and seat

lever.
CAUTION
To remove the O-ring , it will be necessary to

push the seat lever inwards, to remove the
spring pressure from the O-ring.
The removed O-ring should be replaced
with a new one.
Straighten the fork and stroke it several times to

remove the oil.
Hold the fork inverted for a few minutes.
CHASSIS 6-16
Remove the damper rod bolt by using the special tool.

T
Handle : 09940-34520
D
Attachment : 09940-34561
T
Type hexagon wrench (6mm)
: 09914-25811
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Separate the inner tube from outer tube.

Remove oil lock piece and damper rod with
rebound spring.
Remove the snap ring by using the snap ring plier.
Remove the oil seal by using the special tool.

CAUTION
The oil seal removed should be replaced with a new
one.
6-17 CHASSIS
INSPECTION
DAMPER ROD RING
Inspect the damper rod ring for wear and damage.
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INNER TUBE AND OUTER TUBE

Inspect the inner tube and outer tube sliding surfaces
for any scuffing or flaws.
FORK SPRING
Measure the fork spring free length . If it is shorter
than the service limit, replace it.
Standard
433.3 mm (17.1 in)
Fork spring free length
REASSEMBLY
Reassemble and remount the front fork in the
reverse order of disassembly and removal, and also
carry out the following steps :
CHASSIS 6-18
DAMPER ROD BOLT

Apply Bond 1215and Thread Lock 1324
to the damper rod bolt and tighten the bolt
with specified torque by the Special tool
Bond1215
Thread Lock1324
T
Handle : 09940-34520
D
Attachment : 09940-34561
T
Type hexagon wrench (6mm) : 09914-25811
Front fork damper rod bolt
40 N
m (3.0
4.0 kgm)
: 30
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OIL SEAL
Install the oil seal to the outer tube by using the
special tool as shown.
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Fork oil seal installer : 09940-50112
FORK OIL
For the fork oil, be sure to use a front fork oil whose
viscosity rating meets specifications below.
Fornt fork
oil capacity
Front fork oil specification : TELUS #22

Each leg
400 2.5cc
Hold the front fork vertical and adjust the fork oil level
with the special tool.
Front fork oil level
Standard
146 mm (5.8 in)
Front fork level gauge : 09943-74111
CAUTION
When adjusting oil level, remove the fork spring and
compress the inner tube fully.
6-19 CHASSIS
FORK SPRING
The narrow pitch side of spring face to the upper side
when installing the front fork spring.
Up side
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Always use a new stopper ring.

After installing a stopper ring, always insure that
it is completely seated in its groove and securely
fitted.
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CAUTION
STOPPER RING
To install a new stopper ring, it will be necessary to
push the spring seat inward.
REMOUNTING
Tighten the upper and lower clamp bolts.
m
Front fork upper clamp bolts : 22~35 N
m)
(2.2~3.5 kg
m
Front fork lower clamp bolts : 22~35 N
m)
(2.2~3.5 kg
CHASSIS 6-20
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FRONT FORK
(
6-21 CHASSIS
DISASSEMBLY
Remove the front wheel. (Refer to page 6-2)
Remove the brake caliper. (Refer to page 6-7)
CAUTION
Secure the brake caliper to the frame with a string
etc., taking care not to bend the brake hose.
Remove the front fender. (Refer to page 6-1)
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Slightly loosen the front fork upper bolt to

facilitate later disassembly.
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NOTE
Remove the front fork after loosening the front fork

upper and lower clamp bolts .
Remove the front fork upper bolt , O-ring , front

fork inner spacer and spring guide .
Invert the front fork and stroke it several times to

drain out the fork oil.
Hold the front fork in the inverted position for a few
minutes to allow the fork oil to fully drain.
CHASSIS 6-22
With the damper rod held immovable, remove

the damper rod bolt.
Remove the damper rod and rebound spring
from the inner tube.
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Remove the dust seal and oil seal stopper ring .
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Separate the inner tube from the outer tube.
Remove the following parts.

Oil seal
Slide metal
Oil lock piece
CAUTION
The removed oil seal and slide metal should be

replaced with new ones.
6-23 CHASSIS
INSPECTION
FRONT FORK SPRING
Measure the free length of the front fork spring .
If the length is found shorter than the service limit,
replace the spring.
Fork spring free length
Service limit
354 mm (13.9 in)
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INNER TUBE AND OUTER TUBE

Check the sliding surface of the inner tube, outer
tube and damper rod ring for scratch, wear, bending, or other abnormal condition.
REASSEMBLY
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Perform the reassembly and remounting work in the

reverse order of the disassembly and removal procedures while observing the following instructions.
CAUTION
Thoroughly wash all the component parts being assembled.

Insufficient washing can result in oil leakage or premature wear of the parts.
When reassembling the front fork, use new fork oil.
Use the specified fork oil for the front fork.
When reassembling, replace the slide metals, oil seal, dust seal and damper rod bolt gasket with new ones.
On the inner tube, assemble the following parts.

Dust seal
Oil seal stopper ring
Oil seal
Oil seal retainer
Slide metal
Guide bushing
CAUTION
To prevent the lip of oil seal from being damaged, cover the inner tube with vinyl sheet during installation.
CHASSIS 6-24
With the oil lock piece fitted to the inner tube, assemble the inner tube to the outer tube.
Front fork oil seal installer set

: 09940-52861
CAUTION
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SUPER GREASEA
Apply SUPER GREASEAto the lip of the oil seal

and install it into the outer tube using the front fork
oil seal installer.
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Wash and clean the front fork oil seal installer

before using. If dirt is on the installer, the inner
tube may possibly be damaged during press-fitting work.
Fit the stopper ring and dust seal .
CAUTION
Make sure that the stopper ring is securely fitted

into the groove on the outer tube.
Dust seal
Oil seal stopper ring
Oil seal
Oil seal retainer
Slide metal
Fit the rebound spring on the damper rod and

install them together to the inner tube.
6-25 CHASSIS
Apply THREAD LOCK1324to the damper rod bolt

.
With the damper rod held immovable, with the gasket
fitted, tighten the damper rod bolt .

: 30~40 Nm (3.0~4.0 kgm)
THREAD LOCK1324
CAUTION
Front fork oil specification : TELLUS #22

Each leg
Front fork oil capacity
262 cc
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FRONT FORK OIL

With the inner tube in fully compressed position, pour
the specified amount of fork oil and stroke the tube
several times to expel air.
Replace the gasket with a new one.
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With the front fork held in vertical position, compress

the inner tube all the way.
Wait until the fluid level stabilizes, measure and

adjust the level to specification using the special tool.
Standard
155 mm (6.1 in)
Front fork oil level gauge : 09943-74111
Install the front fork spring .

Install the spring guide , front fork inner spacer ,
and O-ring .
CHASSIS 6-26
Fit the O-ring to the front fork upper bolt and apply
SUPER GREASEA.
SUPER GREASEA
CAUTION
Use a new O-ring to prevent oil lieakage.
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Front fork upper clamp bolt

: 22~35 Nm (2.2~3.5 kgm)
Front fork lower clamp bolt
: 22~35 Nm (2.2~3.5 kgm)
Front fork upper bolt
: 22~30 Nm (2.2~3.0 kgm)
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Tighten the front fork lower clamp bolts and front

fork upper bolts to the specified torque.
Tighten the front fork upper clamp bolts to the
specified torque.
Install the front fork to the motocycle.

Align the upper surface of the inner tube with the
upper surface of the steering stem upper bracket.
Install the front fender and tighten the mounting

bolts temporarily.
Install the front brake caliper. (Refer to page 6-8)
Install the front wheel. (Refer to page 6-4)
Move the front fork up and down several times.
Tighten the front fender mounting bolts securely.
6-27 CHASSIS
STEERING
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Take off the front wheel. (See page 6-2)
Remove the four bolts and front fender.
Take off the front fork. (See page 6-15, 6-21)
CHASSIS 6-28
Remove the handlebar clamp bolts.

Remove the steering stem head nut and take off
the steering stem upper bracket .
Remove the steering stem nut and draw out the

steering stem.
Clamp wrench : 09940-10122

Take off the steering stem lower bracket .
CAUTION
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Remove the upper and lower bearing .
Hold the steering stem lower bracket by hand to

prevent from falling.
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Remove the outer race fitted on the steering stem.

This can be done with a chisel.
Draw out the two inner races fitted to the top and bottem ends of the head pipe.
6-29 CHASSIS
INSPECTION
Inspect and check the removed parts for the following
abnormalities.
Handlebar distortion.
Handlebar clamp wear.
Abnormality operation of bearing.
Worn or damaged races.
Distortion of steering stem.
REASSEMBLY
Apply SUPER GREASEAto the upper bearing

and lower bearing .
Tighten the steering stem nut with the special tool.
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Clamp wrench : 09940-10122
SUPER GREASEA
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Reassemble and remount the steering stem in the

reverse order of disassembly and removal, and also
carry out the following steps :
m (8.0~10.0kg
m)
Steering stem nut : 80~100 N
Turn the steering stem right and left, lock-to-lock, five or

six times.
Tighten the steering stem head nut to the specified
torque.
m
Steering stem head nult : 80~100 N
m)
(8.0~10.0 kg
CAUTION
After performing the adjustment and installing
the steering stem upper bracket, rock the front
wheel assembly forward and backward to ensure
that there is no play and that the procedure was
accomplished correctly. If play is noticeable, readjust the steering stem nut.
Set the handlebars to match its punched mark to the
mating face of the holder.
Secure the each handlebar clamp bolts in such a way
that the clearances ahead of and behind the handlebars should be equalized.
Handlebar clamp bolts
m (1.8~2.8 kg
m)
: 18~28 N
CHASSIS 6-30
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REAR WHEEL
REMOVAL
Raise the rear wheel off the ground with a jack or
block.
Loosen the drive chain adjuster , right and left.
Disengage the drive chain from the rear sprocket.
6-31 CHASSIS
Remove the rear wheel by removing the rear axle

.
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Remove the brake disc.
Remove the spacer .

Remove the rear sprocket with mounting drum
from the rear wheel.
NOTE
Before separating the rear sprocket and mounting

drum, slightly loosen the rear sprocket bolts.
Remove the rear wheel shock absorber .
Remove the rear sprocket from the rear sprocket mounting drum.
WHEEL BEARING REMOVAL
Remove the bearing by using the special tool.
Wheel bearing remover : 09941-50111
CAUTION
The removed bearing should be replaced with
new one.
CHASSIS 6-32
INSPECTION
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REAR WHEEL SHOCK ABSORBER

Inspect the rear wheel shock absorber for wear and damage.
Replace the rear wheel shock absorber if there is anything unusual.
WHEEL AXLE : Refer to page 6-3

WHEEL : Refer to page 6-3
WHEEL BEARING : Refer to page 6-3
TIRE : Refer to page 2-18
SPROCKET
Inspect the sprocket
s teeth for wear. If they are worn,
replace the sprocket and drive chain as a set.
Normal
wear
REASSEMBLY
Reassemble the rear wheel and rear brake in the
reverse order of disassembly.
Tighten the rear sprocket nuts to the specified torque.
Rear sprocket nut
: 20~30 Nm (2.0~3.0 kgm)
Excessive
wear
6-33 CHASSIS
Install the rear wheel.

After installing the drive chain to the rear sprocket, adjust
the drive chain.
Tighten both chain adjusting nuts securely.
Tighten the rear axle nut to the specified torque.
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Rear axle nut : 90~140 Nm (9.0~14.0 kgm)
CHASSIS 6-34
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REAR BRAKE
WARNING
Do not mix with brake fluid of different brand.
Do not use a brake fluid kept in an open container or stored for long period of time.
To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of
children.
When filling brake fluid, take care not to allow water or dirt to enter the system.
To wash the brake system parts, use brake fluid and not any other material.
Do not allow dirt and fluid to contact the brake disc or pad.
6-35 CHASSIS
Brake fluid replacement : Refer to page 2-15

Brake pad replacement : Refer to page 2-14
Disassembly of caliper : Refer to page 6-7
Inspection of caliper : Refer to page 6-8
Reassembly of caliper : Refer to page 6-8
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Inspection of brake disc : Refer to page 6-9
CHASSIS 6-36
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REAR SHOCK ABSORBER
REMOVAL
Remove the rear shock absorbers by removing

their nuts.
INSPECTION
Inspect the rear shock absorber for damage and

oil leakage. If any defects are found, replace the rear
shock absorber with a new one.
CAUTION
Do not attempt to disassemble the rear shock
absorber. It is unserviceable.
REMOUNTING
Install the rear shock absorber and tighten the nuts to
Shock absorber mounting nut (upper)
m (4.0~6.0 kgm)
: 40~60 N
Shock absorber mounting nut (lower)
m (4.0~6.0 kgm)
: 40~60 N
6-37 CHASSIS
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SWINGARM

Remove the rear wheel. (See page 6-30)
Remove the rear shock absorber fitting nut and bolt.
(See page 6-36)
Remove the swing arm pivot nut.
Draw out the pivot shaft and take off the swing arm.
CHASSIS 6-38
Remove the chain case.

Remove the two spacers.
Remove the bearing by using the special tools.
Bearing remover (17 mm) : 09923-73210
Rotor remover sliding shaft : 09930-30102
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SWINGARM
Inspect the swingarm for damage.
If any defects are found, replace the swingarm with a
new one.
INSPECTION
CHAIN BUFFER
Inspect the chain buffer for wear and damage. If any
defects are found, replace the chain buffer with a new
one.
SWINGARM PIVOT SHAFT

Measure the pivot shaft runout using the dial gauge.
If the pivot shaft exceeds the service limit, replace it
with a new one.
Dial gauge : 09900-20606
V-block : 09900-21304
Swingarm pivot shaft
runout
Service limit
0.6 mm (0.024 in)
6-39 CHASSIS
REASSEMBLY
Reassemble the swingarm and rear shock absorber in
the reverse order of disassembly.
Press the needle bearings into the swingarm pivot
using the special tool.
Steering race installer : 09941-34513
Apply SUPER GREASEAto the needle bearing

and spacers.
Swingarm pivot nut

: 45~70 Nm (4.5~7.0 kgm)
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Install the swingarm and tighten the swingarm pivot

nut to the specified torque.
SUPER GREASEA
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Install the rear wheel. (Refer to page 6-32)

Install the rear shock absorber. (Refer to page 6-36)
Adjust the following points :
Drive chain slack : Refer to page 2-13
SERVICING INFORMATION
CONTENTS
TROUBLESHOOTING
7- 1
SPECIAL TOOLS
7- 8
TIGHTENING TORQUE
7-11
SERVICE DATA
7-13
(
WIRING DIAGRAM
)
)
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WIRING DIAGRAM
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WIRE AND CABLE ROUTING
7-23
(
7-27
7-31
7-32
7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint
Remedy
Adjust.
Repair or replace.
Adjust.
Replace.
Replace or rebore.
Retighten.
Consultelectrical complaints
Plug not sparking

1. Fouled spark plug.
2. Wet spark plug.
3. Defective ignition coil.
4. Open or short circuit in high tension cord.
Clean or replace.
Clean and dry.
Replace.
Replace..
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No fuel reaching the carburetor

1. Clogged hole in the fuel tank cap.
2. Clogged or defective fuel cock.
3. Defective carburetor float valve.
4. Clogged fuel pipe.
Compression too low

1. Valve clearance out of adjustment.
2. Worn valve guides or poor seating of valves.
3. Valves mistiming
4. Piston rings excessively worn.
5. Worn-down cylinder bore.
6. Poor seating of spark plug.
7. Starter motor cranks but too slowly.
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Engine will not

start, or is hard
to start.
Symptom and possible causes
Clean.
Clean or replace.
Replace.
Clean or replace.

2. Clogged fuel hose.
3. Clogged jets in carburetor.
Clean.
Clean.
Clean.
Adjust.
Noisy engine.
Excessive valve chatter

1. Valve clearance too large.
2. Weakened or broken valve springs.
3. Worn down camshaft.
Adjust.
Replace.
Replace.
Noise appears to come from piston

1. Piston or cylinder worn down.
2. Weakened or broken valve springs.
3. Worn down piston pin or piston pin bore.
4. Piston rings or ring groove worn.
Replace.
Replace.
Replace.
Replace.
Noise seems to come from timing chain

1. Stretched chain.
2. Worn sprockets.
3. Tension adjuster not working.
Replace.
Replace.
Repair or replace.
Noise seems to come from clutch

1. Worn splines of countershaft or hub.
2. Worn teeth of cluth plates.
3. Distorted clutch plates, driven and drive.
Replace.
Replace.
Replace.
Noise seems to come from crankshaft

1. Worn or broken bearings.
2. Big-end bearings worn and broken.
3. Thrust clearance too large.
Replace.
Replace.
Replace.
Engine stalls
easily.
SERVICING INFORMATION 7-2
Remedy
Replace.
Replace.
Replace.
Replace.
Slipping clutch.
1. Clutch control out of adjustment or too much play.

2. Weakened clutch springs.
3. Worn or distorted pressure plate.
Adjust.
Replace.
Replace.
Replace.
Dragging clutch.
1. Clutch control out of adjustment or too much play.

2. Weakened clutch springs.
Adjust.
Replace.
Replace.
Transmission will
not shift.
1. Broken gearshift cam.

2. Distorted gearshift forks.
3. Worn gearshift pawl.
Transmission will
not shift back.
1. Broken return spring on shift shaft.

2. Shift shafts are rubbing or sticky.
3. Distorted or worn gearshift forks.
Transmission
jumps out of gear.
1. Worn shifting gears on driveshaft or countershaft.

2. Distorted or worn gearshift forks.
3. Weakened stopper pawl spring on gearshift cam.
4. Worn gearshift pawl.
Replace.
Replace.
Replace.
Replace.
Engine idles
poorly.

2. Poor seating of valves.
3. Defective valve guides.
4. Defective pick-up coil.
5. Spark plug gap too wide.
6. Defective ignition coil resulting in weak sparking.
7. Float-chamber fuel level out of adjustment in carburetor.
8. Clogged jets.
Adjust.
Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Adjust.
Clean.
Engine runs
poorly in high
speed range.
1. Valve springs weakened.

2. Valve timing out of adjustment.
3. Worn cams.
4. Spark plug gap too narrow.
6. Float-chamber fuel level too low.
7. Clogged air cleaner element.
8. Clogged fuel hose, resulting in inadequate fuel supply to carburetor.
Replace.
Adjust.
Replace.
Repair.
Replace.
Adjust .
Clean.
Clean or replace.
Dirty or heavy
exhaust smoke.
1. Too much engine oil in the engine.
Check with inspection window, drain out excess oil.

Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
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Noise seems to come from transmission

1. Gears worn or rubbing.
2. Badly worn splines.
3. Primary gears worn or rubbing.
3. Badly worn bearings.
Noisy engine.
Complaint
2. Worn piston rings or cylinder.

3. Worn valve guides.
4. Cylinder wall scored or scuffed.
5. Worn valves stems.
6. Defective stem seals.
7. Worn side rails.
Replace.
Replace.
Replace.
Replace.
Repair.
Replace.
Complaint
Remedy
1. Loosen of valve clearance.

2. Weakened valve springs.
3. Valve timing out of adjustment.
4. Worn piston ring or cylinder.
5. Poor seating of valves.
7. Worn camshaft.
8. Spark plug gap incorrect.
9. Clogged jets in carburetor.
10. Float-chamber fuel level out of adjustment.
11. Clogged air cleaner element.
12. Too much enging oil.
13. Defective air intake pipe.
Adjust.
Replace.
Adjust.
Replace.
Repair or replace.
Clean or replace.
Replace.
Adjust or replace.
Clean.
Adjust.
Clean.
Drain out excess oil.
Retighten or replace.
Engine overheats.
1. Heavy carbon deposit on piston head.

2. Not enough oil in the engine.
3. Defective oil pump or clogged oil circuit.
4. Fuel level too low in float chamber.
5. Air leak from intake pipe.
6. Use of incrrect engine oil.
7. Defective oil cooler.
Clean.
Add oil.
Repair or clean.
Adjust.
Retighten or replace.
change.
Clean or replace.
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CARBURETOR
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Complaint
Trouble with
starting.
1. Starter jet is clogged.

2. Starter pipe is clogged.
3. Air leaking from a joint between starter body and carburetor.
Overflow and fuel

level fluctuations.
Clean.
Clean.
Check starter body and
carburetor for tightness,
adjust and replace gasket.
Check and adjust.
1. Pilot jet, pilot air jet are clogged or loose.

2. Pilot outlet or bypass is clogged.
3. Starter plunger is not fully closed.
Check and clean.

Check and clean.
Check and clean.
1. Main jet or main air jet is clogged.

2. Needle jet is clogged.
3. Throttle valve is not operating properly.
4. Filter is clogged.
Check and clean.

Check and clean.
Check throttle valve for
operation.
Check and clean.
1. Needle valve is worn or damaged.

2. Spring in needle valve is borken.
3. Float is not working properly.
4. Foreign matter has adhered to needle valve.
5. Fuel level is too high or low.
Replace.
Replace.
Check and adjust.
Clean.
Adjust float height.
Medium or high
speed trouble.
Remedy
4. Starter plunger is not operating properly.

Idling or low-speed
trouble.
Engine lacks power.
ELECTRICAL
Complaint
Remedy

2. Defective spark plug.
3. Defective CDI unit.
Replace.
Replace.
Replace.
Spark plug soon

become fouled with
carbon.
1. Mixture too rich.

2. Idling speed set too high.
3. Incorrect gasoline.
4. Dirty element in air cleaner.
5. Spark plug too cold.
Adjust carburetor.
Adjust carburetor.
Change.
Clean or replace.
Replace by hot type plug.
Spark plug become

fouled too soon.
1. Worn piston rings.

2. Pistons or cylinder worn.
3. Excessive clearance of valve stems in valve guides.
4. Worn stem oil seal.
Replace.
Replace.
Replace.
Replace.
Spark plug
electrodes
overheat or burn.
1. Spark plug too hot.

2. The engine overheats.
3. Spark plug loose.
4. Mixture too lean.
Generator charge,
but charging
rate is below the
specification.
1. Lead wires tend to get shorted or open-circuited or loosely connected

at terminals.
2. Grounded or open-circuited stator coils of generator.
3. Defective regulator/rectifier.
4. Not enough electrolyte in the battery.
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No sparking or poor
sparking.
5. Defective cell plates in the battery.
1. Internal short-circuit in the battery.

2. Resistor element in the regulator/rectifier damaged or defective.
3. Regulator/rectifier poorly grounded.
Unstable
charging.
Starter switch is
not effective.
Generator
overcharges.
Replace by cold type plug.

Tune up.
Retighten.
Adjust carburetor.
Repair or retighten.
Replace.
Replace.
Add distilled water between
the level lines.
Replace the battery.
Replace.
Clean and tighten
ground connection.
1. Lead wire insulation frayed due to vibration resulting in intermittent

shorting.
2. Generator internally shorted.
3. Defective regulator/rectifier.
Repair or replace
1. Battery run down.

2. Defective switch contacts.
3. Brushes not seating properly on commutator in starter motor.
4. Defective starter relay.
Recharge or replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
BATTERY
Complaint
Sulfationacidic
white powdery
substance or spots
on surfaces of
cell plates.
Remedy
1. Not enough electrolyte.
2. Battery case is cracked.

3. Battery has been left in a run-down condition for a long time.
Add distilled water, if the battery

has not been damaged and
sulfationhas not advanced
too far, and recharge.
Replace the battery or recharge.
1. The charging method is not correct.
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Battery runs down

quickly.
4. Contaminated electrolyte. (Foreign matter has enters the

battery and become mixed with the electrolyte.)
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2. Cell plates have lost much of their active material as a result of

over-charging.
3. A short-circuit condition exists within the battery due to excessive
accumulation of sediments caused by the high electrolyte specific
gravity.
4. Electrolyte specific gravity is too low.
5. Contaminated electrolyte.
6. Battery is too old.
The battery has been connected the wrong way round in the system, so
that it is being charged in the reverse direction.
Reversed battery
polarity.
Batterysulfation
Battery discharges
too rapidly.
Ifsulfationhas not advanced

far, try to restore the battery by
replacing the electrolyte,
recharing it fully with the battery
detached from the motorcycle
and then adjusting electrolyte
specific gravity.
Check the generator, regulator
/rectifier and circuit connections,
and make necessary adjustments
to obtain specified charging
operation.
Replace the battery, and correct
the charging system.
Recharge the battery fully and

adjust electrolyte specific
gravity.
Replace the electrolyte, recharge
the battery and then adjust
specific gravity.
Replace the battery and be
sure to connect the battery
properly.
1. Charging rate too low or too high. (When not in use, batteries
should be recharged at least once a month to avoid sulfation.)
2. Battery electrolyte excessive or insufficient, or its specific gravity too
high or too low.
3. The battery left unused for too long in cold climate.
Replace the battery, if badly

sulfated.
1. Dirty container top and sides.

2. Impurities in the electrolyte or electrolyte specific gravity is too high.
Clean.
Change the electrolyte by
consulting the battery makers
directions.
Keep the electrolyte up to the

prescribed level, or adjust the
specific gravity by consulting
the battery makers directions.
CHASSIS
Complaint
Remedy
1. Steering stem nut overtightened.

2. Worn bearing or race in steering stem.
3. Distorted steering stem.
4. Not enough pressure in tires.
Adjust.
Replace.
Replace.
Adjust.
Steering
oscillation.
1. Loss of balance between right and left front suspensions.

2. Distorted front fork.
3. Distorted front axle or crooked tire.
Replace.
Repair or replace.
Replace.
Wobbling
front wheel.
1. Distorted wheel rim.

2. Worn-down wheel bearings.
3. Defective or incorrect tire.
4. Loosen nut on axle.
Replace.
Replace.
Replace.
Retighten.
Front suspension
too soft.
1. Weakened springs.
2. Not enough fork oil.
Front suspension
too stiff.
1. Fork oil too viscous.

2. Too much fork oil.
Noisy front
suspension.
1. Not enough fork oil.

2. Loosen nuts on suspension.
Wobbling
rear wheel.
1. Distorted wheel rim.

2. Worn-down rear wheel bearing.
3. Defective or incorrect tire.
4. Loose nut on axle.
5. Worn swing arm bushing or bearing.
6. Loosen nut on the rear shock.
Replace.
Replace.
Replace.
Retighten.
Replace.
Retighten.
Rear suspension
too soft.
1. Weakened springs.
2. Rear suspension adjuster improperly set.
Replace.
Adjust.
Rear suspension
too stiff.
1. Rear suspension adjuster improperly set.

Adjust.
Replace.
1. Loosen nuts on suspension.

Retighten.
Replace.
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Noisy rear
suspension.
Steering feels too

heavy or stiff.
Replace.
Refill.
Replace.
Drain excess oil.
Refill.
Retighten.
BRAKES
Complaint
Remedy
1. Not enough brake fluid in the reservoir.

2. Air trapped in brake fluid circuit.
3. Pads worn down.
4. Too much play on brake lever or pedal.
Refill to level mark.

Bleed air out.
Replace.
Adjust.
Insufficient brake
power.
1. Leakage of brake fluid from hydraulic system.

2. Worn pads.
3. Oil adhesion of engaging surface of pads.
4. Worn disk.
5. Air in hydraulic system.
Repair or replace.
Replace.
Clean disk and pads.
Replace.
Bleed air.
Brake squeaking.
1. Carbon adhesion on pad surface.
Repair surface with

sandpaper.
Modify pad fitting.
Replace.
Tighten to specified torque.
Replace.
Replace brake fluid.
Disassemble and clean
master cylinder.
1. Air in hydraulic system.

2. Insufficient brake fluid.
Excessive brake
lever stroke.
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2. Tilted pad.
3. Damaged wheel bearing.
4. Loosen front-wheel axle or rear-wheel axle.
5. Worn pads.
6. Foreign material in brake fluid.
7. Clogged return port of master cylinder.
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3. Improper quality of brake fluid.
1. Insufficient tightening of connection joints.
2. Cracked hose.
3. Worn piston and/or cup.
Leakage of brake
fluid.
Poor braking
(FRONT and REAR)
Bleed air.
Replenish fluid to specified
level ; bleed air.
Replace with correct fluid.
Tighten to specified
torque.
Replace.
Replace piston and/or cup.
SPECIAL TOOLS
Part NumberPart NameDescription
Special tools

09900-21109
Vernier Caliper
Torque wrench
Used to conveniently measure various dimensions.
Measure torque of tightening.
09900-20201
09900-21304
Micrometer(0~25mm)
V-block
Used for precise measurement (00~25mm measure ranges).
With using magnetic stand.
09900-20202
09900-22301
09900-20101
Plastigauge
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Micrometer(25~50mm)
Measure clearance of crankshaft thrust.

09900-22401
09900-20203
Small bore gauge
Micrometer(50~75mm)
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Measure inside diameter of conrod small-end.

09900-25002
Cylinder gauge set
Pocket tester
Measure inside diameter of cylinder.
Measure voltage, electric current, resistance.
09900-20508
09900-20605
09900-26006
Dial calipers
Engine tachometer
Meassure width of conrod big-end.
Measure rotational frequency of engine.
09900-20606
09900-28107
Dial gauge
Electro tester
Meassure oscillation of wheel with using magnetic stand.
Inspect ignition coil.
09900-20701
09900-28500
Magnetic stand
Battery charger
With using dial gauge.
Used to charge the dischared battery.
09900-20806
09910-20115
Thickness gauge
Conrod holder
Measure clearance of piston ring.
Used to lock the crankshaft.
Special tools
Special tools

09913-80112
Crankshaft installer
Bearing installer
Used to install the crankshaft in the crankcase.
Used to drive bearing in.
09910-34510
09915-63310
Piston pin puller
Compression gauge adapter
Use to remove the piston pin.
Used with compression gauge.
09913-10760
09915-64510
09910-32812
Fuel level gauge
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Compression gauge
Measure height of carburetor.
Measure cylinder compression.
09913-50121
09915-74510
Oil seal remover
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Used to remove the oil seal.
Oil pressure gauge

Measure oil pressure of 4-stroke engine.
09916-14510
Bearing installer
Valve spring compressor
Used to remove and remounting valve stem.
09913-70122
09913-75520
09916H35C00
Bearing installer
Used with valve spring compressor.
09913-75820
09916HG5100
Bearing installer
Used with valve spring compressor.
09913-75830
09920-13120
Bearing installer
Crankcase separater
Used to install rear axle shaft oil seal.
Separate to crankcase.
09913-76010
09920-53710
Bearing installer
Clutch sleeve hub holder
Used to drive crankshaft bearing in.
Used to install or remove clutch sleeve hub nut.
Special tools
Special tools

09930-44510
Bearing remover(10mm)
Rotor holder
Used to remove oil seal or bearing.
Widely used to lock rotary parts such as a flywheel magneto.
09921-20210
09940-10122
Clamp wrench
Used to remove oil seal or bearing.
A hook wrench to adjust the steering head of motorcycle.
09923-73210
09940-34520
09921-20200
Used to remove bearing with the rotor remove sliding shaft.
09923-74510
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T-handle
Remove and remounting front fork oil cylinder.
09940-34561
Front fork assembling tool attachmentD
Bearing remover(20~35mm)
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Used to remove bearing with the rotor remove sliding shaft.
Used with T-handle.

09940-50113
Bearing installer
Front fork oil seal installer
Used to drive small bearing in.
Install front fork oil seal.
09924-84521
09930-30102
09941-34513
Rotor remove sliding shaft
Steering race installer
Used to with bearing remover or rotor remover.
Used to install steering outer race.
09930-30162
09941-50111
Special tools
Rotor remover
Wheel bearing remover
Attached to the top of sliding shaft when removing rotor.
Used to remove wheel bearing.
09930-30164
09943-74111
Rotor remover
Front fork oil level gauge
Attached to the top of sliding shaft when removing rotor.
Used to drain the fork oil to the specified level.
09930-40113
Rotor holder
Widely used to lock rotary parts such as a flywheel magneto.
TIGHTENING TORQUE
ENGINE
Nm
kgm
Magneto rotor nut
50 ~ 60
5.0 ~ 6.0
Magneto cover bolt
8 ~ 12
0.8 ~ 1.2
Muffler mounting bolt
20 ~ 30
2.0 ~ 3.0
Exhaust pipe nut
18 ~ 28
1.8 ~ 2.8
Starter clutch bolt
15 ~ 20
1.5 ~ 2.0
Cylinder head bolt
7 ~ 11
0.7 ~ 1.1
Cylinder head cover bolt
12 ~ 16
1.2 ~ 1.6
Cylinder head stud bolt
21 ~ 25
2.1 ~ 2.5
7 ~ 11
0.7 ~ 1.1
15 ~ 20
1.5 ~ 2.0
80 ~ 100
8.0 ~ 10.0
18 ~ 20
1.8 ~ 2.0
40 ~ 60
4.0 ~ 6.0
10 ~ 13
1.0 ~ 1.3
6~8
0.6 ~ 0.8
Cam chain tension adjuster bolt
8 ~ 12
0.8 ~ 1.2
Camshaft sprocket bolt
10 ~ 12
1.0 ~ 1.2
8 ~ 12
0.8 ~ 1.2
30 ~ 50
3.0 ~ 5.0
40 ~ 60
4.0 ~ 6.0
8 ~ 12
0.8 ~ 1.2
Oil cooler union bolt (M10)
20 ~ 25
2.0 ~ 2.5
Oil cooler union bolt (M12)
20 ~ 25
2.0 ~ 2.5
Spark plug
20 ~ 25
2.0 ~ 2.5
Neutral cam stopper plug
20 ~ 25
2.0 ~ 2.5

(
Engine sprocket nut

Engine oil drain plug
Engine mounting bolt

Cam chain sprocket bolt
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Cam chain tensioner bolt
Crankcase bolt
Camshaft housing bolt
Clutch sleeve hub nut

Primary drive gear nut
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ITEM
CHASSIS
Nm
kgm
Rear shock absorber mounting nut (Upper)
40 ~ 60
4.0 ~ 6.0
Rear shock absorber mounting nut (Lower)
40 ~ 60
4.0 ~ 6.0
Rear sprocket nut
20 ~ 30
2.0 ~ 3.0
Rear axle nut
90 ~ 140
9.0 ~ 14.0
Swing arm pivot nut
45 ~ 70
4.5 ~ 7.0
Steering stem nut
80 ~ 100
8.0 ~ 10.0
Steering stem head nut
80 ~ 100
8.0 ~ 10.0
Front and Rear brake disc bolt
18 ~ 28
1.8 ~ 2.8
Front brake master cylinder mounting bolt
5~8
0.5 ~ 0.8
Rear brake master cylinder mounting bolt
18 ~ 28
1.8 ~ 2.8
6~9
0.6 ~ 0.9
18 ~ 28
1.8 ~ 2.8
20 ~ 25
2.0 ~ 2.5
50 ~ 80
5.0 ~ 8.0
15 ~ 25
1.5 ~ 2.5
30 ~ 40
3.0 ~ 4.0
22 ~ 35
2.2 ~ 3.5
22 ~ 30
2.2 ~ 3.0
22 ~ 35
2.2 ~ 3.5
22 ~ 35
2.2 ~ 3.5
18 ~ 28
1.8 ~ 2.8
ITEM
Front and Rear brake caliper mounting bolt

Front and Rear brake hose union bolt
Front axle bolt
Front axle pinch bolt
Front fork upper bolt

Front fork lower clamp bolt
Front footrest bolt
Handlebar clamp bolt
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Front fork upper clamp bolt
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Front and Rear brake caliper air bleeder valve
SERVICE DATA
VALVE + GUIDE
(
Unit : mm (in)
ITEM
STANDARD
22.0 (0.87)
EX.
19.0 (0.75)
IN.
0.1 ~ 0.2 (0.004 ~ 0.008)
EX.
0.2 ~ 0.3 (0.008 ~ 0.012)
IN.
0.010 ~ 0.037 (0.0004 ~ 0.0015)
EX.
0.030 ~ 0.057 (0.0012 ~ 0.0022)
Valve stem deflection
IN. & EX.
0.35 (0.014)
Valve guide I.D.
IN. & EX.
4.500 ~ 4.512 (0.1771 ~ 0.1776)
Valve stem O.D.
IN.
4.475 ~ 4.490 (0.1762 ~ 0.1768)
Valve clearance (When cold)

Valve guide to valve stem clearance
EX.
Valve stem runout
IN. & EX.
IN. & EX.
Valve seat width
IN.
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Valve diam.
LIMIT
4.455 ~ 4.470 (0.1754 ~ 0.1760)
0.05 (0.002)
0.50 (0.02)
0.9 ~ 1.1 (0.035 ~ 0.043)
IN. & EX.
Valve head radial runout
IN. & EX.
Valve seat angle
Valve spring tension
0.03 (0.0012)
IN.
37.80 (1.488)
EX.
37.80 (1.488)
IN.
45
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Valve spring free length
EX.
12.1 ~ 13.9kgf (26.7 ~ 30.6 lbs)

at length 33.7mm (1.33 in)
12.1 ~ 13.9kgf (26.7 ~ 30.6 lbs)

VALVE + GUIDE
(
Unit : mm (in)
ITEM
STANDARD
18.0 (0.71)
EX.
14.5 (0.57)
IN.
0.1 ~ 0.2 (0.004 ~ 0.008)
EX.
0.2 ~ 0.3 (0.008 ~ 0.012)
IN.
0.010 ~ 0.037 (0.0004 ~ 0.0015)
EX.
0.030 ~ 0.057 (0.0012 ~ 0.0022)
Valve stem deflection
IN. & EX.
0.35 (0.014)
Valve guide I.D.
IN. & EX.
4.000 ~ 4.012 (0.1575 ~ 0.1580)
Valve stem O.D.
IN.
3.975 ~ 3.990 (0.1565 ~ 0.1571)
Valve clearance (When cold)

Valve guide to valve stem clearance
EX.
Valve stem runout
IN. & EX.
IN. & EX.
Valve seat width
IN.
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Valve diam.
LIMIT
3.955 ~ 3.970 (0.1557 ~ 0.1563)
0.05 (0.002)
0.50 (0.02)
0.9 ~ 1.1 (0.035 ~ 0.043)
IN. & EX.
Valve head radial runout
IN. & EX.
45
Valve seat angle
0.03 (0.0012)
IN.
37.64 (1.482)
EX.
37.64 (1.482)
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Valve spring free length

Valve spring tension
IN.
EX.
30 kgf (66.1 lbs)

30 kgf (66.1 lbs)

CAMSHAFT + CYLINDER HEAD
Unit : mm (in)
ITEM
Cam height
Camshaft journal holder I.D.
STANDARD
LIMIT
IN.
34.470 ~ 34.510 (1.357 ~ 1.358)
34.170 (1.345)
EX.
34.420 ~ 34.460 (1.355 ~ 1.356)
34.120 (1.343)
IN. & EX.
35.000 ~ 35.018 (1.378 ~ 1.379)
Cylinder and cylinder head distortion
0.05 (0.002)
Cylinder head cover distortion
0.05 (0.002)
16th pin
Cam chain pin (Arrow3)
CYLINDER + PISTON + PISTON RING

(
ITEM
Unit : mm (in)
STANDARD
LIMIT
14~16 kg/cm2 (at 500 rpm)
12 kg/cm2
0.050 ~ 0.060 (0.0020 ~ 0.0024)
0.120 (0.0047)
Cylinder bore
57.000 ~ 57.015 (2.2441 ~ 2.2447)
57.080 (2.2473)
Piston diam.
56.945 ~ 56.960 (2.2419 ~ 2.2425)

(Measure at 15mm (0.6 in) from the skirt end)
56.880 (2.2394)
0.05 (0.002)
Piston to cylinder clearance
Cylinder or cylinder head distortion
Piston ring end gap (Assembly condition)
7.2 (0.284)
5.7 (0.224)
2nd
5.8 (0.228)
4.6 (0.181)
1st
0.20 ~ 0.32 (0.008 ~ 0.013)
0.5 (0.020)
2nd
0.20 ~ 0.32 (0.008 ~ 0.013)
0.5 (0.020)
1st
0.180 (0.007)
2nd
0.150 (0.006)
1st
1.01 ~ 1.03 (0.040 ~ 0.041)
2nd
1.01 ~ 1.03 (0.040 ~ 0.041)
Oil
2.01 ~ 2.03 (0.079 ~ 0.080)
1st
0.970 ~ 0.990 (0.0382 ~ 0.0390)
2nd
0.970 ~ 0.990 (0.0382 ~ 0.0390)
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Piston ring to groove clearance
1st
Piston ring free end gap
Piston ring groove width
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Piston pin hole bore
Piston pin O.D.
15.002 ~ 15.008 (0.5906 ~ 0.5909)
15.030 (0.5917)
14.994 ~ 15.000 (0.5903 ~ 0.5905)
14.980 (0.5898)
CYLINDER + PISTON + PISTON RING

(
ITEM
Unit : mm (in)
STANDARD
LIMIT
11~13 kg/cm2 (at 500 rpm)
10 kg/cm2
0.03 ~ 0.04 (0.0012 ~ 0.0016)
0.1 (0.0040)
Cylinder bore
44.000 ~ 44.015 (1.7323 ~ 1.7329)
44.080 (1.7354)
Piston diam.
43.965 ~ 43.980 (1.7309 ~ 1.7315)

(Measure at 11mm (0.4 in) from the skirt end)
43.890 (1.7280)
0.05 (0.002)
Piston to cylinder clearance
Cylinder or cylinder head distortion
Piston ring end gap (Assembly condition)
Piston ring groove width
2nd
6.0 (0.236)
4.8 (0.189)
1st
0.10 ~ 0.25 (0.004 ~ 0.010)
0.5 (0.020)
2nd
0.25 ~ 0.40 (0.010 ~ 0.016)
0.5 (0.020)
1st
0.180 (0.007)
2nd
0.150 (0.006)
1st
1.01 ~ 1.03 (0.040 ~ 0.041)
2nd
1.01 ~ 1.03 (0.040 ~ 0.041)
Oil
2.01 ~ 2.03 (0.079 ~ 0.080)
1st
0.970 ~ 0.990 (0.0382 ~ 0.0389)
2nd
0.970 ~ 0.990 (0.0382 ~ 0.0389)
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Piston pin hole bore

Piston pin O.D.
ITEM
Conrod small end I.D.
Conrod big end side clearance

Conrod big end width
Crank web to web width
Crankshaft runout
CONROD + CRANKSHAFT
(
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
8.9 ~ 9.1 (0.350 ~ 0.358)
13.030 (0.513)
13.980 (0.550)
CONROD + CRANKSHAFT
(
Crankshaft runout
4.0 (0.158)
Conrod deflection
5.0 (0.197)
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Piston ring to groove clearance
1st
Piston ring free end gap
Unit : mm (in)
STANDARD
LIMIT
15.006 ~ 15.014 (0.5908 ~ 0.5911)
15.040 (0.5921)
3.0 (0.12)
0.40 ~ 0.85 (0.016 ~ 0.034)
1.0 (0.040)
15.95 ~ 16.00 (0.628 ~ 0.630)
72 0.1 (2.84 0.004)
0.05 (0.002)
Unit : mm (in)
STANDARD
LIMIT
13.006 ~ 13.014 (0.5121 ~ 0.5124)
13.040 (0.5134)
3.0 (0.12)
0.15 ~ 0.40 (0.006 ~ 0.016)
1.0 (0.040)
15.95 ~ 16.00 (0.628 ~ 0.630)
72 0.1 (2.84 0.004)
0.05 (0.002)
OIL PUMP
(
)
ITEM
STANDARD
NOTE
2.0 0.5 kg/cm
Oil pressure
(at 65 , 3,000 rpm)

Oil pump reduction ratio
OIL PUMP
(
58/1914/20 = 2.137
STANDARD
NOTE
)
ITEM
0.9 ~ 1.1 kg/cm
Oil pressure
(at 65 , 3,000 rpm)

70/2014/20 = 2.45
H
TE
Oil pump reduction ratio
CLUTCH
ITEM
Clutch cable play
Driven plate distortion

Clutch spring free length
(
Clutch spring free length

(
Unit : mm (in)
LIMIT
4 (0.16)
2.9 ~ 3.1 (0.114 ~ 0.122)
2.6 (0.102)
11.8 ~ 12.0 (0.465 ~0.472)
11.0 (0.433)
PY
RI
Drive plate claw width
STANDARD
Drive plate thickness
0.1 (0.004)
38.2 (1.50)
36.2 (1.43)
29.5 (1.16)
TRANSMISSION + DRIVE CHAIN

(
ITEM
Unit : mm (in)
STANDARD
LIMIT
Primary reduction ratio
3.053 (58/19)
Secondary reduction ratio
3.286 (46/14)
Gear ratio
1st
2.462 (32/13)
2nd
1.556 (28/18)
3rd
1.190 (25/21)
4th
0.957 (22/23)
5th
0.840 (21/25)
Shift fork to groove clearance
0.10 ~ 0.30 (0.004 ~ 0.012)

5.0 ~ 5.1 (0.197 ~ 0.201)
NO.3
5.0 ~ 5.1 (0.197 ~ 0.201)
NO.1 & NO.2
4.8 ~ 4.9 (0.189 ~ 0.193)
NO.3
4.8 ~ 4.9 (0.189 ~ 0.193)
Type
520HO
Links
112 LINKS
20-pitch length
317.5 (12.50)
319.4 (12.58)
H
TE
Shift fork thickness
NO.1 & NO.2
Shift fork groove width
Drive chain
PY
RI
Drive chain slack
TRANSMISSION + DRIVE CHAIN

(
ITEM
Primary reduction ratio
Secondary reduction ratio
Gear ratio
Shift fork thickness

Drive chain
Drive chain slack
20~30 (0.79 ~ 1.18)
Unit : mm (in)
STANDARD
LIMIT
3.000 (70/20)
3.714 (52/14)
1st
2.750 (33/12)
2nd
1.786 (25/14)
3rd
1.350 (27/20)
4th
1.091 (24/22)
5th
0.913 (21/23)
Shift fork to groove clearance

Shift fork groove width
0.5 (0.020)
0.10 ~ 0.30 (0.004 ~ 0.012)
0.5 (0.020)
NO.1 & NO.2
5.0 ~ 5.1 (0.197 ~ 0.201)
NO.3
5.5 ~ 5.6 (0.217 ~ 0.221)
NO.1 & NO.2
4.8 ~ 4.9 (0.189 ~ 0.193)
NO.3
5.3 ~ 5.4 (0.209 ~ 0.213)
Type
428SO
Links
136 LINKS
20-pitch length
254.0 (10.00)
256.5 (10.10)
20~30 (0.79 ~ 1.18)
CARBURETOR
(
Unit : mm (in)
ITEM
SPECIFICATION
Carburetor type
MIKUNI BDS26 TYPE(DOUBLE)
Bore size
26
Idle r.p.m.
1,450~1,550 r.p.m.
17 (0.67)
Float height
0.5~1.0 (0.02 ~ 0.04)
Throttle cable play

Main jet
FRONT
REAR
92.5
95
90
90
(M.J.)
(M.A.J.)
Jet needle
(J.N.)
2ND
2ND
Needle jet
(N.J.)
O-3
O-4
Pilot jet
(P.J.)
20
(B.P.)
Valve seat
(V.S.)
Starter jet
(G.S.)
Pilot outlet
(P.O.)
PV. Stroke
Float height
#1
0.9
#2
0.9
#3
0.8
1.2
1.2
22.5
22.5
0.75
0.75
STD
STD
MIKUNI BDS26 TYPE(DOUBLE)

26
1,450~1,550 r.p.m.
17 (0.67)
0.5~1.0 (0.02 ~ 0.04)
FRONT
REAR
87.5
90
50
50
(M.J.)
Main air jet
(M.A.J.)
Jet needle
(J.N.)
2ND
2ND
Needle jet
(N.J.)
O-5
O-4
Pilot jet
(P.J.)
15
15
(TH.V.)
130
130
Throttle valve
#4
0.8
SPECIFICATION
Throttle cable play

Main jet
#4
0.8
Unit : mm (in)
Idle r.p.m.
#3
0.8
Bore size
#2
0.9
130
ITEM
Carburetor type
#1
0.9
(P.V.)
CARBURETOR
(
20
130
PY
RI
By-pass
H
TE
(TH.V.)
Throttle valve
Main air jet
#1
0.9
#2
0.9
#3
0.8
#4
0.8
#1
0.9
#2
0.9
#3
0.8
By-pass
(B.P.)
Valve seat
(V.S.)
1.2
1.2
Starter jet
(G.S.)
20
20
Pilot outlet
(P.O.)
0.75
0.75
PV. Stroke
(P.V.)
STD
STD
#4
0.8
ELECTRICAL
Unit : mm (in)
ITEM
STANDARD
15/2,000rpm ~ 30/6,000rpm
Ignition timing
Spark plug
Type
CR8E
Gap
0.7~0.8 (0.028 ~ 0.032)
Hot type
CR7E
Standard type
CR8E
Cold type
CR9E
Spark performance
Over 8mm (0.32)
Magneto coil resistance
Primary
0.19 ~ 0.24
Secondary
5.4 ~ 6.6
Pick-up coil
90 ~ 110
G-L
0.6 ~ 0.9
Y-Y
H
TE
Charging coil
67 ~ 99V/5,000 rpm
Magneto no-load voltage

Battery standard charging voltage
14 ~ 15V/5,000 rpm
Type
STX14A-BS
Capacity
12V 12Ah
Battery
WATTAGE
ITEM
PY
RI
Fuse size
Head lamp
(
Ignition coil resistance
Head lamp
(
NOTE
License lamp
15A
Unit : W
SPECIFICATION
HI
60W
LO
55W
HI
35W
LO
35W
5W
Brake/Tail lamp
21/5W
Turn signal lamp
10W
Speedometer lamp
1.7W3
Neutral indicator lamp

Turn signal indicator lamp (Right & left)
High beam indicator lamp
CAUTION
Do not use except the specified bulb (Wattage).
1.7W
1.7W2
1.7W
SUSPENSION
(
Unit : mm (in)
ITEM
STANDARD
LIMIT
120 (4.27)
Front fork spring free length
433.3 (17.1)
Front fork oil type
TELLUS #22
146 (5.8)
400 2.5cc
110 (4.33)
0.6 (0.024)
Rear shock absorber pre-load position
2 / 5 position
Rear shock absorber spring length
179.2 (7.07)
175 (6.89)
Front fork stroke
Front fork oil capacity (each leg)

Rear wheel travel
SUSPENSION
(
H
TE
Swingarm pivot shaft runout
)
ITEM
Unit : mm (in)
STANDARD
LIMIT
120 (4.72)
361 (14.2)
354 (13.9)
TELLUS #22
155 (6.1)
262cc
110 (4.33)
0.6 (0.024)
Rear shock absorber pre-load position
2 / 5 position
Rear shock absorber spring length
179.2 (7.07)
175 (6.89)
Front fork stroke

Front fork spring free length
Front fork oil type

Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
PY
RI
TIRE PRESSURE
NORMAL RIDING
COLD INFLATION
TIRE PRESSURE
SOLO RIDING
DUAL RIDING
kPa
kg/
psi
kPa
kg/
psi
FRONT
196
2.00
29.0
196
2.00
29.0
REAR
221
2.25
32.0
245
2.50
36.0
BRAKE+WHEEL
Unit : mm (in)
ITEM
Rear brake pedal height

Brake disc thickness
STANDARD
LIMIT
290 (11.4) [when one person riding from the ground]
Front
4.0 (0.16)
3.0 (0.12)
Rear
4.3 (0.17)
3.0 (0.12)
Brake disc runout
FrontRear
0.3 (0.012)
Master cylinder bore
FrontRear
12.700 ~ 12.743 (0.5000 ~ 0.5017)
Master cylinder piston diam.
FrontRear
12.657 ~ 12.684 (0.4983 ~ 0.4994)
Brake caliper cylinder bore
FrontRear
25.4 (1.00)
Brake caliper piston diam
FrontRear
25.4 (1.00)
Brake fluid type
DOT3 or DOT4
Wheel runout
2.0 (0.08)
2.0 (0.08)
Front
0.25 (0.01)
Rear
0.25 (0.01)
Front
J17MT3.00
Rear
J17MT4.00
Front
4.6 (0.18)
1.6 (0.06)
Rear
6.3 (0.25)
1.6 (0.06)
H
TE
Radial
Wheel axle runout
Wheel rim size
FUEL + OIL
ITEM
PY
RI
Tire tread depth
Fuel type
Fuel tank capacity
Axial
Engine oil type

Engine oil capacity
(
Engine oil capacity

(
SPECIFICATION
Gasoline used should be graded 85~95 octane or higher.

An unleaded gasoline is recommened.
Including reserve
17
Reserve
API Over SG (SAE 10W/30 or 10W/40)
Change
1,450
Filter change
1,500
Overhaul
1,800
Change
1,450
Filter change
1,500
Overhaul
1,650
NOTE
HEAD LAMP RELAY
TURN SIGLAL RELAY
09407-22402
HARNESS
09407-22402
HARNESS
C.D.I UNIT
REAR BRAKE S/W
H
TE
STARTER RELAY
BATTERY PLUS
FUSE BOX
PY
RI
WELDING CLAMP
L/WIRE STARTER MOTOR
BATTERY MINUS
REGULATOR
BATTERY MINUS
ENGINE EARTH
ASSEMBLY POINT
Rr. SPARK PLUG CAP
FT. SPARK PLUG CAP
DIODE
09407-22402
HARNESS
HANDLE S/W RH
58300HM8102
CABLE ASSY THROTTLE
09407-14408
HARNESS
HANDLE S/W R.L
HANDLE S/W LH
CLUTCH LEVER S/W
58200HM8101
CABLE ASSY.
CLUTCH
09407-22402
HARNESS
58410HM8102
CABLE COMP. STARTER
09407-22402
HARNESS
45280-35000
CABLE COMP. SEAT LOCK
L/WIRE, SPEEDOMETER
L/WIRE STEERING LOCK
HANDLE SWITCH(RH)
OIL COOLER
HOSE LH
59266HM2901
GUIDE, SPEEDOMETER CABLE
HORN
09494-06401
DRAIN HOSE
WELDING CLAMP
34910HM8101
5948HM8102
CABLE, SPEED
HOSE, FRONT BRAKE
HORN COVER
WELDING CLAMP
SIDE STAND SWITCH
HORN
WELDING CLAMP
G
REGULATOR
WELDING CLAMP
MAGNOTO
NEUTRAL S/W
STARTER MOTOR RELAY (RH)
H
TE
C.D.I UNTT
WELDING CLAMP SIDE STAND S/W
NEUTRAL SWITCH
MAGNETO
Rr. IGNITION COIL
DIODE
L/WIRE FUEL
GAUGE
09407-14408
HARNESS
09407-14408
HARNESS
HEAD LAMP RELAY
TURNSIGNAL RELAY
ASSEMBLY POINT
09407-14408
HARNESS
PY
RI
09407-14408
HARNESS
HANDLE SWITCH R,L
CLUTCH LEVER SWITCH
SWITCH, CLUTCH LEVER(LH)
C
HANDLE SWITCH(LH)
Ft, IGNITION
09407-14403
HANDLE SWITCH(RH)
FUSE BOX
09407-14408
HARNESS
HARNESS
HANDLE S/W RH
G
D
FRONT IGNITION COIL VIEW A
H
TE
58410HM 8102
CABLE COMP. SPEEDOMETER
PY
RI
59480HM8102
HOSE COMP. FRONT
BRAKE
59266HM8100
CLAMP, BRAKE HOSE &
SPEEDOMETER CABLE
HANDLE S/W LH
CLUTCH LEVER S/W
09404-06401
REAR BRAKE S/W
REAR BRAKE
L/WIRE, STARTER MOTOR
58300HM8102
CABLE ASSY THROTTLE
09404-06401
G
WELDING CLAMP
OIL COOLER HOSE RH
STARTER MOTOR
H
TE
58410HM8102
CABLE COMP. STARTER
58200HM8101
CABLE ASSY CLUTCH
09403H09304
CLUTCH CABLE
WELDING CLAMP
BATTERY MINUS
Rr. BARKE S/W
PY
RI
09404-06401
BATTERY MINUS
FUSE BOX
H
TE
TURN SIGLAL REALY
09407-14408
HARNESS
BATTERY PLUS STARTER RELAY
Rr. SPARK PLUG CAP
09407-14408
HARNESS
58300HM8102
CABLE ASSY THROTTLE
09407-14408
HARNESS
HANDLE S/W R,L
58200HM8101
CABLE ASSY.
CLUTCH
HANDLE S/W LH
58410HM8102
CABLE COMP. STARTER
CLUTCH LEVER S/W
REGULATOR
BATTERY MINUS
ASSEMBLY POINT
09407-14408
HARNESS
DIODE
HANDLE S/W RH
FUEL GAUGE
ENGINE EARTH
FT. SPARK PLUG CAP
C.D.I UNIT
PY
RI
REAR BRAKE S/W

WELDING CLAMP
BATTERY MINUS
45280-35000
CABLE COMP. SEAT LOCK
09407-14408
HARNESS
09407-14408
HARNESS
Ft, IGNITION
34910HM8101
CABLE, SPEED
SIDE STAND S/W
NEUTRAL SWITCH
MAGNETO
DIODE
WELDING CLAMP
WELDING CLAMP
09494-06401 DRAIN HOSE
HORN
HORN COVER
WELDING CLAMP
SIDE STAND SWITCH
HORN
Rr. IGNITION COIL
09407-14408
HARNESS
TURNSIGNAL RELAY
09407-14408
HARESS
D
WELDING CLAMP
MAGNOTO
NEUTRAL S/W
REGULATOR
STARTER MOTOR RELAY (RH)
H
TE
09407-14408 ASSEMBLY POINT

HARNESS
C.D.I UNTT
L/WIRE FUEL
GAUGE
PY
RI
09407-14408
HARNESS
HANDLE SWITCH R,L
CLUTCH LEVER SWITCH
SWITCH, CLUTCH LEVER(LH)
HANDLE SWITCH(LH)
09407-14403
HANDLE SWITCH(RH)
WELDING CLAMP
HANDLE SWITCH(RH)
59266HM2901
GUIDE, SPEEDOMETER CABLE
5948HM8102
HOSE, FRONT BRAKE
L/WIRE, SPEEDOMETER
L/WIRE STEERING LOCK
FUSE BOX
09407-14408
HARNESS
HARNESS
HANDLE S/W RH
G
D
FRONT IGNITION COIL VIEW B
H
TE
58410HM 8102
CABLE COMP. SPEEDOMETER
PY
RI
59480HM8102
HOSE COMP. FRONT
BRAKE
59266HM8100
CLAMP, BRAKE HOSE &
SPEEDOMTTER CABLE
HANDLE S/W LH
CLUTCH LEVER S/W
09404-06401
REAR BRAKE S/W
REAR BRAKE
L/WIRE, STARTER MOTOR
BATTERY MINUS
09404-06401
09404-06401
WELDING CLAMP
OIL COOLER HOSE RH
H
TE
STARTER MOTOR
58410HM8102
CABLE COMP. STARTER
58300HM8102
CABLE ASSY THROTTLE
PY
RI
58200HM8101
CABLE ASSY CLUTCH
09403H09304
CLUTCH CABLE
WELDING CLAMP
BATTERY MINUS
Rr. BARKE S/W
Rr. TURN LH
Ft. POSITION
HEAD LAMP
HANDLE SWITCH LH
HORN
Lg
O
R
Sb
W
NEUTRAL S/W
:
:
:
:
:
Y
BG
BW
BR
LW
RB
RW
WB
WR
YB
ENGINE EARTH
Rr. TURN LH
TAIL & STOP
LICENSE LAMP
Rr. TURN RH
Rr. IGNITION COIL

SPARK PLUG
: Red with Black tracer

: Red with White tracer
: White with Black tracer
: White with Red tracer
: Yellow with Black tracer
BATTERY(MF)
START
MOTOR
START RELAY
FUSE BOX
Ft. IGNITON COIL

SPARK PLUG
TURN SIG. RELAY
: Yellow
: Black with Green tracer
: Black with White tracer
: Black with Red tracer
: Blue with White tracer
SIDE STAND
S/W
CLUTCH LEVER S/W
Light green
Orange
Red
Light blue
White
DIODE
REGULATOR
H
TE
C.D.I UNIT
PY
RI
WIRE COLOR
B : Black
Br : Brown
G : Green
Gr : Gray
L : Blue
MAGNETO
Rr. BRAKE S/W
FUEL GAUGE
FUEL PUMP
FUEL PUMP RELAY
IGNITION S/W
HANDLE SWITCH RH
WIRING DIAGRAM
Ft. TURN RH
SPEEEEDOMETER
Rr. TURN LH
POSITION LAMP
HANDLE SWITCH LH
IGNITION S/W
HANDLE SWITCH RH
Lg
O
R
Sb
W
:
:
:
:
:
Light green
Orange
Red
Light blue
White
Y
BG
BW
BR
LW
RB
RW
WB
WR
YB
Rr. TURN LH
TAIL & STOP
LICENSE LAMP
Rr. TURN RH
: Red with Black tracer

: Red with White tracer
: White with Black tracer
: White with Red tracer
: Yellow with Black tracer
ENGINE EARTH
BATTERY(MF)
START MOTOR
: Yellow
: Black with Green tracer
: Black with White tracer
: Black with Red tracer
: Blue with White tracer
SIDE STAND
S/W
NEUTRAL S/W
CLUTCH LEVER S/W
DIODE
FUSE BOX
START RELAY
H
TE
C.D.I UNIT
PY
RI
FUEL GAUGE Rr. BRAKE S/W
WIRE COLOR
B : Black
Br : Brown
G : Green
Gr : Gray
L : Blue
MAGNETO
HORN
Ft. IGNITON COIL Rr. IGNITION COIL

SPARK PLUG
SPARK PLUG
REGULATOR TURN SIG. RELAY
WIRING DIAGRAM
HEAD LAMP
Ft. TURN RH
SPEEEEDOMETER
1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.31-0.35
1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.95 2.00 2.05 2.10 2.15 2.20
2.00 2.05 2.10 2.15 2.20
2.05 2.10 2.15 2.20
2.10 2.15 2.20
2.15 2.20
2.20
0.46-0.50
0.51-0.55
0.56-0.60
0.61-0.65
0.66-0.70
0.71-0.75
0.76-0.80
0.81-0.85
0.86-0.90
0.91-0.95
0.96-1.00
1.01-1.05
1.06-1.10
1.11-1.15
(EXAMPLE)
When the tappet clearance is 0.23mm and the
shim thickness at present is 1.70mm, the shim
thickness should be used 1.80mm.
1. Measure the tappet clearance.(When cold)

2. Measure the shim thickness at present.
3. Look for meeting space in that horizontal line
for thickness and vertical line for clearance.
HOW TO USE THE CHART
1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45
H
TE
1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.36-0.40
1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.26-0.30
0.21-0.25
Specified clearance - Adjustment unnecessary

1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.10-0.20
PY
RI
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.05-0.09
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
SHIM THICKNESS
AT PRESENT
(mm)
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.00-0.04
MEASURING
TAPPET
CLEARANCE (mm)
SHIM No.
TAPPET SHIM SELECTION CHART (IN.)
1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.36-0.40
1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55
0.56-0.60
0.61-0.65
0.66-0.70
1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.90 1.95 2.00 2.05 2.10 2.15 2.20

1.95 2.00 2.05 2.10 2.15 2.20
2.00 2.05 2.10 2.15 2.20
2.05 2.10 2.15 2.20
2.10 2.15 2.20

2.15 2.20
2.20
0.81-0.85
0.86-0.90
0.91-0.95
1.01-1.05
1.06-1.10
1.11-1.15
1.21-1.25
1.16-1.20
(EXAMPLE)
When the tappet clearance is 0.33mm and the
shim thickness at present is 1.70mm, the shim
thickness should be used 1.80mm.
1. Measure the tappet clearance.(When cold)

2. Measure the shim thickness at present.
3. Look for meeting space in that horizontal line
for thickness and vertical line for clearance.
1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.76-0.80
0.96-1.00
1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75
HOW TO USE THE CHART
1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50
H
TE
1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45
1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.31-0.35
Specified clearance - Adjustment unnecessary
PY
RI
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.15-0.19
0.20-0.30
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.10-0.14
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
SHIM THICKNESS
AT PRESENT
(mm)
120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.05-0.09
MEASURING
TAPPET
CLEARANCE (mm)
SHIM No.
TAPPET SHIM SELECTION CHART (EX.)
D
H
TE
Prepared by
PY
RI
Overseas Technical Department

1st Ed. NOV. 2002.
Manual No. 99000-94710

Printed in Korea

GT125 250 Manual

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HYOSUNG MOTORS & MACHINERY INC.

latest specification at the time of publication.

This manual has been prepared on the basis of the

dures for its inspection/service and overhaul of its main

basic principles of operation and work procedures.

This manual is intended for those who have

HYOSUNG MOTORS & MACHINERY INC.

COPYRIGHT HYOSUNG MOTORS & MACHINERY INC. 2002.

HOW TO USE THIS MANUAL

1. The text of this manual is divided into sections.

Example: Front wheel

Apply oil. Use engine oil unless otherwise

Apply or use brake fluid.

Apply SUPER GREASEA.

Measure in voltage range.

Apply SUPER GREASEC.

Measure in resistance range.

Apply MOLY PASTE.

Measure in current range.

Apply SILICONE GREASE.

Torque control required.

Use special tool.

SERIAL NUMBER LOCATION

FUEL AND OIL RECOMMENDATIONS

1-1 GENERAL INFORMATION

WARNING / CAUTION / NOTE

Indicates a potential hazard that could result in vehicle damage.

Indicates special information to make maintenance easier or instructions cleaner.

GENERAL INFORMATION 1-2

1-3 GENERAL INFORMATION

SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

GENERAL INFORMATION 1-4

FUEL AND OIL RECOMMENDATION

Use a premium quality 4-stroke motor oil to ensure

If an SAE 10W/30 or 10W/40 motor oil is not available,

Specification and classification: DOT3 or DOT4

FRONT FORK OIL

1-5 GENERAL INFORMATION

Less than 1/2 throttle

Less than 3/4 throttle

GENERAL INFORMATION 1-6

1-7 GENERAL INFORMATION

GENERAL INFORMATION 1-8

2,080 mm (81.9 in)

760 mm (29.9 in)

1,120 mm (44.1 in)

1,455 mm (53.7 in)

180 mm (7.1 in)

170 kg (375 lbs)

Four-stroke, DOHC, air-cooled and oil-cooled

57.0 mm (2.24 in)

44.0 mm (1.73 in)

48.8 mm (1.92 in)

41.0 mm (1.61 in)

167 kg (368 lbs)

124.7 (7.6 in3 )

BDS 26TYPE (DOUBLE)