HYOSUNG 2010 ST7 Service Manual
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HYOSUNG 2010 ST7 Service Manual

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ST7
GV700C
2010 -
Servicemanual
Holtvej 8-10, Høruphav
6470 Sydals
Telefon: +45 73 15 11 00
Fax: +45 73 15 11 01
E-mail: info@scanmi.dk
www.scanmi.dk
CVR: 27 73 31 07

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Summary of Contents for HYOSUNG 2010 ST7

  • Page 1 GV700C 2010 - Servicemanual Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 E-mail: info@scanmi.dk www.scanmi.dk CVR: 27 73 31 07...

  • Page 2: Table Of Contents

    This manual is intended for those who have enough knowledge and skills for servicing SERVICING INFORMATION 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.

  • Page 3: How To Use This Manual

    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 is listed on the previous page as GROUP INDEX, select the section where you are looking for.
  • Page 4 SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Apply THREAD LOCK 1324 . Data beside it indicates specified torque.
  • Page 5 NOTE Difference between photographs and actual motorcycles depends on the markets.

  • Page 6: Abbreviations Used In This Manual

    ABBREVIATIONS USED IN THIS MANUAL : Light Emitting Diode : Left Hand ABDC : After Bottom Dead Center : Alternating Current : American Petroleum Institute ATDC : After Top Dead Center : Maximum : Minimum BBDC : Before Bottom Dead Center : Bettom Dead Center Sensor : Oxygen Sensor (O...
  • Page 7 WIRE COLOR : Black : Gray : Light blue : Blue : Light green : White : Brown : Orange : Yellow : Green : Red : Black with Blue tracer : Black with Brown tracer : Black with Green tracer : Black with Orange tracer : Black with Red tracer : Black with White tracer...
  • Page 8 GENERAL INFORMATION CONTENTS INFORMATION LABELS 1 - 1 GENERAL PRECAUTIONS 1 - 1 SERIAL NUMBER LOCATION 1 - 3 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS 1 - 4 BREAK-IN PROCEDURES 1 - 6 CYLINDER CLASSIFICATION 1 - 6 EXTERIOR ILLUSTRATION 1 - 7 SPECIFICATIONS 1 - 8...

  • Page 9: General Information

    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 mean- ings. Pay special attention to the messages highlighted by these signal words. WARNING Indicates a potential hazard that could result in death or injury.

  • Page 10: General Precautions

    WARNING 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.

  • Page 11: Serial Number Location

    1-3 GENERAL INFORMATION SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head tube. The engine serial number is stamped on the left downside of the crankcase assembly. These numbers are required especially for registering the machine and ordering spare parts.

  • Page 12: Fuel, Oil And Engine Coolant Recommendations

    GENERAL INFORMATION 1-4 FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS FUEL Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is recommended. ENGINE OIL ENGINE OIL SPECIFICATION Classification system Grade 20W50 Over SL 15W40 15W50 10W/40 ENGINE OIL 10W40 10W50...
  • Page 13 Hyosung recommends the use of HYOSUNG COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator.

  • Page 14: Break-In Procedures

    GENERAL INFORMATION 1-6 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 to BREAK-IN before subjecting the engine to maximum stresses.

  • Page 15: Exterior Illustration

    1-7 GENERAL INFORMATION EXTERIOR ILLUSTRATION Unit : mm...

  • Page 16: Specifications

    GENERAL INFORMATION 1-8 SPECIFICATIONS DIMENSIONS AND DRY MASS I T E M Overall length 2,470 mm (97.2 in) Overall width 960 mm (37.8 in) Overall height 1,135 mm (44.7 in) Wheelbase 1,690 mm (66.5 in) Ground clearance 155 mm (6.1 in) Mass of vehicle in running order 244 kg (538 lbs) ENGINE...
  • Page 17 1-9 GENERAL INFORMATION CHASSIS I T E M Front suspension Telescopic type Rear suspension Swingarm type Steering angle 38 (right & left) Caster Trail 142 mm (5.6 in) Front brake Disk brake Rear brake Disk brake Front tire size 120/80 - 16 60H Rear tire size 170/80 - 15 77H Front fork stroke...
  • Page 18 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 - 1 2 - 1 PERIODIC MAINTENANCE CHART 2 - 2 LUBRICATION POINTS MAINTENANCE PROCEDURES 2 - 3 2 - 3 VALVE CLEARANCE 2 - 5 SPARK PLUG 2 - 7 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS 2 - 7 AIR CLEANER 2 - 9...

  • Page 19: Periodic Maintenance Schedule

    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 Interval...

  • Page 20: Lubrication Points

    PERIODIC MAINTENANCE 2-2 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. ❶ ❷ ❹ ❺ ❸ ❻ ❼ ❷ ❹ ❽ Clutch lever holder and clutch cable Speedo sensor Passenger footrests pivot Front brake lever holder...

  • Page 21: Maintenance Procedures

    2-3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES This section describes the service procedures for each item mentioned in the Periodic Maintenance chart. VALVE CLEARANCE ① Inspect Interval Inspect Initial 1,000 km and Every 6,000 km thereafter. CAUTION The clearance specification is for COLD state. FRONT CYLINDER Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and...
  • Page 22 PERIODIC MAINTENANCE 2-4 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 to present by A , B , C , D mark on the cylinder head.

  • Page 23: Spark Plug

    2-5 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1,000 km and Every 6,000 km thereafter. Replace Every 12,000 km. Remove the four radiator cover mounting bolts. Remove the four radiator mounting bolts. WARNING The hot radiator and the hot engine can burn you. Wait until the radiator and the engine are cool enough to touch.
  • Page 24 PERIODIC MAINTENANCE 2-6 ▣ ▣ CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a wire or pin with a pointed end. ▣ ▣ SPARK PLUG GAP Measure the spark plug gap using a thickness gauge.

  • Page 25: Exhaust Pipe Bolts And Muffler Mounting Bolts

    2-7 PERIODIC MAINTENANCE EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS Inspect Interval Tighten Initial 1,000 km and Every 6,000 km thereafter. Tighten the exhaust pipe bolts ①, and muff ler mounting bolts ② to the specified torque. Exhaust pipe bolt : 18 ~ 28 N m (1.8 ~ 2.8 kgf m) ①...
  • Page 26 PERIODIC MAINTENANCE 2-8 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.

  • Page 27: Engine Idle Speed

    2-9 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect Interval Inspect Initial 1,000 km and Every 6,000 km there- after. NOTE Make this inspection when the engine is hot. Connect an engine tachometer to the high ten- sion cord. Start the engine and inspect the engine idle speed between specified range.

  • Page 28: Fuel Hose

    PERIODIC MAINTENANCE 2-10 FUEL HOSE Inspect Interval Inspect Initial 1,000 km and Every 6,000 km thereafter. Replace every 4 years. Remove the seat. (Refer to page 8-1) Remove the fuel tank. (Refer to page 5-2) Remove the frame cover. (Refer to page 8-2) Inspect the fuel hoses for damage and fuel leakage.
  • Page 29 2-11 PERIODIC MAINTENANCE FOOTREST POSITION ADJUST- MENT has 2 type of the footrest position, right and left. To change the position, remove the footrest mounting bolt , footrest boss cap and bolt Install the bolt to the desired position and footrest boss cap , bolt to the position...

  • Page 30: Engine Oil

    PERIODIC MAINTENANCE 2-12 ENGINE OIL Inspect Interval Replace Initial 1,000 km and Every 6,000 km thereafter. Necessary amount of engine oil Oil change 3,000 Oil and filter change 3,200 Engine overhaul 3,400 SAE 10W/40 Engine oil type API Over SL The oil should be changed while the engine is warm.
  • Page 31 2-13 PERIODIC MAINTENANCE Start up the engine and allow it to run for sever- al minutes at idling speed. Turn off the engine and wait about three minutes, then check the oil level through the inspection win- dow. If the level is below mark L , add oil to F level. If the level is above mark F , drain oil to F level.

  • Page 32: Engine Oil Filter

    Use HYOSUNG MOTORS GENUINE OIL FILTER only, since the other make s genuine filters and after-market parts may differ filtering perfor- mance and durability, which could cause engine damage or oil leaks. Hyosung motors genuine oil filter is also not usable for the motocycles.

  • Page 33: Drive Belt

    2-15 PERIODIC MAINTENANCE DRIVE BELT Inspect Interval Inspect Every 1,000 km. Visually check the drive belt for the possible defects listed below. (Support the motorcycle by the jack or block, turn the rear wheel slowly by hand with the NOTE transmission shifted to Neutral.) Edges of the belt for cuts or unusual wear patterns When replacing the drive belt, replace the drive...
  • Page 34 PERIODIC MAINTENANCE 2-16 Recheck the drive belt slack after tightening the rear axle. WARNING Be careful not to touch the muffler when it is hot : a hot muffler can burn you. CAUTION The drive belt for this motorcycle is made of the special material.

  • Page 35: Brake System

    2-17 PERIODIC MAINTENANCE BRAKE SYSTEM Inspect Interval [ BRAKE ] Inspect Initial 1,000 km and Every 6,000 km thereafter. [ BRAKE HOSES & BRAKE FLUID ] Inspect Initial 1,000 km and Every 6,000 km thereafter. Replace the brake hoses Every 4 years, CAUTION Replace the brake fluid Every 2 years.
  • Page 36 PERIODIC MAINTENANCE 2-18 FRONT AND REAR BRAKE PAD REPLACEMENT Remove the brake caliper. FRONT BRAKE Remove the brake pad mounting bolt’s E-ring ①. Remove the brake pad mounting bolts ② and spring ③ REAR BRAKE Remove the brake pad mounting bolts ④. Remove the brake pad spring.
  • Page 37 2-19 PERIODIC MAINTENANCE 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 diaph- ragm. Suck up the old brake fluid as much as possible. Fill the reservoir with new brake fluid.
  • Page 38 PERIODIC MAINTENANCE 2-20 AIR BLEEDING OF THE BRAKE ① FLUID CIRCUIT 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 brak- ing performance of the brake caliper.
  • Page 39 2-21 PERIODIC MAINTENANCE FRONT BRAKE LAMP SWITCH The front brake lamp switch ① is located beneath the front brake lever. Loosen the switch fitting screws and adjust the timing by moving the switch body forward or backward. ① REAR BRAKE LAMP SWITCH Adjust the rear brake lamp switch ②...

  • Page 40: Steering

    PERIODIC MAINTENANCE 2-22 STEERING Inspect Interval Inspect Initial 1,000 km and Every 6,000 km thereafter. Steering should be adjusted properly for smooth turning of handlebars and safe running. Overtight steering pre- vents 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...

  • Page 41: Tire

    The use of tires other than those specified may SOLO RIDING DUAL RIDING cause instability. It is highly recommended to use COLD INFLATION a HYOSUNG Genuine Tire. TIRE PRESSURE kgf/cm KPa kgf/cm Front 2.00 30.0...

  • Page 42: Engine Coolant

    PERIODIC MAINTENANCE 2-24 ENGINE COOLANT Inspect Interval Replace Every 2 years. ENGINE COOLANT LEVEL CHECK Keep the motorcycle upright. Check the engine coolant level by observing the “F” (Full) and “L” (Low) level lines on the engine coolant reserve tank. If the level is below the “L”...
  • Page 43 2-25 PERIODIC MAINTENANCE OPEN THE RADIATOR CAP Remove the right frame head cover ① to operate the radiator cap ③. ① To disassemble the right frame head cover ①, remove the two mounting bolts ②. WARNING You can be injured by scalding fluid or steam if ②...

  • Page 44: Radiator Hose

    PERIODIC MAINTENANCE 2-26 AIR BLEEDING THE COOLING CIRCUIT Add engine coolant up to the raditor cap inlet. Support the motorcycle upright. Slowly swing the motorcycle, right and left, to bleed the air trapped in the cooling circuit. Add engine coolant up to the radiator cap inlet. Start up the engine and bleed air from the radiator cap inlet completely.

  • Page 45: Compression Pressure

    2-27 PERIODIC MAINTENANCE COMPRESSION PRESSURE The compression pressure reading of a cylinder is a Low compression pressure can indicate some of the good indicator of its internal condition. following conditions : The decision to overhaul the cylinder is often based on Excessively worn cylinder wall the results of a compression test.

  • Page 46: Oil Pressure

    PERIODIC MAINTENANCE 2-28 OIL PRESSURE Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts. Standard Oil pressure 6.0 kgf/cm (at 60 3,000 rpm) If the engine oil pressure is lower or higher than the specification, the following causes may be considered. LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage...
  • Page 47 ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING 3 - 1 ENGINE REMOVAL 3 - 1 3 - 9 ENGINE REMOUNTING ENGINE DISASSEMBLY 3 - 11 3 - 11 STARTER MOTER 3 - 12 THERMOSTAT 3 - 12 CYLINDER HEAD COVER 3 - 16 PISTON MAGNETO COVER 3 - 16...

  • Page 48: Engine Removal And Remounting

    3-1 ENGINE ENGINE REMOVAL AND ① REMOUNTING ENGINE REMOVAL NOTE If the engine is dirtied, wash the machine with a suitable cleaner before removing the engine. Remove the seat. (Refer to page 8-1) Remove the fuel tank. (Refer to page 5-2) Remove the frame cover.
  • Page 49 ENGINE 3-2 With the bolt removed, take out the air cleaner cham- ber. COOLING FAN After removing the two mounting bolts ②, remove the right frame head cover ①. ① ② Remove the radiator cap case and cap case bolt ③. ③...
  • Page 50 3-3 ENGINE Disconnect the radiator outlet hose ①. ① Remove the radiator mounting bolts. Disconnect the cooling fan thermo-switch lead wire coupler ②. Disconnect the radiator inlet hose ③. ③ ② Disconnect the reserve tank hose ④. Disconnect the cooling fan motor lead wire coupler ⑤.
  • Page 51 ENGINE 3-4 SENSORS Remove the all sensor couplers. (Refer to chapter 4 and 5) Disconnect the fuel injector hoses ① THROTTLE BODY Remove the throttle body after removing the intake pipes. (Refer to page 5-7) CLUTCH CABLE Disconnect the clutch cable end out of clutch lever. Disconnect the clutch cable end out of clutch release arm.
  • Page 52 3-5 ENGINE EXHAUST PIPE AND MUFFLER With the exhaust pipe bolts , exhaust pipe connect- ing bolts and muffler mounting bolts removed, remove the exhaust pipes and muffler. Front Cylinder Rear Cylinder ELECTRIC PARTS By taking out the spark plug caps, remove the spark plug.
  • Page 53 ENGINE 3-6 Remove the starter motor lead wire. Remove the engine ground lead wire ①. ① Disconnect the two magneto coupler ②. ③ Disconnect the neutral switch terminal ③. Disconnect the side-stand switch lead wire couper ④. ② ④...
  • Page 54 3-7 ENGINE ENGINE PULLEY Remove the engine pulley cover ①. ① Disconnect the front crankcase breather hose ② and rear crankcase breather hose ③. ② ③ Remove the gearshift arm ④. Flatten the lock washer. Remove the engine pulley nut ⑤ and washer. ⑤...
  • Page 55 ENGINE 3-8 Remove the engine pulley. NOTE If it is difficult to remove the engine pulley, loosen ① ① ② ② to provide the rear axle bolt, belt adjusters additional belt slack. (Refer to page 2-15) ① ② Remove the frame down tube. Remove the frame down tube.

  • Page 56: Engine Remounting

    3-9 ENGINE ENGINE REMOUNTING CAUTION Reinstall the engine in the reverse order of engine of engine mounting bolt ① ① align Set the part removal. center line by the hand temporarily and install the engine mounting bolt to the specified torque. Install the engine mounting bolts, nuts and engine If otherwise, it is damage to the thread of engine mounting lock nuts with the special tool.
  • Page 57 ENGINE 3-10 ENGINE PULLEY Loosen the rear axle ① and belt adjusters ②, left and right. Install the engine pulley. ② ① ② Tighten the engine pulley nut ③ to the specified torque. Engine pulley nut : 130 ~ 160 N m (13.0 ~ 16.0 kgf m) NOTE W h e n t i g h t e n i n g t h e e n g i n e p u l l e y n u t , depress the rear brake pedal.

  • Page 58: Engine Disassembly

    3-11 ENGINE ENGINE DISASSEMBLY CAUTION Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their origi- nal positions. STARTER MOTOR Remove the starter motor. Remove the gear position switch. Remove the contacts ①...

  • Page 59: Thermostat

    ENGINE 3-12 THERMOSTAT ① Remove the thermostat case ① along with the hose ②. NOTE Thermostat inspection and servicing : Refer to page 6-9 ② CYLINDER HEAD COVER Remove the cylinder head cover. To set the piston at TDC (Top Dead Center). CAUTION Align the index mark on the magneto rotor with the index mark on the magneto cover as...
  • Page 60 3-13 ENGINE Rear Cylinder With the three bolts removed, remove the cam chain guide NO.2 ①. ① Remove the camshaft housing ②. NOTE Mark an identification of assembly location ② on each removed parts so that each will be restored to the original position during reassembly.
  • Page 61 ENGINE 3-14 Loosen the cylinder head base bolt. Loosen the six cylinder head bolts. NOTE When loosening the cylinder head bolts, loosen each bolt little by little diagonally. Remove the chain guide NO.1 and cylinder head. Remove the tappet and the shim. CAUTION D r a w o u t t h e t a p p e t a n d s h i m w i t h t h e strong magnet not to be scratched.
  • Page 62 3-15 ENGINE CAUTION The tappet and shim should be lined so that each will be restored to the original posi- tion during reassembly. Compress the valve spring by using the special tool. Valve spring compressor : 09916-14510 Valve spring compressor attachment : 09916-14520 Take out the valve cotter from the valve stem.

  • Page 63: Piston

    ENGINE 3-16 Remove the rear cylinder head and cylinder with the Rear Cylinder same manner of the front cylinder head and cylinder removal. Front 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.

  • Page 64: Magneto Rotor

    3-17 ENGINE Remove the starter idle shaft ①, starter idle gear ②. ② ① MAGNETO ROTOR 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 : 09930-30165 Remove the key ③.

  • Page 65: Clutch Cover

    ENGINE 3-18 Remove the cam chain tensioner ①. ① CLUTCH COVER ② Remove the clutch release arm ②. Remove the clutch cover bolts. Remove the clutch cover ③. ③ ④ NOTE When remove or inspect the clutch drive and driven plate, remove only the clutch pressure cover...

  • Page 66: Clutch

    3-19 ENGINE CLUTCH With the primary drive gear held immovable using the special tool, remove the clutch spring mounting bolts diagonally. Conrod holder : 09910-20115 Remove the disk pressure ①. ① Remove the clutch drive plates NO. 1 and driven plates.

  • Page 67: Primary Drive Gear

    ENGINE 3-20 Remove the clutch sleeve hub ① and primary driv- en gear assembly ② . ② ① PRIMARY DRIVE GEAR With the crankshaft held immovable using special tool, remove the primary drive gear nut ③ Remove the water pump drive gear ④ and primary drive gear ⑤.

  • Page 68: Gearshift Shaft

    3-21 ENGINE Remove the pin ① and shim. With the three screws loosened, remove the oil pump ②. ② ① GEARSHIFT SHAFT Draw out the gearshift shaft ③. ③ Remove the gearshift cam stopper ④ Loosen the gearshift cam plate bolt ⑤ ⑤...
  • Page 69 ENGINE 3-22 Remove the mission oil pipe mounting bolt. 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.

  • Page 70: Engine Component Inspection And Service

    3-23 ENGINE Remove the crankshaft by using the special tool. Crankcase separator : 09920-13120 ENGINE COMPONENT INSPECTION AND SERVICE CAUTION Be sure to identify each removed part as to its location, and lay the parts out in groups desig- nated as Front cylinder , Rear cylinder , E x h a u s t , Intake , so that each will be restored to the original location during assembly.
  • Page 71 ENGINE 3-24 CAMSHAFT (T.D.C) The camshaft should be checked for runout and also for (B.T.D.C) (A.T.D.C) Intake open Exhaust close wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out- put power.
  • Page 72 3-25 ENGINE Inspect the tappet for wear and scratch. If modification or scratch is present, replace the tap- pet. When you checked the valve clearance, if the valve clearance is wide please replace the present shim into thick one, if the valve clearance is narrow please replace the present shim into thin shim.

  • Page 73: Valve Spring

    ENGINE 3-26 VALVE SPRING The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power out- put 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.
  • Page 74 3-27 ENGINE CAM CHAIN TENSIONER ADJUSTER Check that the push rod slides smoothly with the lock shaft handle clockwise. If it does not slide smoothly, replace the cam chain ① tensioner adjuster with a new one. CAM CHAIN TENSIONER Check the contacting surface of the cam chain tensioner. If it is worn or damaged, replace it with a new one.
  • Page 75 ENGINE 3-28 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 Service limit Piston-to-cylin- 0.045~0.075 mm 0.120 mm der clearance (0.0018~0.0030 in) (0.0047 in) PISTON PIN HOLE BORE Using a dial calipers, measure the piston pin hole bore both the vertical and horizontal directions.

  • Page 76: Piston Ring End Gap

    3-29 ENGINE 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) 0.20~0.35 mm...
  • Page 77 ENGINE 3-30 OVERSIZE RINGS Oversize piston ring The following two types of oversize piston ring are used. They bear the following identification numbers. Oversize piston ring 0.5 mm 1.0 mm Oversize oil ring The following two types of oversize oil ring are used. They bear the following identification marks.

  • Page 78: Crankshaft Runout

    3-31 ENGINE 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 stan- dard value, measure the conrod big end and the crank pin widths individually to determine which one is to be replaced.
  • Page 79 ENGINE 3-32 STARTER CLUTCH 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.

  • Page 80: Oil Jet

    3-33 ENGINE DISASSEMBLY Remove the bush using the special tool. Bearing remover (20~35 mm) : 09923-74510 OIL JET ① REMOVAL Remove the oil jet ①, ② from the right crankcase half. ② Remove the oil jet ③ from the left crankcase half. NOTE If it is difficult to remove the oil jet, use a sting.

  • Page 81: Inspection And Cleaning

    ENGINE 3-34 INSPECTION AND CLEANING Check the oil jets for clogging. If they are clogged, clean their oil passage with a proper wire and compressed air. INSTALLATION Fit the new O-ring to each oil jets. CAUTION Use the new O-ring to prevent oil leakage. Apply engine oil to the O-ring.
  • Page 82 3-35 ENGINE REASSEMBLY Drive in the oil seal using the special tool. Bearing installer : 09913-75820 Install the circlip. CLUTCH DRIVE PLATES 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.
  • Page 83 ENGINE 3-36 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 51 mm (2.008 in) Vernier calipers : 09900-20101 CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality,...
  • Page 84 3-37 ENGINE GEARSHIFT SHAFT Disassemble and reassemble the gearshift shaft as shown in right picture. TRANSMISSION INSPECTION GEAR-SHIFTING FORK Using a thickness gauge, check the clearance between 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.
  • Page 85 ENGINE 3-38 CAUTION Never reuse a circlip. After a circlip has been removed from a shaft, it should be Thrust discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larg- er than required to slip the circlip over the shaft.

  • Page 86: Bearing Inspection

    3-39 ENGINE CRANKCASE play play 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.
  • Page 87 ENGINE 3-40 Remove the bearing ①. Bearing installer : 09913-76010 ① CAUTION The removed bearing should be replaced with a new one. LEFT CRANKCASE BEARING Remove the oil seals ② and ③. Oil seal remover : 09913-50121 ③ ② Remove the bearings ④ ⑤ and ⑥. ④...

  • Page 88: Engine Reassembly

    3-41 ENGINE LEFT CRANKCASE BEARING Drive in the bearings ① ② and ③ ③ Bearing installer : 09913-70122 Bearing installer : 09913-76010 ② ① Install the oil seals ④ and ⑤ Apply SUPER GREASE A on the lip of oil seal. SUPER GREASE A ENGINE REASSEMBLY ④...
  • Page 89 ENGINE 3-42 TRANSMISSION Install the transmission. GEARSHIFT CAM AND GEARSHIFT FORKS Install the gearshift fork NO.1 ①, NO.2 ②, and NO.3 ③. ① ③ ② ① ③ ② Install the gearshift cam ④, and gearshift fork shaft ⑤ ⑥. ⑥ ⑤...
  • Page 90 3-43 ENGINE Apply BOND 1215 to the right crankcase. BOND 1215 CAUTION Application of BOND 1215 must be performed within a short period of time. T a k e e x t r e m e c a r e n o t t o l e t B O N D 1215 enter into the oil hole or bearing.
  • Page 91 ENGINE 3-44 Apply the SUPER GREASE A to the driveshaft O- ring and oil seal lip. SUPER GREASE A Install the driveshaft spacer. Install the oil seal retainer. GEARSHIFT CAM STOPPER Apply a small quantity THREAD LOCK 1324 to the ①...
  • Page 92 3-45 ENGINE CAUTION After the cam driven gear, cam guide, gearshift 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.
  • Page 93 ENGINE 3-46 CAM CHAIN TENSIONER ① ② Install the washer and cam chain tensioner ②, tighten the cam chain tensioner bolt ①. ③ Cam chain tensioner bolt : 8 ~ 12 N m (0.8 ~ 1.2 kgf m) Install the cam chain ③. PRIMARY DRIVE GEAR Install the primary drive gear and NO.2 gear to the crankshaft, put the key to the key groove.
  • Page 94 3-47 ENGINE PRIMARY DRIVEN GEAR NOTE Apply the engine oil to the inside face of primary driven gear bearing. Install the primary driven gear assembly. CLUTCH ② Install the clutch sleeve hub ①, lock washer ②. ① Install the clutch sleeve hub nut, and tighten it to the specified torque using the special tool.
  • Page 95 ENGINE 3-48 Install the clutch release rack ①, bearing ② and washer ③. ③ ① ② Install the clutch pressure plate ④ retainer, clutch ④ springs and clutch spring mounting bolts. Hold the primary drive gear nut and tighten the clutch spring mounting bolts in a crisscross pattern.
  • Page 96 3-49 ENGINE Install the clutch cover, and tighten the clutch cover bolts securely. Install the clutch release arm as following : ① Turn the clutch release shaft toward(This time, mark on the shaft align outside contact line the stopper screw) the right. ②...
  • Page 97 ENGINE 3-50 MAGNETO ROTOR Fit the key into the key slot on the crankshaft. With the magneto rotor, install the starter clutch on the crankshaft. Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft. THREAD LOCK 1324 Tighten the magneto rotor bolt to the specified torque.

  • Page 98: Piston Ring

    3-51 ENGINE MAGNETO COVER Install the new gasket and dowel pin. Apply oil to the each gear, bearing and starter clutch. Install the magneto cover and tighten the magneto cover bolts. Magneto cover bolt : 10 N m (1.0 kgf m) PISTON RING First, install the piston ring in order of oil ring, 2nd ring and 1st ring at the front cylinder.

  • Page 99: Cylinder Head

    ENGINE 3-52 CYLINDER ① Apply BOND 1215 to the parting line of crankcase. BOND 1215 Place the dowel pin ① and new gasket on the crankcase. CAUTION Make sure to replace the gasket with a new one. Apply the engine oil to the conrod small end, piston and the piston rings.
  • Page 100 3-53 ENGINE CAUTION Pay caution to prevent the cam chain from drop- ping into the crankcase. Tighten the cylinder head base bolt. Cylinder head base bolt : 8 ~ 12 N m (0.8 ~ 1.2 kgf m) Install the tappet and shim. CAUTION Tappet With the tappet fitted, it should be replaced if it...
  • Page 101 ENGINE 3-54 CAMSHAFT ASSEMBLY Distinguish the EX mark for the exhaust camshaft, the IN mark for the intake camshaft. With pulling up the camshaft drive chain, align the F mark of magneto rotor into the punching mark of magneto cover to turn the crankshaft. (Front cylinder) CAUTION When adjusting the rear cylinder, align the...
  • Page 102 3-55 ENGINE The 1F arrow of exhaust camshaft sprocket should be toward the outside and aligned with the plane of FRONT cylinder head. At that time, the 2 arrow of exhaust camshaft sprocket should be in a vertical position to the plane of cylinder head when exhaust camshaft sprocket was geared into cam chain.
  • Page 103 ENGINE 3-56 CAUTION The cam chain is installed to the all of three sprocket. Be sure to lie the crankshaft until the two holder and cam chain tensioner adjuster are installed completely. Rotated Direction 1 Link 16 Link 16 Pins Exhaust Intake Front cylinder...
  • Page 104 3-57 ENGINE Put the intake or exhaust camshaft housing to the cylinder head upper surface. Tighten the camshaft housing bolt with the specified torque diagonally. 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.
  • Page 105 ENGINE 3-58 Turn the crankshaft about 10 times counter-clock- wise ( ) on the basis of the magneto rotor. If the valve clearance is within standard after mea- sured 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.
  • Page 106 3-59 ENGINE Install the rear cylinder head and cylinder with the Rear Cylinder same manner which installed the front cylinder head and cylinder. Front Cylinder THERMOSTAT ① Install the thermostat case ① along with the hose ②. NOTE Thermostat reassembly : Refer to page 6-10 ②...

  • Page 107: Ei System Diagnosis

    EI SYSTEM DIAGNOSIS CONTENTS PRECAUTIONS IN SERVICING ………………………………………… 4 - 1 EI SYSTEM TECHNICAL FEATURES ………………………………… 4 - 5 SELF-DIAGNOSIS FUNCTION ………………………………………… 4 - 10 EI SYSTEM TROUBLESHOOTING …………………………………… 4 - 19 CUSTOMER COMPLAINT ANALYSIS…………………………………… 4 - 19 SELF-DIAGNOSTIC PROCEDURES …………………………………… 4 - 21 SELF-DIAGNOSIS RESET PROCEDURE ………………………………...

  • Page 108: Precautions In Servicing

    4-1 EI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the EI system, observe the following points for the safety of the system. ⊙ ⊙ ELECTRICAL PARTS ▣ ▣ CONNECTOR / COUPLER ● When connecting a connector, be sure to push it in until a click is felt.
  • Page 109 EI SYSTEM DIAGNOSIS 4-2 ● When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female termi- nal to open.
  • Page 110 4-3 EI SYSTEM DIAGNOSIS ● When disconnecting and connecting the ECU, make sure to turn “OFF” the ignition switch, or electronic parts may get damaged. ● Battery connection in reverse polarity is strictly pro- hibited. Such a wrong connection will damage the compo- nents of the EI system instantly when reverse power is applied.

  • Page 111: Using Testers

    EI SYSTEM DIAGNOSIS 4-4 ● Never connect an ohmmeter to the ECU with its cou- pler connected. If attempted, damage to the ECU or sensors may result. ● Be sure to use a specified voltmeter / ohmmeter. Otherwise, accurate measurements may not be obtained and personal injury may result.

  • Page 112: Ei System Technical Features

    4-5 EI SYSTEM DIAGNOSIS EI SYSTEM TECHNICAL FEATURES ⊙ ⊙ EI SYSTEM’S CONTROL DIAGRAM FUEL IAT Sensor FUEL TANK AIR CLEANER ISC Solenoid TP Sensor FUEL PUMP THROTTLE BODY IAP Sensor INTAKE PIPE FUEL INJECTOR WT Sensor Pick-up Coil CYLINDER Sensor EXHAUST PIPE : Electrical signal flow...
  • Page 113 EI SYSTEM DIAGNOSIS 4-6 ⊙ ⊙ INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

  • Page 114: Injection Stop Control

    4-7 EI SYSTEM DIAGNOSIS ⊙ ⊙ COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION WATER COOLANT TEMPERATURE When engine coolant temperature is low, injection time (volume) SENSOR SIGNAL is increased.
  • Page 115 EI SYSTEM DIAGNOSIS 4-8 ⊙ ⊙ EI SYSTEM PARTS LOCATION E E C C U U ① Speedometer ⑥ Fuel injector, NO.2 ② Fuel pump relay ⑦ GP switch ③ Fuel injector, NO.1 ⑧ Pick-up coil ④ TP sensor ⑨ Ignition coil, NO.1 ⑤...
  • Page 116 4-9 EI SYSTEM DIAGNOSIS 1 1 2 2 E E C C U U 1 1 1 1 1 1 0 0 1 1 3 3 1 1 5 5 1 1 4 4 ⑩ RO switch ⑬ WT sensor ⑪...

  • Page 117: Self-Diagnosis Function

    EI SYSTEM DIAGNOSIS 4-10 SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECU. The function has two modes, “USER MODE” and “DEALER MODE”. The user can only be notified by the “FI” check lamp “ ” To check the function of the individual EI system devices, the dealer mode is prepared. In this check, the special tool or additional movement is necessary to read the code of the malfunction items.

  • Page 118: Dealer Mode

    4-11 EI SYSTEM DIAGNOSIS ⊙ ⊙ DEALER MODE The defective function is memorized in the ECU. The memorized malfunction code is displayed on the LCD (DISPLAY) panel or with blinks signal of the “FI” check lamp “ ” Malfunction means that the ECU does not receive signal from the devices or fault signal received. These affected devices are indicated in the code form on the LCD (DISPLAY) panel or displayed with blinks signal of the “FI”...
  • Page 119 EI SYSTEM DIAGNOSIS 4-12 CAUTION Confirm the malfunction code after turn the ignition switch “ON” position and after starting the engine in twice. The dealer mode coupler is located under the front seat. LCD (DISPLAY) “FI” CHECK LAMP INDICATION CLASSIFICATION MALFUNCTION INDICATION INDICATION...
  • Page 120 4-13 EI SYSTEM DIAGNOSIS B. “FI” CHECK LAMP To confirm the memorized malfunction code : 1. Turn the ignition switch alternately, “ON” and “OFF” position, for 2 seconds by three times. CAUTION Take special care when operating above procedure. If the ignition switch is turned alternately, “ON” and “OFF” position, for 2 seconds by five times, the ECU is initialized.
  • Page 121 EI SYSTEM DIAGNOSIS 4-14 CODE CODE MALFUNCTION PART REMARKS 0031 NO.1 O ₂ ₂ S heater Circuit Low Voltage For NO.1 cylinder 0032 NO.1 O ₂ ₂ S heater Circuit High Voltage For NO.1 cylinder 0037 NO.2 O ₂ ₂ S heater Circuit Low Voltage For NO.2 cylinder 0038 NO.2 O ₂...
  • Page 122 4-15 EI SYSTEM DIAGNOSIS CODE CODE MALFUNCTION PART REMARKS 0117 WTS Circuit Low Voltage 0118 WTS Circuit High Voltage or Open 0122 TPS Circuit Low Voltage or Open 0123 TPS Circuit High Voltage 0131 NO.1 O ₂ ₂ S Circuit Low Voltage For NO.1 cylinder 0132 NO.1 O ₂...
  • Page 123 EI SYSTEM DIAGNOSIS 4-16 CODE CODE MALFUNCTION PART REMARKS 0201 NO.1 Fuel injector Circuit Malfunction For NO.1 cylinder 0202 NO.2 Fuel injector Circuit Malfunction For NO.2 cylinder 0230 Fuel pump relay Circuit Low Voltage or Open 0232 Fuel pump relay Circuit High Voltage 0336 Pick-up coil Noisy Signal 0337...
  • Page 124 4-17 EI SYSTEM DIAGNOSIS CODE CODE MALFUNCTION PART REMARKS 0444 PV Circuit Open California model only 0445 PV Circuit Shorted California model only 0505 ISC Error 0562 Battery Voltage Low 0563 Battery Voltage High 0650 “FI” check lamp Circuit Malfunction 0850 GP or Clutch lever Switch Circuit Malfunction ※...
  • Page 125 EI SYSTEM DIAGNOSIS 4-18 LCD (DISPLAY) INDICATION In the LCD (DISPLAY) panel ①, the malfunction code is indicated in chronological order. “FI” CHECK LAMP INDICATION ” ②, the malfunction code is blinked in chronological order. In the “FI” check lamp “ ②...

  • Page 126: Ei System Troubleshooting

    4-19 EI SYSTEM DIAGNOSIS EI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper analysis and diagnosis.
  • Page 127 EI SYSTEM DIAGNOSIS 4-20 MOTORCYCLE / ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °F / °C) Always Frequency Always Sometimes ( times / day, month) Only once Under certain condition Road Urban Suburb...

  • Page 128: Self-Diagnostic Procedures

    4-21 EI SYSTEM DIAGNOSIS SELF-DIAGNOSTIC PROCEDU- Don’t disconnect couplers from ECU, battery cable from battery, ECU ground wire harness from engine or main fuse before confirming malfunction code (self-diagnostic trouble code) stored in memory. The memorized malfunction code is displayed on the LCD (DISPLAY) panel or displayed with blinks sig- nal of the “FI”...

  • Page 129: Self-Diagnosis Reset Procedure

    EI SYSTEM DIAGNOSIS 4-22 SELF-DIAGNOSIS RESET PRO- CEDURE ▣ ▣ A. LCD (DISPLAY) PANEL ① ① ● After repairing the trouble, turn the ignition switch “OFF” position and turn “ON” position again. ● If “noEr” then CLOCK (LCD INDICATION ①) is indicates, the malfunction codes are cleared.

  • Page 130: Malfunction Code And Defective Condition

    4-23 EI SYSTEM DIAGNOSIS MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR noEr NO FAULT After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 0031 Low Voltage times test cycle, the code 0031 is indicated.
  • Page 131 EI SYSTEM DIAGNOSIS 4-24 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V Sensor output voltage 0117 Low Voltage Without the above range for 6.25 sec. and more, 0117 is indicated. Water temperature sensor, lead wire / coupler connection.
  • Page 132 4-25 EI SYSTEM DIAGNOSIS DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if NO.1 fuel injector signal open or is hap- pened the high / ground short fault for 1 second by 5 times in 10 NO.1 Fuel Injector 0201 times test cycle, the code 0201 is indicated.
  • Page 133 EI SYSTEM DIAGNOSIS 4-26 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if purge control valve signal open or is happened the ground short fault for 1 second by 10 times in 12 times test cycle, the code 0444 is indicated. 0444 Open Purge control valve, wiring / coupler connection, power supply...

  • Page 134: Oxygen Sensor Heater Circuit Malfunction

    4-27 EI SYSTEM DIAGNOSIS “0031”, “0032”, “0037” or “0038” OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION & “0131”, “0132”, “0137” or “0138” OXYGEN SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0031 0032 0037 0038 0131 0132 0137 0138 DETECTED CONDITION POSSIBLE CAUSE ●...
  • Page 135 EI SYSTEM DIAGNOSIS 4-28 ▣ ▣ INSPECTION 1) Remove the front seat and right side cover. 2) Turn the ignition switch “OFF” position. 3) Check the Oxygen sensor coupler for loose or poor contacts. Is OK? ● B or GR (NO.1 O ₂ ₂ S) / R or GR (NO.2 O ₂...

  • Page 136: 0107" Or "0108" Iap Sensor Circuit Malfunction

    4-29 EI SYSTEM DIAGNOSIS “0107” or “0108” IAP SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0107 0108 DETECTED CONDITION POSSIBLE CAUSE ● Clogged vacuum passage between throttle body ☞ ☞ Refer to page 4-23 and IAP sensor. ●...
  • Page 137 EI SYSTEM DIAGNOSIS 4-30 Step 2 1) Connect the IAP sensor coupler ①. 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed. ① 4) Measure the IAP sensor output voltage at the wire side coupler (between BL and GR wires).

  • Page 138: 0112" Or "0113" Iat Sensor Circuit Malfunction

    4-31 EI SYSTEM DIAGNOSIS “0112” or “0113” IAT SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0112 1 1 2 1 1 2 1 1 2 ] 0113 DETECTED CONDITION POSSIBLE CAUSE ● IAT sensor circuit open or short. ☞...
  • Page 139 EI SYSTEM DIAGNOSIS 4-32 IAT sensor resistance Intake Air Temp. Resistance ㏀ -40 ℃ (-40 ℉ ) 44.642 ± 5% ㏀ -20 ℃ (-4 ℉ ) 14.958 ± 5% ㏀ 0 ℃ (32 ℉ ) ± 5% 5.734 ㏀ 20 ℃ (68 ℉ ) ±...

  • Page 140: 0117" Or "0118" Wt Sensor Circuit Malfunction

    4-33 EI SYSTEM DIAGNOSIS “0117” or “0118” WT SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0117 0118 DETECTED CONDITION POSSIBLE CAUSE ● WT sensor circuit open or short. ☞ ☞ Refer to page 4-24 ● WT sensor malfunction. ●...
  • Page 141 EI SYSTEM DIAGNOSIS 4-34 WT sensor resistance Engine Coolant Temp. Resistance (To ECU) ㏀ -40 ℃ (-40 ℉ ) Approx. 48.140 ㏀ 0 ℃ (32 ℉ ) Approx. 5.790 ㏀ 20 ℃ (68 ℉ ) Approx. 2.450 ㏀ 40 ℃ (104 ℉ ) Approx.

  • Page 142: 0122" Or "0123" Tp Sensor Circuit Malfunction

    4-35 EI SYSTEM DIAGNOSIS “0122” or “0123” TP SENSOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0122 0123 DETECTED CONDITION POSSIBLE CAUSE ● TP sensor circuit open or short. ● TP sensor malfunction. ☞ ☞ Refer to page 4-24 ●...
  • Page 143 EI SYSTEM DIAGNOSIS 4-36 ◈ Step 2 1) Remove the frame cover. 2) Turn the ignition switch “OFF” position. 3) Disconnect the TP sensor coupler. 4) Check the continuity between (LY) and ground. ∞ Ω (Infinity) TP sensor continuity - Ground) Ω...
  • Page 144 4-37 EI SYSTEM DIAGNOSIS Is the output voltage OK? ● OB, LY or GR wire open or shorted to ground, or poor , or connection of ECU coupler. ● If wire and connection are OK, intermittent trouble or faulty ECU. Gray Black ●...

  • Page 145: 0201" Or "0202" Fuel Injector Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-38 “0201” or “0202” FUEL INJECTOR CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0201 0202 DETECTED CONDITION POSSIBLE CAUSE ● Injector circuit open or short. ☞ ☞ Refer to page 4-25 ● Injector malfunction. ● ECU malfunction. ▣...
  • Page 146 4-39 EI SYSTEM DIAGNOSIS ◈ Step 2 1) Turn the ignition switch “ON” position. 2) Measure the injector voltage between YR(NO.1) or RB(NO.2) wire and ground. Battery voltage Injector voltage ( ~NO.1₩ YR - Ground, ~NO.2₩ RB - Ground ) Tester knob indication : Voltage ( NO.2 NO.1 NOTE...

  • Page 147: 0230" Or "0232" Fuel Pump Relay Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-40 “0230” or “0232” FUEL PUMP RELAY CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0230 0232 DETECTED CONDITION POSSIBLE CAUSE ● Fuel pump relay circuit open or short. ☞ ☞ Refer to page 4-25 ● Fuel pump relay malfunction. ●...

  • Page 148: 0336" Or "0337" Pick-Up Coil Circuit Malfunction

    4-41 EI SYSTEM DIAGNOSIS “0336” or “0337” PICK-UP COIL CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0336 0337 DETECTED CONDITION POSSIBLE CAUSE ● Metal particles or foreign materiel being attached on the pick-up coil and rotor tip. ● Pick-up coil circuit open or short. ☞...
  • Page 149 EI SYSTEM DIAGNOSIS 4-42 Are the resistance and continuity OK? ● L or G wire open or shorted to ground, or poor connection of ECU coupler. ● If wire and connection are OK, intermittent trouble or faulty ECU. ● Recheck each terminal and wire harness for open circuit and poor Gray Black...

  • Page 150: 0351" Or "0352" Ignition Coil Malfunction

    4-43 EI SYSTEM DIAGNOSIS “0351” or “0352” IGNITION COIL MALFUNCTION Refer to the IGNITION COIL for details. (See page 7-5) LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0351 0352...

  • Page 151: 0444 " " Or " " 0445 " " Purge Control Valve Circuit

    EI SYSTEM DIAGNOSIS 4-44 “0444” or “0445” PURGE CONTROL VALVE CIRCUIT MALFUNCTION (California model only) LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0444 0445 DETECTED CONDITION POSSIBLE CAUSE ● PV circuit open and short. ☞ ☞ Refer to page 4-26 ●...
  • Page 152 4-45 EI SYSTEM DIAGNOSIS Are the resistance and continuity OK? ● GW wire open or shorted to ground, or poor connection of ECU coupler. ● YL coupler open or shorted to the wiring harness. ● If wire and connection are OK, intermittent trouble or faulty ECU.

  • Page 153: 0505" Isc Solenoid Range Abnormal

    EI SYSTEM DIAGNOSIS 4-46 “0505” ISC SOLENOID RANGE ABNORMAL LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0505 DETECTED CONDITION POSSIBLE CAUSE ● ISC solenoid malfunction. ☞ ☞ Refer to page 4-26 ● ISC solenoid’s step is out of the specified range. ●...

  • Page 154: 0562" Or "0563" Battery Voltage Malfunction

    4-47 EI SYSTEM DIAGNOSIS “0562” or “0563” BATTERY VOLTAGE MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0562 0563 DETECTED CONDITION POSSIBLE CAUSE ● Battery voltage circuit open and short. ☞ ☞ Refer to page 4-26 ● Battery malfunction. ● ECU malfunction. ▣...

  • Page 155: 0650" "Fi" Check Lamp Circuit Malfunction

    EI SYSTEM DIAGNOSIS 4-48 “0650” “FI” CHECK LAMP CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0650 DETECTED CONDITION POSSIBLE CAUSE ● “FI” check lamp circuit open and short. ☞ ☞ Refer to page 4-26 ● “FI” check lamp malfunction. ●...

  • Page 156: 0850" Gp Or Clutch Lever Switch Circuit Malfunction

    4-49 EI SYSTEM DIAGNOSIS “0850” GP or CLUTCH LEVER SWITCH CIRCUIT MALFUNCTION LCD (DISPLAY) INDICATION “FI” CHECK LAMP INDICATION 0850 POSSIBLE CAUSE DETECTED CONDITION ● GP switch circuit open or short. ● GP switch malfunction. ☞ ☞ Refer to page 4-26 ●...
  • Page 157 EI SYSTEM DIAGNOSIS 4-50 6) Disconnect the clutch lever switch coupler ② and ② then check the continuity between GR wire and Br wire when the squeezing the clutch lever. Ω Clutch lever switch continuity (GR - Br) Ω Ω Tester knob indication : Resistance ( 7) Measure the voltage between of the ECU and...

  • Page 158: Sensors

    4-51 EI SYSTEM DIAGNOSIS SENSORS ① ⊙ ⊙ PICK-UP COIL INSPECTION The pick-up coil ① is installed in the magneto cover. (Refer to page 4-41) ⊙ ⊙ PICK-UP COIL REMOVAL AND INSTALLATION ● Remove the magneto cover. ● Install the magneto cover in the reverse order of removal.

  • Page 159: Iat Sensor Inspection

    EI SYSTEM DIAGNOSIS 4-52 ⊙ ⊙ WT SENSOR INSPECTION The water temperature (WT) sensor ① is installed at the rear side of the thermostat case. (Refer to page 4-33) ⊙ ⊙ WT SENSOR REMOVAL AND ① INSTALLATION ● Remove the WT sensor. ●...

  • Page 160: Fuel System And Throttle Body

    FUEL SYSTEM AND THROTTLE BODY CONTENTS FUEL SYSTEM ……………………………………………………………… 5 - 1 REMOVAL AND DISASSEMBLY…………………………………………… 5 - 2 REASSEMBLY AND INSTALLATION ……………………………………… 5 - 3 FUEL PRESSURE OF FUEL PUMP INSPECTION ……………………… 5 - 4 FUEL PUMP RELAY INSPECTION ………………………………………… 5 - 4 FUEL MESH FILTER INSPECTION AND CLEANING ……………………...

  • Page 161: Fuel System

    5-1 FUEL SYSTEM AND THROTTLE BODY FUEL SYSTEM...

  • Page 162: Removal And Disassembly

    FUEL SYSTEM AND THROTTLE BODY 5-2 REMOVAL AND DISASSEMBLY ● Remove the front seat. WARNING Gasoline is very explosive. Extreme care must be taken. ● Remove the fuel tank mounting bolts and take off the hooks. ● Disconnect the fuel gauge coupler ①. ①...

  • Page 163: Reassembly And Installation

    5-3 FUEL SYSTEM AND THROTTLE BODY ● Remove the fuel tank rearward. CAUTION As gasoline leakage may occur in this operation, keep away from fire and sparks. ● Remove the fuel pump assembly ① by removing ① its mounting bolts diagonally. WARNING Gasoline is highly flammable and explosive.

  • Page 164: Fuel Pressure Of Fuel Pump Inspection

    FUEL SYSTEM AND THROTTLE BODY 5-4 FUEL PRESSURE OF FUEL PUMP INSPECTION ● Remove the seat. ● Place a rag under the fuel injector hose. ● Disconnect the fuel injector hose from the fuel hose joint. ● Install the special tool between the fuel tank and fuel hose joint.

  • Page 165: Fuel Mesh Filter Inspection And Cleaning

    5-5 FUEL SYSTEM AND THROTTLE BODY First, check the insulation between ① and ② termi- ① ③ nals with pocket tester. Then apply 12 volts to ③ and ④ terminals, to ③ and to ④, and check the continuity between ① and ②. If there is no continuity, replace it with a new one.

  • Page 166: Throttle Body

    FUEL SYSTEM AND THROTTLE BODY 5-6 THROTTLE BODY...

  • Page 167: Removal

    5-7 FUEL SYSTEM AND THROTTLE BODY REMOVAL ● Remove the fuel tank. ● Disconnect the fuel hoses. ● Remove the all couplers to related the throttle body. ● Loosen the throttle body clamp screws. ● Remove the air cleaner chamber. ●...

  • Page 168: Cleaning

    FUEL SYSTEM AND THROTTLE BODY 5-8 CLEANING ● Clean all passageways with a spray-type throttle body cleaner and blow dry with compressed air. WARNING Some throttle body cleaning chemicals, especial- ly dip-type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical manufacturer’s instructions on proper use, handling and storage.

  • Page 169: Cooling System

    COOLING SYSTEM CONTENTS ENGINE COOLANT 6 - 1 COOLING CIRCUIT 6 - 2 RADIATOR 6 - 2 COOLING FAN 6- 5 COOLING FAN THERMO-SWITCH 6- 6 WATER TEMPERATURE SENSOR 6 - 8 THERMOSTAT 6 - 9 WATER PUMP 6 - 11...
  • Page 170 6-1 COOLING SYSTEM ENGINE COOLANT Anti-freeze density Freezing point ( 24 ) At the time of manufacture, the cooling system is filled with a 50 : 50 mixture of distilled water and ethylene gly- ( 40 ) col anti-freeze. ( 67 ) This 50 : 50 mixture will provide the optimum corrosion protection and excellent heat protection, and will protect the cooling system from freezing at temperatures above...

  • Page 171: Cooling Circuit

    COOLING SYSTEM 6-2 COOLING CIRCUIT RESERVE TANK RADIATOR FRONT CYLINDER HEAD FRONT CYLINDER THERMOSTAT WATER PUMP REAR CYLINDER REAR CYLINDER HEAD RADIATOR REMOVAL ① Drain engine coolant. (Refer to page 2-25) ②, remove After removing the two mounting bolts the right frame head cover ①. Remove the radiator cap case bolt ③.
  • Page 172 6-3 COOLING SYSTEM Disconnect the cooling fan thermo-switch lead wire coupler ①. Disconnect the radiator inlet hose ②. ② ① Disconnect reserve tank hose ③. ③ Disconnect the cooling fan motor lead wire coupler ④. ④ Remove the radiator by the mounting bolts. INSPECTION AND CLEAN- Road dirt or trash stuck to the fins must be removed.
  • Page 173 COOLING SYSTEM 6-4 Fins bent down or dented can be repaired by straighten- ing them with the blade of a small screwdriver. INSPECTION OF WATER HOSE Any water hose found in a cracked condition or flattened or water leaked must be replaced. Any leakage from the connecting section should be cor- rected by proper tightening.
  • Page 174 6-5 COOLING SYSTEM COOLING FAN ① INSPECTION Remove the radiator cover. (Refer to page 6-2) ② Disconnect the cooling fan motor lead wire coupler ① and its thermo-switch lead wire coupler ②. Test the cooling fan motor for load current with an ammeter connected as shown in the illustration.
  • Page 175 COOLING SYSTEM 6-6 COOLING FAN THERMO- SWITCH The cooling fan is secured behind the radiator by three bolts and is automatically controlled by the thermo-switch. The thermo-switch remains open when the temperature of the engine coolant is low, ① but closes when the temperature reaches approxi- mately 78 ℃...
  • Page 176 6-7 COOLING SYSTEM INSTALLATION ① Install the cooling fan thermo-switch in the reverse order of removal. Pay attention to the following points : Install a new O-ring ① and apply engine coolant to the O-ring. Tighten the cooling fan thermo-switch to the specified torque.

  • Page 177: Water Temperature

    COOLING SYSTEM 6-8 WATER TEMPERATURE SENSOR REMOVAL ② Drain engine coolant. (Refer to page 2-25) Remove the front seat. (Refer to page 8-1) Remove the fuel tank. (Refer to page 5-2) Remove the throttle body. (Refer to page 5-7) ① Disconnect the WT (Water Temperature) sensor lead wire coupler ①.
  • Page 178 6-9 COOLING SYSTEM THERMOSTAT REMOVAL Drain engine coolant. (Refer to page 2-25) Place a rag under the thermostat case. Remove the thermostat case cap. Remove the thermostat ①. ① INSPECTION Inspect the thermostat pellet for signs of cracking. Test the thermostat at the bench for control action, in the follwing manner.
  • Page 179 COOLING SYSTEM 6-10 Keep on heating the water to raise its temperature. Just when the water temperature reaches specified value, the thermostat valve should have lifted by at least 8.0 mm (0.32 in). Standard Thermostat valve lift Over 8.0 mm at 100 (Over 0.32 in at 212 A thermostat failing to satisfy either of the two requirements, start-to-open temperature and valve...

  • Page 180: Water Pump

    6-11 COOLING SYSTEM WATER PUMP REMOVAL AND DISASSEM- Drain engine coolant. (Refer to page 2-25) ② Drain engine oil. (Refer to page 2-12) Remove the water pump cover ①. Remove the radiator outlet hose cover ②. Disconnect the water hoses ③, ④, ⑤. ①...
  • Page 181 COOLING SYSTEM 6-12 Remove the water pump ① from the clutch cover. ① Remove the O-rings ②. ② Remove the E-ring ③ from the impeller shaft. ③ Remove the impeller ④ from the other side. ④...
  • Page 182 6-13 COOLING SYSTEM Remove the bearing. NOTE If there is no abnormal noise, bearing removal is not necessary. INSPECTION BEARING Inspect the play of the bearing by hand while it is in the water pump case. Rotate the inner race by hand to inspect abnormal noise and smooth rotation.
  • Page 183 COOLING SYSTEM 6-14 Apply SUPER GREASE A to the impeller shaft. SUPER GREASE A Install the impeller to the water pump body. Fix the impeller shaft with the E-ring ①. Fill the bearing with engine oil until engine oil comes out from the hole of the bearing housing.

  • Page 184: Electrical System

    ELECTRICAL SYSTEM CONTENTS LOCATION OF ELECTRICAL COMPONENTS 7 - 1 IGNITION SYSTEM 7 - 4 CHARGING SYSTEM 7 - 8 STARTER SYSTEM AND SIDE STAND IGNITION INTERLOCK SYSTEM 7 - 10 SWITCHES 7 - 14 LAMP 7 - 15 BATTERY 7 - 17...

  • Page 185: Location Of Electrical Components

    7-1 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS ① ② ④ ⑤ ⑥ ③ ⑦ ① Ignition coil NO.1 ④ Regulator / Rectifier ⑦ ISC solenoid ② Turn signal relay ⑤ Main relay ③ Side stand relay ⑥ Fuel pump relay ⑪...
  • Page 186 ELECTRICAL SYSTEM 7-2 ⑭ ⒕ ⒔ ⒖ ⑮ ⒃ ⑭ Starter motor relay ⒔ Fuel injector NO.2 ⒖ IAP sensor ⑮ Cooling fan motor relay ⒕ Fuel injector NO.1 ⒃ Head lamp relay (22) (23) ⒗ (24) (21) ⒗ Oxygen sensor NO.1 (22) WT sensor (24) Rear brake lamp switch (21) Oxygen sensor NO.2...
  • Page 187 7-3 ELECTRICAL SYSTEM (25) (26) (27) (25) RO switch (26) Ignition coil NO.2 (27) TP sensor (30) (28) (29) (28) ECU fuse (15A) (28) (27) IAT sensor Front brake lamp switch (29) Main fuse (30A) (30) ECU (30) Battery...

  • Page 188: Ignition System

    ELECTRICAL SYSTEM 7-4 IGNITION SYSTEM IGNITION SWITCH ENGINE STOP SWITCH FUSE FUSE REGULATOR RECTIFIER BATTERY 12V 12Ah ⊙ ⊙ INSPECTION ▣ ▣ MAGNETO Using the pocket tester, measure the resistance between the lead wires in the following table. If the resistance is not within the specified value, Charging coil replace the stator coil, with a new one.

  • Page 189: Voltage Inspection

    7-5 ELECTRICAL SYSTEM ▣ ▣ IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION ● Remove the fuel tank and frame cover. ● Disconnect the two spark plug caps. ● With the spark plug cap connected, place a new spark plug on the engine to ground it. NOTE Check that all the couplers are connected.
  • Page 190 ELECTRICAL SYSTEM 7-6 ▣ ▣ IGNITION COIL RESISTANCE INSPECTION ● Remove the fuel tank. (Refer to page 5-2) ● Disconnect the ignition coil read wire. Measure the ignition coil resistance in bolt the prima- ry and secondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one.
  • Page 191 7-7 ELECTRICAL SYSTEM ELECTRODE’S CONDITION Check to see the worn or burnt condition of the elec- trodes. If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc. CAUTION Use recommended spark plugs only.

  • Page 192: Charging System

    ELECTRICAL SYSTEM 7-8 CHARGING SYSTEM Regulator / Rectifier Ignition switch A. C generator 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 If the voltage is not within the specified value, check the magneto no-load performance and regulator / rectifier.
  • Page 193 7-9 ELECTRICAL SYSTEM MAGNETO NO-LOAD PERFOR- MANCE 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 volt- age between the three lead wires. If the voltage is under the specified value, replace the magneto with a new one.

  • Page 194: Starter System Description

    ELECTRICAL SYSTEM 7-10 STARTER SYSTEM AND SIDE STAND IGNITION INTER- LOCK SYSTEM STARTER SYSTEM DESCRIPTION The starter system consists of the following components : the starter motor, starter relay, clutch lever switch, side stand switch, neutral 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.
  • Page 195 7-11 ELECTRICAL SYSTEM TRANSMISSION : Neutral - ON Side stand - Down Clutch lever - Squeeze SIDE STAND RELAY IGNITION SWITCH BATTERY IGNITION COIL BATTERY NEUTRAL INDICATOR LAMP DIODE SIDE STAND SWITCH SIDE STAND NEUTRAL DOWN POSITION SWITCH ON TRANSMISSION : Neutral - OFF Side stand - Up Clutch lever - Squeeze...

  • Page 196: Starter Motor Removal

    ELECTRICAL SYSTEM 7-12 STARTER MOTOR REMOVAL AND DISASSEMBLY Disconnect the starter motor lead wire. ① After loosening the bolts ①, remove the starter motor. Disassemble the starter motor. STARTER MOTOR INSPEC- TION CARBON BRUSH Inspect abnormal wear, crack or smoothness of the brushes in the brush holder.

  • Page 197: Starter Motor Reassembly

    7-13 ELECTRICAL SYSTEM STARTER MOTOR REASSEMBLY Reassemble the starter motor. Pay attention to the following points : Reassembly the starter motor as shown in the illustration. Align the match mark ① on the housing with the ① ② ② ① line ②...
  • Page 198 ELECTRICAL SYSTEM 7-14 SWITCHES Measure each switch for continuity using a tester. If any abnormality is found, replace the respective switch assemblies with new ones. Pocket tester : 09900-25002 IGNITION SWITCH ENGINE STOP SWITCH STARTER SWITCH HAZARD SWITCH PUSH ● DIMMER SWITCH CLUTCH LEVER SWITCH TURN SIGNAL SWITCH...
  • Page 199 7-15 ELECTRICAL SYSTEM LAMP CAUTION If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. HEAD LAMP TURN SIGNAL LAMP BRAKE / TAIL LAMP...

  • Page 200: Combination Meter

    ELECTRICAL SYSTEM 7-16 COMBINATION METER Remove the combination meter. Disassemble the combination meter as shown in the illustration. INSPECTION Using the pocket tester, check the continuity between lead wires (Blue color coupler and 3 pin coupler) in the following illustration. If the continuity measured incorrect, replace the respective part.

  • Page 201: Chassis

    7-17 ELECTRICAL SYSTEM BATTERY CAUTION OF BATTERY TREATMENT The battery needs attention generally as it occur flammability gas. If you don t follow the instruction in the below, there may be a explosion and severe accident. Therefore, please pay attention to the following points. Positively prohibit battery from contacting to short, spark or firearms.
  • Page 202 ELECTRICAL SYSTEM 7-18 Seal ③ Pouring of battery electrolyte When insert the nozzles of the electrolyte container into the battery s electrolyte filler holes, holding the container firmly so that it does not fall. Take precaution not to allow any fluid to spill. CAUTION The pouring of electrolyte may not be done if the electrolyte container is pushed slopely.

  • Page 203: Recharging Operation

    7-19 ELECTRICAL SYSTEM ⑤ 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 remaining electrolyte vaporize. ⑥...
  • Page 204 CHASSIS CONTENTS EXTERIOR PARTS 8- 1 FRAME COVER 8 - 2 SEAT TAIL COVER & SEAT TAIL COVER BRACE 8 - 5 FRONT WHEEL 8 - 7 FRONT BRAKE 8-11 HANDLEBAR 8 - 18 FRONT FORK 8 - 21 STEERING 8 - 29 REAR WHEEL 8 - 36...

  • Page 205: Exterior Parts

    8-1 CHASSIS EXTERIOR PARTS ⊙ ⊙ FRONT FENDER Loosen the mounting bolts, right and left, and disen- gage the front fender from the front fork. NOTE When removing the front fender, slide the front fender backward. ⊙ ⊙ FRONT SEAT The front seat lock is located the left side cover under the front seat.

  • Page 206: Frame Cover

    CHASSIS 8-2 FRAME COVER FRAME HEAD COVER Loosen the two mounting bolts, and disengage the right and left frame head cover from the frame. Right...

  • Page 207: Side Cover

    8-3 CHASSIS Left AIR CLEANER COVER Loosen the two mounting bolts, and remove the air cleaner cover. FUEL TANK LOWER DECO- RATION COVER Loosen the two mounting bolts, and remove the fuel tank lower decoration cover. SIDE COVER Unhook the three hook, and remove the side cover, right and left.
  • Page 208 CHASSIS 8-4 Left ⊙ ⊙ PILLION RIDER PLATE Loosen the two mounting bolts from the inside of the seat tail cover. Disengage the right and left pillion rider plate from the seat tail cover.
  • Page 209 8-5 CHASSIS SEAT TAIL COVER & SEAT TAIL COVER BRACE Remove the front and rear seat. (Refer to page 8-1) Remove the rear shock absorber upper bolts from the inside of the frame, right and left. Install the rear shock absorber upper bolts with the frame in the outside direction temporarily.
  • Page 210 CHASSIS 8-6 ① fuses ②, ③ and ECU ④. Remove the battery Disconnect the rear turn signal lamp coupler and rear combination lamp coupler. ④ ① ② ③ Remove the two bolts ⑤. ⑤ After loosening the two bolts ⑥, remove the seat tail cover and seat tail cover brace.

  • Page 211: Front Wheel

    8-7 CHASSIS FRONT WHEEL REMOVAL AND DISASSEM- Remove the front axle pinch bolt cap ①. Loosen the front axle pinch bolt (the right side of the motorcycle). Loosen the front axle ②. ② Raise the front wheel off the ground with a block or jack.

  • Page 212: Front Axle

    CHASSIS 8-8 Remove the brake disk from the left side. INSPECTION AND DISAS- SEMBLY TIRE For inspection of the tire : Refer to page 2-23. FRONT AXLE Measure the front axle runout using the dial gauge. If the runout exceeds the limit, replace the front axle. Service limit Axle shaft runout 0.25 mm (0.01 in)

  • Page 213: Brake Disk

    8-9 CHASSIS 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. REASSEMBLY AND REMOU- NTING Reassemble and remount the front wheel in the reverse order of removal and disassembly.
  • Page 214 CHASSIS 8-10 Tighten the front axle ① and front axle pinch bolt to the specified torque. Front axle : 50 ~ 80 N m (5.0 ~ 8.0 kgf m) Front axle pinch bolt ① : 15 ~ 25 N m (1.5 ~ 2.5 kgf m) Install the front axle pinch bolt cap ②...

  • Page 215: Front Brake

    8-11 CHASSIS FRONT BRAKE WARNING Do not mix brake fluid with 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.
  • Page 216 CHASSIS 8-12 BRAKE FLUID REPLACEMENT For replacing procedure of brake fluid : Refer to page 2-19 BRAKE PAD REPLACEMENT For replacing procedure of brake pad : Refer to page 2-18 CALIPER REMOVAL AND ① DISASSEMBLY Drain brake fluid. (Refer to page 2-19) CAUTION ②...
  • Page 217 8-13 CHASSIS Using compressed air, push out the caliper pistons. WARNING Place a rag over the pistons 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.
  • Page 218 CHASSIS 8-14 CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and 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.
  • Page 219 8-15 CHASSIS Tighten the caliper mounting bolts and brake hose ① union bolt ① to the specified torque. Front brake caliper mounting bolts : 18 ~ 28 N m (1.8 ~ 2.8 kgf m) ② Front brake hose union bolts : 20 ~ 25 N m (2.0 ~ 2.5 kgf m) NOTE Before remounting the caliper, push the piston all...
  • Page 220 CHASSIS 8-16 MASTER CYLINDER REMO- VAL AND DISASSEMBLY Drain brake fluid the master cylinder. Disconnect the brake lamp switch lead wire coupler. Remove the union bolt ①. CAUTION Place a rag under the union bolt so that brake fluid can not contact the parts. ①...
  • Page 221 8-17 CHASSIS MASTER CYLINDER INSPEC- TION Inspect the master cylinder bore for any scratches or other damage. Inspect the piston surface for any scratches or other damage. MASTER CYLINDER REASS- EMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly.
  • Page 222 CHASSIS 8-18 HANDLEBAR HANDLEBAR RIGHT SIDE PARTS REMOVAL AND DISASSEMBLY ① Remove the right handlebar switches. Disconnect the brake lamp switch lead wires and remove the master cylinder. (Refer to page 8-16) ② Remove the handlebar balancer ① and grip ②. HANDLEBAR LEFT SIDE PARTS REMOVAL AND ④...
  • Page 223 8-19 CHASSIS REASSEMBLY AND REMOU- NTING Perform the reassembly and remounting work in the reverse order of the removal and disassembly proce- dures while observing the following instructions. ① Install the punch mark ① of the handlebar aligned with the handlebar clamp as shown. Tighten the handlebar clamp bolts to the specified torque.
  • Page 224 CHASSIS 8-20 Apply SUPER GREASE A to the throttle cables. Throttle grip SUPER GREASE A Install the throttle cable and returning cable to the throttle grip ①, ②. ① : Throttle cable ② : Returning cable Throttle cable Rotated direction...
  • Page 225 8-21 CHASSIS FRONT FORK...
  • Page 226 CHASSIS 8-22 REMOVAL AND DISASSEM- Remove the front fender. (Refer to page 8-1) Take off the front wheel. (Refer to page 8-7) Remove the brake caliper. (Refer to page 8-12) CAUTION Secure the brake caliper to the frame with a string etc., taking care not to bend the brake hose.
  • Page 227 8-23 CHASSIS ● With the damper rod held immovable, remove the damper rod bolt ①. ① ● Remove the damper rod ② and rebound spring ③ from the inner tube. ② ③ ● Remove the dust seal ④ and oil seal stopper ring ⑤. ④...

  • Page 228: Front Fork Spring

    CHASSIS 8-24 ● Remove the following parts. ① Oil seal ② Slide metal ① ③ Oil lock piece CAUTION ② The removed oil seal and slide metal should be replaced with new ones. ③ ● Loosen the front fork cover bolt. ●...
  • Page 229 8-25 CHASSIS ⊙ ⊙ REASSEMBLY AND REMOUNTING Reassemble and remount the front fork in the reverse order of removal and disassembly. Pay attention to the following points : 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.

  • Page 230: Front Fork Oil

    CHASSIS 8-26 ● Fit the stopper ring ② and dust seal ①. CAUTION ① Make sure that the stopper ring is securely fitted ② into the groove on the outer tube. ③ ① Dust seal ④ ② Oil seal stopper ring ③...
  • Page 231 8-27 CHASSIS ● Wait until the fluid level stabilizes, measure and adjust the level to specification using the special tool. Standard 136 mm (5.4 in) Front fork oil level from end of outer tube (When maximum com- pressed without spring) Front fork oil level gauge : 09943-74111 ●...
  • Page 232 CHASSIS 8-28 ● Tighten the front fork lower clamp bolts ① and front ③ ② fork upper clamp bolts ② to the specified torque. ● Tighten the front fork cap bolts ③ to the specified torque. Front fork upper clamp bolt : 22 ~ 35 N·...
  • Page 233 8-29 CHASSIS STEERING REMOVAL AND DISASSEM- Take off the front wheel. (Refer to page 8-7) Remove the front fender. (Refer to page 8-1) Take off the front fork. (Refer to page 8-22)
  • Page 234 CHASSIS 8-30 Remove the front turn signal lamp assembly. ● Remove the handlebars. (Refer to page 8-18) ● Remove the steering stem head nut ①. ● Remove the steering stem upper bracket ②. ② ① ● Remove the steering stem upper nut ③ and steering stem nut ④...
  • Page 235 8-31 CHASSIS Take off the steering stem lower bracket ①. CAUTION Hold the steering stem lower bracket by hand to prevent from falling. ② Remove the upper and lower bearing ②. ① Remove the handlebar holders by removing the nuts. Draw out the steering stem upper and lower bearing outer races using the steel rod.
  • Page 236 CHASSIS 8-32 INSPECTION Inspect and check the removed parts for the following abnormalities. Handlebar distortion. Handlebar holder wear. Abnormality operation of bearing. Distortion of steering stem. Bearing wear or damage. Race wear or damage. ⊙ ⊙ REASSEMBLY AND REMOU- NTING Reassemble and remount the steering stem in the reverse order of removal and disassembly.
  • Page 237 8-33 CHASSIS ● Install the handlebar holders and tighten their nuts temporarily. ● Install the steering stem. ● Tighten the steering stem nut ① and steering stem upper nut ② using the special tool. Steering stem nut : 80 ~ 100 N· · m (8.0 ~ 10.0 kgf· · m) NOTE The torque value of the steering stem nut and steering stem upper nut is reference data.
  • Page 238 CHASSIS 8-34 ● Install the steering stem upper bracket ① and wash- er ②. ● Tighten the steering stem head nut ③ temporarily. ① ② ③ ● Install the handlebars. (Refer to page 8-19) ● Tighten the handlebar holder nuts ④ to the specified torque.
  • Page 239 8-35 CHASSIS NOTE Hold the front fork legs, move them back and forth and make sure that the steering is not loose.

  • Page 240: Rear Wheel

    CHASSIS 8-36 REAR WHEEL REMOVAL AND DISASSEM- Raise the rear wheel off the ground with a jack or block. After loosening the four mounting bolts, remove the engine pulley cover.
  • Page 241 8-37 CHASSIS After loosening the four mounting bolts, remove the drive belt cover. Loosen the lock nuts ① and drive belt adjusters ②, right and left. Disengage the drive belt from the rear pulley. ① ② Right ② ① Left Remove the rear axle ③...
  • Page 242 CHASSIS 8-38 After loosening the disk mounting bolts, remove the rear brake disk cover and brake disk. Remove the spacer ①. ④ ③ ② ① Remove the rear pulley ② with the rear pulley mounting drum ③ from the rear wheel. NOTE Before separating the rear pulley and rear pulley mounting drum, slightly loosen the rear pulley...
  • Page 243 8-39 CHASSIS REAR WHEEL SHOCK ABSOR- Inspect the rear wheel shock absorber for wear and damage. Replace the rear wheel shock absorber if there is any- thing unusual. REAR PULLEY Inspect the pulley’s teeth for wear. If they are worn, replace the pulley and drive belt as a set.
  • Page 244 CHASSIS 8-40 After installing the drive belt to the rear pulley, adjust the drive belt by turning both belt adjusters ①. Tighten both belt adjuster lock nuts ② securely. ② ① Right ① ② Left...

  • Page 245: Rear Brake

    8-41 CHASSIS REAR BRAKE WARNING Do not mix brake fluid with different brand. Do not use a brake fluid kept in an open container or stored for a long period. To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach of chil- dren.
  • Page 246 CHASSIS 8-42 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 2-19 BRAKE PAD REPLACEMENT For replacing procedure of brake pad : Refer to page 2-18 CALIPER REMOVAL AND DI-...
  • Page 247 8-43 CHASSIS Remove the brake caliper holder ①. ① Using compressed air, push out the caliper pistons. WARNING Place a rag over the pistons to prevent it from popping out and flying and keeping hand off the piston. Be careful of brake fluid which can possibly splash.
  • Page 248 CHASSIS 8-44 CALIPER REASSEMBLY AND REMOUNTING Reassemble and remount the caliper in the reverse order of removal and 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.
  • Page 249 8-45 CHASSIS Fill the system with brake fluid and bleed air. (Refer to page 2-19 ~ 20) Inspection after reassembly : Refer to page 2-17 BRAKE DISK INSPECTION : Refer to page 8-15...

  • Page 250: Rear Shock Absorber

    CHASSIS 8-46 REAR SHOCK ABSORBER REMOVAL Remove the rear shock absorbers by removing their bolts and nuts.
  • Page 251 8-47 CHASSIS 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 Remount the rear shock absorber in the reverse order of removal.
  • Page 252 CHASSIS 8-48 SWINGARM REMOVAL AND DISASSEM- Remove the rear wheel. (Refer to page 8-36) Remove the exhaust pipes and muffler. (Refer to page 3-5)
  • Page 253 8-49 CHASSIS Remove the engine pulley cover ① and drive belt covers ②. ② ① After loosening the rear shock absorber lower bolts, disconnect the rear shock absorber from swingarm. Remove the swingarm mounting lock nut. Remove the swingarm pivot nut. Remove the swingarm by removing the pivot shaft.
  • Page 254 CHASSIS 8-50 INSPECTION SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm 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.
  • Page 255 8-51 CHASSIS REASSEMBLY Reassemble the swingarm and rear shock absorber in the reverse order of disassembly. Pay attention to the following points : Install the swingarm and tighten the swingarm pivot shaft, nut and swingarm mounting lock nut with the special tool to the specified torque.

  • Page 256: Servicing Information

    SERVICING INFORMATION CONTENTS TROUBLESHOOTING 9 - 1 SPECIAL TOOLS 9 - 15 TIGHTENING TORQUE 9 - 18 SERVICE DATA 9 - 20 WIRE AND CABLE ROUTING 9 - 30 WIRING DIAGRAM 9 - 37...

  • Page 257: Troubleshooting

    9-1 SERVICING INFORMATION TROUBLESHOOTING MALFUNCTION CODE AND DEFECTIVE CONDITION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR NO FAULT noEr After engine running, if oxygen sensor heater signal open or is happened the ground short fault for 1 second by 10 times in 12 0031 Low Voltage times test cycle, the code 0031 is indicated.
  • Page 258 SERVICING INFORMATION 9-2 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR The sensor voltage should be the following. 0.1 V Sensor output voltage 0117 Low Voltage Without the above range for 6.25 sec. and more, 0117 is indicated. Water temperature sensor, lead wire / coupler connection. WTS Circuit The sensor voltage should be the following.
  • Page 259 9-3 SERVICING INFORMATION DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if NO.1 fuel injector signal open or is hap- pened the high / ground short fault for 1 second by 5 times in 10 NO.1 Fuel Injector 0201 times test cycle, the code 0201 is indicated.
  • Page 260 SERVICING INFORMATION 9-4 DETECTED FAILURE CONDITION MALFUNCTION DETECTED ITEM CODE CHECK FOR After engine running, if purge control valve signal open or is happened the ground short fault for 1 second by 10 times in 12 times test cycle, the code 0444 is indicated. 0444 Open Purge control valve, wiring / coupler connection, power supply...
  • Page 261 9-5 SERVICING INFORMATION ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low Adjust. 1. Tappet clearance out of adjustment. start or is hard Repair or replace. 2. Worn valve guides or poor seating of valves. to start. Adjust.
  • Page 262 SERVICING INFORMATION 9-6 Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust. 2. Poor seating of valves. Replace or repair. 3. Defective valve guides. Replace. 4. Worn down camshafts. Replace. 5. Too wide spark plug gaps. Adjust or replace.
  • Page 263 9-7 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Excessive valve chatter 1. Too large tappet clearance. Adjust. 2. Weakened or broken valve springs. Replace. 3. Worn tappet or cam surface. Replace. 4. Worn and burnt camshaft journal. Replace.
  • Page 264 SERVICING INFORMATION 9-8 Complaint Symptom and possible causes Remedy Engine runs poorly Defective engine internal / electrical parts in high speed 1. Weakened valve springs. Replace. 2. Worn camshafts. Replace. range. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gaps. Adjust.
  • Page 265 9-9 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks Defective engine internal / electrical parts power. 1. Loss of tappet clearance. Adjust. 2. Weakened valve springs. Replace. 3. Valve timing out of adjustment. Adjust. 4. Worn piston rings or cylinders. Replace.
  • Page 266 SERVICING INFORMATION 9-10 Complaint Symptom and possible causes Remedy Dirty or heavy 1. Too much engine oil in the engine. Check with inspection win- dow, drain out excess oil. exhaust smoke. 2. Worn piston rings or cylinders. Replace. 3. Worn valve guides. Replace.
  • Page 267 9-11 SERVICING INFORMATION ELECTRICAL Symptom and possible causes Complaint Remedy 1. Defective ignition coils or spark plug caps. Replace. No sparking or 2. Defective spark plugs. Replace. poor sparking. 3. Defective pick-up coil. Replace. 4. Defective ECU. Replace. 5. Defective RO switch. Replace.
  • Page 268 SERVICING INFORMATION 9-12 BATTERY Complaint Remedy Symptom and possible causes 1. Not enough electrolyte. Add distilled water, if the bat- Sulfation acidic tery has not been damaged white powdery and sulfation has not adv- substance or anced too far, and recharge. 2.
  • Page 269 9-13 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy 1. Steering stem nut overtightened. Adjust. Steering feels too 2. Worn bearing or race in steering stem. Replace. heavy or stiff. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust.
  • Page 270 SERVICING INFORMATION 9-14 BRAKES Complaint Symptom and possible causes Remedy 1. Not enough brake fluid in the reservoir. Refill to level mark. Poor braking 2. Air trapped in brake fluid circuit. Bleed air out. (FRONT and 3. Pads worn down. Replace.

  • Page 271: Special Tools

    9-15 SERVICING INFORMATION SPECIAL TOOLS Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09900-20806 09900-20101 Vernier Caliper Thickness gauge Measure clearance of piston ring. Used to conveniently measure various dimensions. 09900-20201 09900-21109 Micrometer (0~25mm) Torque wrench Used for precise measurement (00~25mm measure ranges).
  • Page 272 SERVICING INFORMATION 9-16 Special tools Part Number Part Name Description Special tools Part Number Part Name Description Part Number Part Name Description 09910-20115 09915-54510 Conrod holder Fuel pump pressure gauge Used to lock the crankshaft. Measure fuel pressure of fuel pump. 09910-32812 09915-64511 Compression gauge...
  • Page 273 9-17 SERVICING INFORMATION Special tools Part Number Part Name Description Special tools Part Number Part Name Description 09943-74111 09923-73210 Front fork oil level gauge Bearing remover (17mm) Used to drain the fork oil to the specified level. Used to remove bearing with the rotor remove sliding shaft. 09923-74510 Bearing remover (20~35mm) Used to remove bearing with the rotor remove sliding shaft.

  • Page 274: Tightening Torque

    SERVICING INFORMATION 9-18 TIGHTENING TORQUE ENGINE ITEM kgf m Coolant drain bolt 11 ~ 14 1.1 ~ 1.4 Cooling fan mounting bolt 8 ~ 12 0.8 ~ 1.2 Cooling fan motor mounting bolt Cooling fan thermo-switch Radiator mounting bolt 8 ~ 12 0.8 ~ 1.2 Magneto rotor bolt 110 ~ 170...
  • Page 275 9-19 SERVICING INFORMATION CHASSIS ITEM kgf m Rear shock absorber mounting nut (Upper) 20 ~ 30 2.0 ~ 3.0 Rear shock absorber mounting bolt (Lower) 35 ~ 55 3.5 ~ 5.5 Rear pulley bolt 20 ~ 30 2.0 ~ 3.0 Rear axle bolt 90 ~ 140 9.0 ~ 14.0...

  • Page 276: Service Data

    SERVICING INFORMATION 9-20 SERVICE DATA VALVE + GUIDE Unit : mm (in) ITEM STANDARD LIMIT 31.0 (1.22) Valve diam. 25.5 (1.00) 0.1 ~ 0.2 (0.004 ~ 0.008) Valve clearance (When cold) 0.28 ~ 0.32 (0.011 ~ 0.013) 0.020 ~ 0.047 (0.0008 ~ 0.0019) Valve guide to valve stem clearance 0.030 ~ 0.057 (0.0012 ~ 0.0022) Valve stem deflection...
  • Page 277 9-21 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit : mm (in) ITEM STANDARD LIMIT Compression pressure 14 kgf/cm (at 500 rpm) 12 kgf/cm Piston to cylinder clearance 0.045 ~ 0.075 (0.0018 ~ 0.0030) 0.120 (0.0047) Cylinder bore 81.500 ~ 81.515 (3.2087 ~ 3.2093) 81.575 (3.2116) 81.440 ~ 81.455 (3.2063 ~ 3.2069) Piston diam.
  • Page 278 SERVICING INFORMATION 9-22 OIL PUMP ITEM STANDARD NOTE 2.0 ~ 6.0 kgf/cm Oil pressure (at 60 , 3,000 rpm) Oil pump reduction ratio 1.3 (45/34) CLUTCH Unit : mm (in) ITEM STANDARD LIMIT Clutch cable play 2 (0.08) 2.62 (0.103) NO.
  • Page 279 9-23 SERVICING INFORMATION TRANSMISSION + DRIVE BELT Unit : mm (in) ITEM STANDARD LIMIT Primary reduction ratio 2.09 (71/34) Secondary reduction ratio 2.69 (78/29) 2.46 (32/13) 1.78 (32/18) 1.38 (29/21) Gear ratio 1.13 (27/24) 0.96 (25/26) Shift fork to groove clearance 0.10 ~ 0.30 (0.004 ~ 0.012) 0.50 (0.020) NO.1 &...
  • Page 280 SERVICING INFORMATION 9-24 EI SENSORS ITEM SPECIFICATION NOTE 4.5 ~ 5.5 V IAP sensor input voltage Approx. 2.7 V at idle speed IAP sensor output voltage 4.9 ~ 5.1 V TP sensor input voltage Approx. 1.07 ~ 1.17 V Closed TP sensor output voltage Approx.
  • Page 281 9-25 SERVICING INFORMATION THERMOSTAT + COOLING FAN + COOLANT ITEM STANDARD NOTE Valve opening (190 ) Valve full open (212 ) Thermostat valve operating temperature Valve closing (181 ) Thermostat valve lift Over 8 mm (0.32 in) / 100 (212 ) ㏀...
  • Page 282 SERVICING INFORMATION 9-26 ELECTRICAL Unit : mm (in) ITEM STANDARD NOTE Ignition timing BTDC 5 / 1,600 rpm and BTDC 35 / 7,000rpm Type CR8E 0.7 ~ 0.8 (0.028 ~ 0.032) Spark plug Hot type CR7E Standard type CR8E Cold type CR9E Spark performance Over 8 mm (0.32 in)
  • Page 283 9-27 SERVICING INFORMATION SUSPENSION Unit : mm (in) ITEM STANDARD LIMIT Front fork stroke 130 (5.12) Front fork spring free length 321 (12.6) 338 (13.3) Front fork oil type TELLUS #32 136 mm (5.4 in) from end of outer tube Front fork oil level (when maximum compressed without spring) 4 cc...
  • Page 284 SERVICING INFORMATION 9-28 BRAKE + WHEEL Unit : mm (in) ITEM STANDARD LIMIT Front 4.0 (0.16) 3.0 (0.12) Brake disk thickness Rear 4.3 (0.17) 3.0 (0.12) Brake disk runout Front Rear 0.3 (0.012) Front 14.280 ~ 14.320 (0.5622 - 0.5638) Master cylinder bore Rear 12.700 ~ 12.743 (0.5000 ~ 0.5017)

  • Page 285: Tire Pressure

    9-29 SERVICING INFORMATION TIRE PRESSURE NORMAL RIDING COLD INFLATION DUAL RIDING SOLO RIDING TIRE PRESSURE 2.00 30.0 2.25 33.0 FRONT REAR 2.25 33.0 2.50 36.0 FUEL + OIL NOTE ITEM SPECIFICATION Gasoline used should be graded 91 octane or higher. Fuel type An unleaded gasoline is recommened.

  • Page 286: Wire And Cable Routing

    SERVICING INFORMATION 9-30 WIRE AND CABLE ROUTING...
  • Page 287 9-31 SERVICING INFORMATION...
  • Page 288 SERVICING INFORMATION 9-32...
  • Page 289 9-33 SERVICING INFORMATION...
  • Page 290 SERVICING INFORMATION 9-34...
  • Page 291 9-35 SERVICING INFORMATION...
  • Page 292 SERVICING INFORMATION 9-36...

  • Page 293: Wiring Diagram

    9-37 SERVICING INFORMATION WIRING DIAGRAM...
  • Page 294 SERVICING INFORMATION 9-38...
  • Page 297 Prepared by 1st Ed. JAN. 2010. Manual No. 99000H99D10 Printed in Korea...
  • Page 298 S&T Motors Co., Ltd.

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