specifications - scooter masters people 50-complete.pdf · specifications 1-0 1 ... this service...

1. SPECIFICATIONS

1-0

1

TABLE OF CONTENTS

SPECIFICATIONS ............................................................................. 1

GENERAL INFORMATION............................................................... 2

INSPECTION/ADJUSTMENT ............................................................ 3

LUBRICATION SYSTEM................................................................... 4

ENGINE REMOVAL/INSTALLATION............................................... 5

CYLINDER HEAD/CYLINDER/PISTON ............................................ 6

A.C. GENERATOR ............................................................................ 7

KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY........ 8

FINAL REDUCTION.......................................................................... 9

CRANKCASE/CRANKSHAFT ........................................................... 10

CARBURETOR .................................................................................. 11

FRAME COVERS .............................................................................. 12

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/

FRONT SHOCK ABSORBER/FRONT FORK .................................... 13

REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER .............. 14

ELECTRICAL EQUIPMENT.............................................................. 15

INSTRUMENT/SWITCHES/LIGHTS.................................................. 16

1

1. SPECIFICATIONS

1-1

SPECIFICATIONS

Name & Model BA10AB.AC

Overall length (mm) 1850

Overall width (mm) 685

Overall height (mm) 1075

Wheel base (mm) 1270

Engine type Air cooled 2-stroke

Displacement (cc) 49.5 cc

Front wheel 37

Net weight (kg) Rear wheel 58.5

Total 95.5

Seating capacity 2 riders (110kg)

Front wheel 79

Gross weight(kg) Rear wheel 126.5

Total 205.5

Front wheel 70/90-16 42JTires

Rear wheel 90/90-16 54J

Ground clearance (mm) 175

Braking distance (m)(Initial speed Km/h) 4.4m (30km/h)

Min. turning radius (mm) 1900

Starting system Starting motor &kick starter

Fuel type Gasoline, 2-strokemotor oil

Cylinder arrangement Single cylinder, flat

Combustion chamber type Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke (mm) 39 x 41.4

Compression ratio 10.3:1 ±0.2

Compression pressure(kg/cm≤ rpm)

11.8kg/cm≤ ±2

Max. output (kw/r/min) 1.765/5400 kw/r/min

Max. torque (kg m/rpm) 0.33/4600 kg m/rpm

Open Automatic controlledIntake

Close Automatic controlled

Port Open ⎯

timingExhaust

Close ⎯

Open ⎯Scavenge

Close ⎯

Idle speed (rpm) 2000±100

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Lubrication oil capacity

(liter)

1.1

Air cleaner type & No. Wet, single

Fuel capacity (liter) 5.8

Type Plunger type

Carburetor Piston dia. (mm) ⎯

Venturi dia. (mm) 16

Ignition system type CDI electromagneticIgnition

Ignition timing F mark 8ϒ~14ϒ±1.5ϒBTDC/2000

rpm

Spark NGK BR8HSA

plug ND

Spark plug gap (mm) 0.6 0.7

Battery capacity 12V4AH

Power to transmission gear Power-transmissiongear-clutch

Reduction ratio of power totransmission

⎯

Clutch type Dry multi-disc clutch

Transmission gear operationtype

Automaticcentrifugal type

Transmission ratio 1 speed ⎯

Reduction Type Two-stage reduction

gear 1st reduction ratio 3.113~0.895

2nd reduction

ratio

14.69

Transmission gear type Non-stage transmission

Tire pressure Front 1.75 kg/cm≤(kg/cm≤) Rear wheel 2.0 kg/cm≤

Turning angle Right & left 45ϒ

Brake system Front Expanding/hydraulictype Rear wheel Expanding

Suspension Front Telescopetype Rear wheel Unit swing

Shock absorber Front Telescope

type Rear wheel Unit swing

Frame type Pipe under bone

2. GENERAL INFORMATION

2-0

2

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GENERAL INFORMATION__________________________________________________________________________________

ENGINE SERIAL NUMBER/IDENTIFICATION ........................ 2- 1

SERVICE PRECAUTIONS ........................................................ 2- 2

SERVICE INFORMATION........................................................ 2-10

TORQUE VALUES................................................................... 2-12

SPECIAL TOOLS ..................................................................... 2-13

LUBRICATION POINTS........................................................... 2-15

WIRING DIAGRAM.................................................................. 2-16

CABLE & HARNESS ROUTING ............................................... 2-18

TROUBLESHOOTING.............................................................. 2-22

2


2-1

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Number


2-2

SERVICE PRECAUTIONS

n Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. when reassembling.

n When tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.


2-3

n Apply or add designated greases andlubricants to the specified lubricationpoints.

n After reassembly, check all parts forproper tightening and operation.

n When two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.

n When using a spanner or other tools, makesure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.

n When connecting the battery, the positive(+) terminal must be connected first.

n After connection, apply grease to thebattery terminals.

n Terminal caps shall be installed securely.


2-4

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

n When taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,protruding or loose.

ConfirmCapacity


2-5

n The connector shall be insertedcompletely.

n If the double connector has a lock, lockit at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal.

n Check the double connector cover forproper coverage and installation.

n Insert the terminal completely.

n Check the terminal cover for propercoverage.

n Do not make the terminal cover openingface up.

n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

Snapping!


2-6

n After clamping, check each wire to makesure it is secure.

n Do not squeeze wires against the weld orits clamp.

n After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.

n When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.

n Route wire harnesses passing through theside of bolts and screws. Avoid theprojected ends of bolts and screws.

No Contact !


2-7

n Route harnesses so they are neitherpulled tight nor have excessive slack.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.

n When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.

n Do not break the sheath of wire.

n If a wire or harness is with a broken sheath,repair by wrapping it with protective tapeor replace it.

n When installing other parts, do not press orsqueeze the wires.

Do not pulltoo tight!

Do not press orsqueeze the wire.


2-8

n After routing, check that the wire harnessesare not twisted or kinked.

n Wire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

n When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

n When rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

Do you understandthe instrument? Isthe instrument setcorrectly?

Remove Rust !


2-9

n Symbols:

The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Use special tool.

: Caution

: Warning

Engine Oil

Grease

Special


2-10

SERVICE INFORMATION

ENGINE Standard (mm) Service Limit (mm)

Item BA10AB.AC. BA10AB.AC.

Cylinder head warpage ⎯ 0.10

Piston O.D.(5mm from bottom of piston 38.970 38.955 38.90

Cylinder-to- piston clearance 0.10

Piston pin hole I.D. 12.002 12.008 12.03

Piston pin O.D. 11.994 12.0 11.98

Piston-to-piston pin clearance ← ←

Piston ring end gap (top/second) 0.10 0.25 0.40

Connecting rod small end I.D. 17.005 17.017 17.03

Cylinder bore 39.0 39.025 39.05

Drive belt width 18 17

Drive pulley collar O.D. 20.01 20.025 ←

Movable drive face ID. 20.035 20.085 19.97

Weight roller O.D. 13.0 12.4

Clutch outer I.D. 107 107.2 107.5

Driven face spring free length 87.9 82.6

Driven face O.D. ← ←

Movable driven face I.D. ← ←

Connecting rod big end side clearance ← ←

Connecting rod big end radial clearance ← ←

Crankshaft runout A/B ⎯ ←

CARBURETOR BA10AB.AC

Venturi dia. 14mm

Identification number PB058

Float level 8.6mm

Main jet #85

Slow jet #35

Air screw opening 1_ ± _

Idle speed 2000±100rpm

Throttle grip free play 2 6mm

Jet needle clip notch 1st notch

A

1. SPECIFICATIONS

2-11

FRAME Standard (mm) Service Limit (mm)

Item BA10AB.AC. BA10AB.AC.

Axle shaft runout ⎯ 0.2

RadialFront wheel rim runout

Axial

Front shock absorber spring free length 200.0 182.8

Rear wheel rim runout 2.0

Brake drum I.D. Front/rear 110 111

Brake lining thickness Front/rear 4.0/4.0 2.0/2.0

Brake disk runout Front/rear ⎯ 0.30

Rear shock absorber spring free length 235.7 218.7

ELECTRICAL EQUIPMENT BA10AB.AC

Capacity 12V4AH

Voltage 13.0 13.2V

Charging Standard 0.4A/5HBattery

current Quick 4A/0.5H

Spark plug (NGK) BR8HSA

Spark plug gap 0.6 0.7mm

Primary coil 0.153 0.187Ω

Secondary coil(with plug cap) 6.99 10.21KΩIgnition coil resistance

Secondary coil(without plug cap) 3.24 3.96KΩ

Pulser coil resistance (20 ) 80 160Ω

Ignition timing 8ϒ~14ϒ±1.5ϒBTDC/2000rpm


2-12

TORQUE VALUES

ENGINE

Item Thread dia. (mm) Torque (kg-m) Remarks

Cylinder head bolt

Clutch drive plate nut

Clutch outer nut

Drive face nut

Oil check bolt

Engine mounting bolt

Engine hanger bracket bolt

Exhaust muffler joint lock nut

Exhaust muffler lock bolt

Spark plug

BF7x115

10

NH10

NH12

10

BF10x95

BF10x50

NC6mm

BF8x35

1.5 1.7

3.5 4.0

3.5 4.5

5.0 6.0

1.0 1.5

4.5 5.5

3.5 4.5

1.0 1.4

3.0 3.6

1.1 1.7

(cold)

(cold)

FRAME

Item Thread dia. (mm) Torque (kg-m) Remarks

Handlebar lock nut

Steering stem lock nut

Steering top cone race

Front axle nut

Rear axle nut

Rear brake arm bolt

Front shock absorber:

upper mount bolt

lower mount bolt

hex bolt

Front damper nut

Front pivot arm bolt

Rear shock absorber:

upper mount bolt

lower mount bolt

lower joint nut

10

25.4

25.4

12

16

8

8

10

8

8

4.5 5.0

8.0 12.0

0.5 1.3

5.0 7.0

11.0 13.0

3.3

3.3

1.5 3.0

1.5 3.0

3.5 4.5

2.4 3.0

1.5 2.5

Flange bolt/U-nut

Flange U-nut

Flange U-nut

Flange nut

Flange bolt/U-nut

Cross head

Apply locking agent

Flange screw/U-nut

Flange nut

Torque specifications listed above are for important fasteners. Others should be tightened tostandard torque values below.

STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt

Item Torque (kg-m) Item Torque (kg-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

0.45 0.6

0.8 1.2

1.8 2.5

3.0 4.0

5.0 6.0

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut



0.35 0.5

0.7 1.1

1.0 1.4

2.4 3.0

3.5 4.5

1. SPECIFICATIONS

2-13

SPECIAL TOOLS

Tool Name Tool No. Remarks

Universal bearing puller Crankshaft bearing removal

Lock nut wrench, 39mm Drive pulley disassembly/assembly

Lock nut socket wrench Top cone race holding

Lock nut wrench, Stem lock nut tightening

Crankcase puller Crankcase disassembly

Bearing remover set, 12mm

(Spindle assy, 15mm)

(Remover weight)

Drive shaft bearing removal/installation


(Spindle assy, 15mm)

(Remover head, 15mm)

(Remover shaft, 15mm)

Drive shaft bearing removal/installation

Bearing outer driver, 28x30mm Bearing installation

Bearing remover Driven pulley outer bearing installation

Clutch spring compressor Driven pulley disassembly/assembly

Crankcase assembly collarDriven shaft, crankshaft & crankcaseassembly

Crankcase assembly tool Crankshaft & crankcase assembly

Rear shock absorber removerFront shock absorber disassembly/assembly

Ball race remover Steering stem bearing races

Rear shock absorber compressor Rear shock absorber disassembly/assembly

Float level gauge Carburetor fuel level check

Lock nut socket wrench, 32mmOne-way clutch lock nut removal/installation

Universal holder Flywheel holding

Flywheel puller Flywheel removal

Pilot, 12mm Drive shaft bearing installation

Bearing outer driver, 32x35mmDrive shaft bearing installationFinal shaft bearing installation


2-14

Tool Name Tool No. Remarks

Bearing outer driver, 37x40mmDrive shaft bearing installation Final shaftbearing installation Crankshaft bearinginstallation

Outer driver, 24x26mm Driven pulley bearing installation

Pilot, 10mm Front wheel bearing installation

Bearing driver pilot, 17mm Drive shaft bearing installation

Snap ring pliers (close) Circlip removal/installation

Bearing outer driver, 42x47mm Crankshaft bearing installation

Pilot, 20mm Crankshaft bearing installation

Bearing outer driver handle ABearing installation

Drive in ball race

Bearing puller head, 10mm Front wheel bearing removal

Universal bearing puller Crankshaft bearing removal

Bearing puller Front wheel bearing removal

Pressure tester set Cylinder compression gauge

1. SPECIFICATIONS

2-15

LUBRICATION POINTS

ENGINE

NO. Lubrication Points Lubricant Remarks

1 Crankcase sliding & movable parts JASO-FC or API-TC

2 Cylinder movable parts

3 Transmission gear (final gear) SAE-90#

4 Kick starter spindle bushing Grease

5 Drive pulley movable parts Grease

6 Starter pinion movable parts Grease

FRAME

Apply clean engine oil or grease to cables and movable parts not specified. This will avoidabnormal noise and rise the durability of the motorcycle.

Front/Rear Brake LeverSeat Lock

Rear WheelBearing

Throttle Cable

Speedometer Cable

Main Stand Pivot

Grease

Engine Oil

Grease

Engine Oil

Speedometer Gear/Brake Cam/FrontShock AbsorberLower MountBushings/Pivot

Grease

Grease

Grease

Grease Engine Oil

Rear Brake Cable

Brake Cam/Anchor Pin


2-16

BA10AB.AC. WIRING DIAGRAM

B Black Br Brown

Y Yellow O Orange

L Blue Sb Light blue

G Green Lg Light green

R Red P Pink

W White Gr Gray

1. SPECIFICATIONS

2-17

CABLE & HARNESS ROUTING

Front Brake Reservoir

Rear Brake Cable

Throttle Cable

Ignition Switch

Regulator/Rectifier

Front Brake FluidTube

Ground

Speedometer Cable

Horn

Starter Relay


2-18

Wire Harness

Starter Relay

Rear Brake CableThrottle Cable

Front Brake Fluid Tube

Speedometer Cable

1. SPECIFICATIONS

2-19

Ignition Coil

Fuel Unit

Fuel Filter

Left Crankcase Breather

Oil Tube

Spark Plug

Fuel Vapor Recovery Tube

Ignition Coil


2-20

Ignition Coil

Vacuum Tee

Throttle Cable

Oil Meter

Spark Plug Cap

Oil Filter

Oil PumpControl Cable

Auto Bystarter

Oil Tube

Fuel Unit

Fuel Tank Cap

Fuel Tube

Fuel Filter

Oil Tank Cap

1. SPECIFICATIONS

2-21

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Å Empty fuel tankÇ Clogged float valveÉ Clogged charcoal

canisterÑ Clogged fuel filterÖ Faulty auto fuel valve

Å Faulty spark plugÇ Fouled spark plugÉ Faulty CDI unitÑ Faulty A.C. generatorÖ Broken or shorted

ignition coilÜ Broken or shorted

exciter coiláFaulty ignition switch

Å Burned or worncylinder piston

Ç Faulty reed valveÉ Blown cylinder head

gasketÑ Leaking crankcaseÖ Faulty crankcase oil

seal

Å Incorrectly adjusted idlespeed

Ç Air leaking throughintake pipe

É Incorrect ignitiontiming

Å Flooded carburetorÇ Throttle valve

excessively open

Å Faulty auto bystarter

Check if fuel reachescarburetor byloosening drain screw.

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground.

Inspection/Adjustment Symptom Probable Cause

Fuel reaches carburetor

Spark jumps

Dry spark plug

Not clogged

Normal compression

Engine does not fire

Fuel does not reach carburetor

Weak or no spark

Wet spark plug

Clogged

Low or no compression

Engine fires but does not start

Test cylindercompression.

Remove spark plug andinspect again.

Wait for 30 minutesand then remove thecarbu-retor auto chokecircuit hose and blowthe hose with mouth.

Start engine by follow-ing normal startingprocedure.


2-22

ENGINE STOPS IMMEDIATELY AFTER IT STARTS

Å Empty fuel tankÇ Clogged float valveÉ Clogged charcoal

canisterÑ Clogged fuel filterÖ Faulty auto fuel valve

Å Fouled spark plugÇ Incorrect heat range

plug

Å Fouled spark plugÇ Faulty CDI unitÉ Faulty A.C. generatorÑ Faulty ignition coilÖ Broken or shorted high

tension wireÜ Faulty ignition switch

Å Worn cylinder andpiston rings

Ç Blown cylinder headgasket

É Flaws in cylinder headÑ Faulty reed valveÖ Seized piston

Å Clogged carburetor jets

Å Faulty CDI unit or A.C.generator

Ç A.C.G. flywheel notaligned

Å Mixture too rich (turnscrew out)

Ç Mixture too lean (turnscrew in)

Check if fuel reachescarburetor byloosening drain screw.


Fuel reaches carburetor

Good spark

Correct timing

Correctly adjusted

Plug not fouled ordiscolored

Normal compression

Not Clogged

Fuel does not reach carburetor

Weak or intermittent spark

Incorrect timing

Incorrectly adjusted

Plug fouled or discolored

Abnormal compression

Clogged

Remove spark plug.

Test cylindercompression (using acompression gauge).

Check carburetor forclogging.

Check ignition timing.

Check carburetor airscrew adjustment.


1. SPECIFICATIONS

2-23

Å Carburetor not securelytightened

Ç Faulty intake manifoldgasket

É Deformed or brokencarburetor O-ring

Å Broken cableÇ Dirty auto bystarterÉ Faulty auto bystarter



No air leak

Not clogged

Clogged

Air leaks

Clogged

Not Clogged

Check carburetorgasket for air leaks.

Connect auto bystarterwire to battery. Waitfor 5 minutes, thenconnect a hose to fuelenriching circuit andthen blow the hosewith mouth.

Remove auto bystarterconnecting wire andcheck if bypass fuelline is clogged.


2-24

ENGINE LACKS POWER

Å Clogged air cleanerÇ Clogged fuel filterÉ Clogged exhaust

mufflerÑ Faulty auto bystarterÖ Faulty charcoal canister

Å Faulty CDI unitÇ Faulty A.C. generator

Å Worn cylinder andpiston rings

Ç Blown cylinder headgasket

É Faulty reed valve

Å Clogged carburetor jets

Å Fouled spark plugÇ Incorrect heat range

plug

Å Mixture too leanÇ Poor quality fuelÉ Excessive carbon build-

up in combustion chamberÑ Ignition timing too

early

Å Excessive carbon build-up in combustion chamber

Ç Poor quality fuelÉ Clutch slippingÑ Mixture too lean


Engine speed increases

Engine overheats

Correct timing

Engine does not knock

Plug not fouled ordiscolored

Normal compression

Not Clogged

Engine speed does not increase sufficiently

Engine does not overheats

Incorrect timing

Engine knocks

Plug fouled or discolored

Abnormal compression

Clogged

Start engine andaccelerate lightly forobservation.

Check ignition timing(using a timing light).

Rapidly accelerate orrun at high speed

Test cylindercompression (using acompression gauge)

Check carburetor forclogging

Remove spark plugandinspect

Check if engineoverheats

1. SPECIFICATIONS

2-25

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Å Faulty CDI unitÇ Faulty A.C. generator

Å Mixture too rich (turnscrew out)

Ç Mixture too lean (turnscrew in)

Å Carburetor not securelytightened

Ç Faulty intake manifoldgasket

É Deformed carburetorO-ring

Å Faulty or fouled sparkplug

Ç Faulty CDI unitÉ Faulty A.C. generatorÑ Faulty ignition coilÖ Broken or shorted high

tension wireÜ Faulty ignition switch

Å Broken auto bystarterwire

Ç Faulty auto bystarter


Clogged Not clogged





Check carburetorgasket for air leaks.

Check carburetor airscrew adjustment.

Correct timing Incorrect timing

Correctly adjusted Incorrectly adjusted

No air leak Air leaks

Good spark Weak or intermittent spark

Not clogged Clogged


2-26

POOR PERFORMANCE (AT HIGH SPEED)

Å Faulty CDI unitÇ Loose A.C.G. statorÉ Faulty A.C. generator

Å Empty fuel tankÇ Clogged fuel tube or

filterÉ Clogged charcoal

canister

Å Clean and unclog

Å Broken auto bystarterwire

Ç Faulty auto bystarter



Clogged Not clogged




Check carburetor jetsfor clogging.

Check auto fuel valvefor fuel supply.

Correct timing Incorrect timing

Fuel flows freely Fuel flow

restricted

Not clogged Clogged

Not clogged Clogged

1. SPECIFICATIONS

2-27

CLUTCH, DRIVE AND DRIVEN PULLEYS

Å Worn or slipping drive beltÇ Broken ramp plateÉ Broken driven face springÑ Separated clutch liningÖ Damaged driven pulley shaft

splinesÜ Damaged final geará Seized final gear

Å Broken shoe springÇ Clutch outer and clutch weight

stuckÉSeized pivot

Å Worn or slipping drive beltÇ Worn weight rollersÉ Seized drive pulley bearingsÑ Weak driven face springÖ Worn or seized driven pulley

bearings

Å Worn or slipping drive beltÇ Worn weight rollersÉ Worn or seized driven pulley

bearings

Å Oil or grease fouled drive beltÇ Worn drive beltÉ Weak driven face springÑ Worn or seized driven pulley

bearings

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Å Steering stem nut too tightÇ Broken steering steel balls

Å Excessive wheel bearing playÇ Bent rimÉ Loose axle nut

Å Misaligned front and rear wheelsÇ Bent front fork

Engine starts butmotor-cycle does notmove

Engine lacks power atstart of a grade (poorslope performance)

Steering is heavy

Front or rear wheel iswobbling

Symptom

Symptom

Probable Cause

Probable Cause

Engine lacks power athigh speed

There is abnormalnoiseor smell while running

Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)

Steering handlebar pullsto one side


2-28

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Å Weak shock springÇ Excessive loadÉ Shock damper oil leaking

Å Bent fork tube or shock rodÇ Fork slider and tube binding

Å Fork tube and spring bindingÇ Fork slider and tube binding

POOR BRAKE PERFORMANCE

(Adjust brake according to standards)

Å Worn brake liningsÇ Worn brake cam contacting area

onbrake shoes

É Worn brake camÑ Worn brake drum

Å Worn brake liningsÇ Foreign matter on brake liningsÉ Rough brake drum contacting area

Å Sluggish or elongated brake cablesÇ Brake shoes improperly contact

brake drumÉ Water and mud in brake systemÑ Oil or grease on brake linings

Å Faulty brake master cylinderÇ Faulty brake caliperÉ Oil or grease on brake diskÑ Deformed brake diskÖ Leaking brake fluid tube

Suspension is too soft

Brake squeaks

Symptom

Symptom

Probable Cause

Probable Cause

Suspension is too hard

Suspension is noisy

Brake performance ispoor

Index mark on brakepanel aligns with wearindicator arrow

ExpandingBrake

HydraulicBrake

1. SPECIFICATIONS

2-29

Faulty

OIL METER

1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)

Å Burned out fuseÇ Weak or dead batteryÉ Faulty ignition switchÑ Loose or disconnected

connectorÖ Broken wire harness

ÅBurned out bulb

Å Loose wire connectorÇ Broken wire harnessÉ Incorrectly connected

wire

Å Faulty floatÇ Broken or shorted wire

inmeter

2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)

Å Loose or disconnectedconnector

Ç Broken wire harnessÉ Incorrectly connected

wire

Å Faulty floatÇ Broken or shorted wire

in meter

Å Damaged oil tankÇ Foreign matters in oil

tank

Inspection/Adjustment Symptom

Inspection/Adjustment

Probable Cause

Symptom Probable Cause

Signals operate properly

Signals dim, remainon or don‘toperate

Bulb lights Bulb does not light

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors forproper connection.

Good

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors forproper operation.

Connect indicatorlight bulb to batteryfor bulb inspection.

Check battery circuitby operating turnsignals.

Good Faulty

Float up = Light offFloat down = Light on

Float up = Light offFloat down = Light on


2-30

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)



Å Faulty float

Å Broken or shorted fuelunit wire


Ç Incorrectly connectedconnector

Å Broken or shorted wirein fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)



Å Poor contact in fuelunit

Å Insufficient damping oilin fuel gauge


Å Broken or shorted wirein fuel gauge



Symptom

Symptom





Pointer does not move

Pointer does not move

Good

Good

Pointer moves

Pointer moves

Pointer moves

Pointer does notmove in accord-ance with float

Faulty

Faulty

Pointer does notmove

Pointer moves inaccordance withfloat

Probable Cause

Probable Cause

Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals.

Check operation ofpointer by openingand shorting fuel unitterminal on wireharness side.


Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals and horn.

Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer.


1. SPECIFICATIONS

2-31

STARTER MOTOR

1. Starter motor won‘t turn

Å Burned out fuseÇ Weak or dead batteryÉ Faulty stop switchÑ Loose or disconnected

connectorÖ Broken or shorted

ignition switch wire

Å Faulty or weak battery

Å Poor starter buttonconnection

Ç Faulty starter relayÉ Loose or disconnected

connector

Å Faulty starter motor

Å Faulty wire harness

2. Starter motor turns slowly or idles

Å Weak or dead battery


Ç Faulty starter relay

Å Seized cylinder

Å Broken or shortedstarter motor cable

Ç Faulty starter pinion3. Starter motor does not stop turning

Å Faulty starter pinion

Å Starter relay shorted orstuckclosed




Symptom

Symptom

Symptom





Stoplight does notcome on

Starter motorturns

Turns easily

Not stopped

Stoplight comes

on

Starter does not

turn

Hard to turn

Stopped

Relay operates properly

Starter motor turns slowly

Probable Cause

Probable Cause

Probable Cause

Relay does not operate

Starter motor turns normally

Check operation ofstop switch byapplying brake.

Check batterycircuit by operatingturn signals.

Check batterycircuit by operatingturn signals.

Turn ignition switchOFF.

Check operation ofstarter relay bydepressing starterbutton.

Connect startermotor directly tobattery.

Connect startermotor directly tobattery.

Rotate crankshaft.

3. INSPECTION/ADJUSTMENT

3-0

3

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INSPECTION/ADJUSTMENT__________________________________________________________________________________

INSPECTION AND MAINTENANCE SCHEDULE..................... 3- 1

BRAKE SYSTEM ..................................................................... 3- 4

MOVING DEVICE.................................................................... 3- 6

DAMPING DEVICE.................................................................. 3- 7

POWER DRIVE SYSTEM ......................................................... 3- 7

ELECTRICAL EQUIPMENT..................................................... 3- 8

ENGINE................................................................................... 3- 9

OTHERS .................................................................................. 3-12

3


3-1

INSPECTION AND MAINTENANCE SCHEDULE

(Note) 1. means time for inspection.

2. means regular replacement for the specified parts.

This inspection and maintenance schedule is based upon average riding conditions.Machines subjected to serve use, or ridden in unusually dusty areas, require more frequentservicing.

FrequencyInspection & Maintenance Item

Preride1st

monthEvery 6months

Every 12months

Judgment Standards Remarks

Check for loosenessand vertical playSteering

handlebarOperating performance

Right/left turning angle

Suspension Damage

Check for front forkpivot installation

Checksteeringstem

Frontfork

Check front fork pivotfor looseness andabnormal noise

Checksteeringstem

Front/rear brake leverfree play

Free play:

10 20mm

Brake lever operationBrakeLever

Brake performance

Lever/Cable

Looseness, abnormalnoise and damage

BrakeSystem

Drum-to-liningclearance

Brake shoe and liningwear

IndicatortypeBrake

drum/shoe

Brake drum wear anddamage

Standard: Rear : 110 mm

Service Limits: Rear : 111 mm

MovingDevice

Tire Tire pressure

Front Rear

1rider

1.50kg/cm_

1.75kg/cm_

TireSize

70/90-16 90/80-16


3-2


Preride1st

monthEvery 6months

Every 12months


Tire crack and damage

Tire groove andabnormal wear

Groove Depth: Front: 0.8mm Rear : 0.8mm

Imbedded objects,gravel, etc.

Moving

Device

Motor-cycle

Axle nut looseness

Torque Values: Front axle nut 5.0 7.0kg-m Rear axle nut 11.0 13.0kg-m

Axle nuttorque

Check wheel rim, rimedge and spoke platefor damage

Rim runout at rim end:

Front: Axial 2.0mm Radial 2.0mmRear: Axial 2.0mm Radial 2.0mm

Check front wheelbear-ing for excessiveplay and abnormalnoise

Check front wheelbear-ing for excessiveplay and abnormalnoise

Frame

SpringDamage

Shockspringfreelength

Suspen-sion arm

Connecting partsloose-ness and armdamage

Shock Oil leakage and damage

Damping

Device

absorber Assembly parts loose-ness abnormal noise

Power Clutch Operation

DriveSystem

Transmis-sion case Oil leakage and oil

level

Oil level: Oil check bolt hole at lower hole edge

Rear wheeltransmis-sion case

Ignitiondevice Spark plug condition Plug gap:

0.6 0.7mm

ElectricalEquipment

Battery Terminal connection

WiresLoose connection anddamage


3-3


Preride1st

monthEvery 6months

Every 12months


Performance and abnormalnoise

BodyConditions at low and highspeeds

Exhaust smoke

Air cleaner

Oil quality and quantity r Oil level indicatorIndicator light comeson when oil isinsufficient

Engine Oil leakage

Oil level

Lubrica-tionsystem

Check oil filter for clogging

Fuel leakage

Carburetor, throttle valveand auto bystarter

Check fuel filter forclogging

Fuel level

FuelSystem

Fuel tube replacement Every 4 years

Operation

Lights & Winker Winking action, dirt anddamage

Buzzer &Steering Lock Operation

Rearview Mirror& Reflector Rearview mirror position

RearviewMirror

Reflector &License Plate Dirt and damage

Counter Operation

Exhaust Joint looseness and damage

Muffler Exhaust mufflerperformance

Body & Frame Looseness and damage

AbnormalConditionsHappened LastTime

Check if the abnormalconditions occur again

Lubrication points

OthersRemove carbon deposits oncombustion chamber,breather hole and exhaustmuffler


3-4

BRAKE SYSTEM

BRAKE LEVER

Free Play

Measure the front and rear brake lever freeplays.

Free Play: Front: 10 20mm

Rear: 10 20mm

If the free plays do not fall within thelimits, turn the right and left adjusting nutsfor adjustment.

<Rear> “ ” Marks

Adjusting Nuts

Front 10 20mm

Rear 10 20mm


3-5

BRAKE DRUM/SHOE

Brake Shoe Wear

Replace the brake shoes if the arrow on thebrake arm aligns with reference mark“ ”on the brake panel when the brake is fullyapplied.

Brake Drum Wear/Damage

Check the brake drum appearance fordamage. Check if the brake lining wear iswithin the specified service limit. Checkthe brake operation for abnormal noise andbrake drum inside for wear or damage.

BRAKE DISK/LINING

Brake Disk Surface and Brake PadWear

Check the brake disk surface for scratch.Check if the brake pad wear is within thespecified service limit.

Brake Disk Runout Inspection

Jack the motorcycle wheels off the groundand check if the brake disk runout is withinthe specified service limit.

BRAKE FLUID LEVEL INSPECTION

Brake Master Cylinder Fluid LevelInspection

Turn the steering handlebar upright andcheck if the front brake fluid level is withinthe specified limits through the front brakemaster cylinder check hole.

<Rear> “ ” Marks

Adjusting Nuts

Brake Disk

Brake Master Cylinder


3-6

MOVING DEVICE

TIRES

Tire Pressure

Check the tire pressure.

Tire Pressure (one rider)

Front: 1.50 kg/cm_

Rear: 1.75 kg/cm_

Tire Size

Front 70/90 − 16

Rear 90/80 − 16

Axle Nut/Axle ShaftLooseness

Check the front and rear axle nuts forlooseness.If the axle nuts are loose, tighten them tothe specified torques.

Torques:

Front: 5.0 7.0kg-m

Rear: 11.0 13.0kg-m

Wheel Rim/Spoke PlateDamage

Check the wheel rim and spoke plate forwear or damage and measure the rim runout.

Axle Nut

Tire pressure should be checked whentires are cold.

Axle Nut

Rear Wheel

Front Wheel


3-7

DAMPING DEVICE

SHOCK ABSORBERS

Oil Leak/Damage

Fully apply the front brake and check theaction of the front shock absorber bycompressing it several times.Check the entire shock absorber assemblyfor looseness or damage.Check the action of the rear shock absorberby compressing it several times.Check the entire shock absorber assemblyfor looseness or damage.

POWER DRIVE SYSTEM

TRANSMISSION CASE

Check the rear wheel transmission casesurrounding area for oil leaks.Stop the engine and remove the oil checkbolt.

The gear oil level shall be at the oil checkbolt hole. If the oil level is low, add thespecified oil to the proper level.

Specified Gear Oil: SAE10W90#

Install and tighten the oil check bolt.

Torque: 1.0 1.5kg-m

Start the engine and check for oil leaks.

Oil Check Bolt

Place the motorcycle on its main standon level ground.


3-8

ELECTRICAL EQUIPMENT

IGNITION APPARATUS

Spark Plug

Remove the frame center cover.Remove the spark plug cap and spark plug.Check the spark plug for wear, fouling andcarbon deposits.Remove the fouling and carbon depositswith a spark plug cleaner or wire brush.

Specified Spark Plug

NGK

BA10AB.AC.

BR8HSA

Spark Plug Gap: 0.6 0.7mm

Ignition Apparatus

Remove the right side rail. (12-4)Remove the A.C. generator fan cover. (7-3)Remove the four bolts attaching the fan andthen remove the fan.Warm up the engine and check the ignitiontiming with a timing light.

When the engine is running at the specifiedrpm, the ignition timing is correct if the “F”mark on the flywheel aligns with the indexmark on the crankcase within ±1.5ϒ.

Ignition Timing:

BA10AB.AC.:

8ϒ~ 14ϒ±1.5ϒBTDC/2000rpm

Gap, Wear andFouling Deposits

Washer Damage

Cracks

Bolt

Index Mark

The CDI ignition timing is not adjust-able. If the timing is incorrect, check theCDI unit, ignition coil and A.C.generator and replace any faulty parts.

F Mark


3-9

ENGINE

BODY

At High and Low Speeds

Adjust the idle speed to the specified rangeby turning the throttle stop screw and airscrew.

Idle Speed:

BA10AB.AC.50: 2000±100rpm

Air Cleaner

Remove the air cleaner cover by removingthe five bolts cleaner cover screws.Remove the air cleaner element.

The engine must be warm for accurateidle speed adjustment.

Air Cleaner

Screws

Air Screw

Throttle Stop Screw


3-10

Wash the air cleaner element in detergentoil, squeeze out and allow to dry.

After washing, soak the element in cleanengine oil SAE 15W-40# and squeeze outexcess oil. Reinstall the element.

Cylinder Compression

Remove the spark plug and insert acompression gauge.Open the throttle valve fully and push thestarter button for 7 8 seconds to testthe compression.

Compression:

BA10AB.AC.50: 11.8kg/cm_

If the compression is low, check for thefollowing:

∞ Leaking cylinder head gasket∞ Worn piston/cylinder

If the compression is high, it indicates thatcarbon deposits have accumulated on thecombustion chamber and the piston head.

LUBRICATION SYSTEM

Oil Filter Cleaning

Disconnect the oil tube at the oil pump sideand allow oil to drain into a clean container.Remove the tube clip at the oil tank sideand disconnect the oil tube.Remove the oil filter.

Oil Filter

Clip

Soak in oilSqueeze outand dry

Wash Squeeze outexcess oil dry

Warm up the engine before compressiontest.

Never use gasoline or organic vaporableoil with acid or alkali for washing.


3-11

Clean the oil filter screen with compressedair.Install the oil filter in the reverse order ofremoval and fill the oil tank with specifiedoil up to the proper level.Bleed air from the oil pump and oil lines.

Oil Pump Condition

Open the throttle valve fully and check thatthe index mark on the pump body alignswith the aligning mark on the oil pumpcontrol lever.Reference tip alignment within 1mm ofindex mark on open side is acceptable.Start and idle the engine, then slowly openthe throttle to increase engine rpm andcheck the operation of the oil pump controllever.If adjustment is necessary, adjust the oilpump control cable by loosening the controlcable lock nut and turning the adjusting nut.After adjustment, tighten the lock nut.

If the oil pump is not synchronizedproperly, the following will occur:

∞Excessive white smoke or hard startingdue to pump control lever excessivelyopen

∞Seized piston due to pump control leverinsufficiently open

Filter Screen

∞Connect the oil tubes securely.

∞Install the tube clip at the oil tank sideand also install the clip to the lower oiltube that goes to the oil pump.

∞Check for oil leaks.

Adjust oil pump control cable after thethrottle grip free play is adjusted.

Reference tip alignment within 1mm ofindex mark on open side is acceptable.However, the aligning mark on thecontrol lever must never be on the closedside of the index mark, otherwise enginedamage will occur because of insufficientlubrication.

Pump Body IndexMark

Adjusting Nut

Lock Nut Control Lever Aligning Mark


3-12

FUEL SYSTEM

Throttle Grip Free Play

Measure the throttle grip free play.

Free Play: 2 6mm

If the throttle grip free play does not fallwithin the specified range, adjust byloosening the lock nut and turning theadjusting nut.

OTHERS

LIGHTS

Headlight

Adjust the headlight beam by loosening theheadlight adjusting bolt and moving theadjusting bolt forward and backward to aproper position. Tighten the adjusting bolt.

Adjusting Nut

Lock Nut

Headlight Adjusting Bolt

4. LUBRICATION SYSTEM

4-0

4

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LUBRICATION SYSTEM__________________________________________________________________________________



OIL PUMP REMOVAL ............................................................. 4-3

OIL PUMP INSPECTION.......................................................... 4-3

OIL PUMP INSTALLATION..................................................... 4-4

OIL PUMP BLEEDING............................................................. 4-5

OIL TANK ............................................................................... 4-6

4


4-1

LUBRICATION SYSTEM


4-2

SERVICE INFORMATION

GENERAL INSTRUCTIONS

∞Use care when removing and installing the oil pump not to allow dust and dirt to enter the engineand oil line.

∞Do not attempt to disassemble the oil pump.

∞Bleed air from the oil pump if there is air between the oil pump and oil line.

∞If the oil is disconnected, refill the oil line with motor oil before connecting it.

SPECIFICATIONS

∞Recommended Motor Oil: SAE20W20# 2-stroke Motor Oil

∞Oil Capacity : 1.1 liter

Light comes on : 0.5 liter

TROUBLESHOOTING

Excessive white smoke or carbon deposits on spark plug

∞Oil pump not properly synchronized (excessive oil)∞Poor quality oil

Engine overheating

∞Oil pump not properly adjusted (insufficient oiling)

∞Poor quality oil

Seized piston

∞No oil in tank or clogged oil line

∞Oil pump not properly adjusted (insufficient oiling)

∞Air in oil line

∞Faulty oil pump

Oil not flowing out of tank to engine

∞Clogged oil tank cap breather hole

∞Clogged oil filter


4-3

OIL PUMP REMOVAL

Remove the met-in box. (12-4)

Disconnect the oil pump control cable fromthe pump body.Disconnect the oil inlet line from the oilpump.Then, disconnect the oil outlet line.

Remove the oil pump control cable platebolt .Remove the oil pump from the crankcase.

OIL PUMP INSPECTION

Remove the oil pump and inspect thefollowing items:

∞ Weakened O-ring

∞ Damage to crankcase mating surface

∞ Damage to pump body

∞ Control lever operation

∞ Oil leaks through oil seals

∞ Worn or damaged pump pinion

Do not allow foreign matters to enter thecrankcase. Before removing the oilpump, clean the oil pump and crankcasesurfaces.

Do not disassemble the oil pump whichcannot be used after disassembly.

Before disconnecting the oil line, clipthe oil line to avoid oil flowing out andthen plug the oil line after it isdisconnected.

Oil Outlet Line

Oil Inlet LineControl Cable

Oil Pump

Bolt

O-ring

PinionControl Lever

Control Cable Plate


4-4

OIL PUMP INSTALLATION

Install the oil pump onto the crankcase.

Install the oil pump control cable plate.Connect the oil inlet line and oil outlet lineproperly.Connect the oil pump control cable.Bleed air from the oil pump.

∞Lubricate the O-ring with grease orengine oil before installation.

∞Make sure that the oil pump isinserted into the crankcase.

∞Apply molybdenum disulfide or greaseto the pump pinion.

Control Cable Plate

Grease or Engine Oil

Bolt

Control Cable

Oil Outlet Line


4-5

OIL PUMP BLEEDING

OIL INLET LINE/OIL PUMP BLEEDING

Fill the oil tank with recommended oil.Place a shop towel around the oil pump.Disconnect the oil inlet line from the oilpump and clip it.Fill the oil pump with oil by squirting cleanoil through the joint. (About 3cc)Fill the oil line with oil and connect it to theoil pump.

OIL OUTLET LINE BLEEDING

1. Disconnect the oil outlet line and bend itinto U shape. Force air out of the tubeby filling it with oil.

2. Start the engine and allow it to idle withthe oil control lever in the fully openposition. Visually check the oil flow.

3. If there is no oil flowing out within 1minute, bleed air from the oil inlet lineand oil pump.

∞Air in the oil lines will block oil flowand result in severe engine damage.

∞Bleed air from the oil lines and oilpump whenever the oil lines or pumphave been removed or there is air in theoil lines.

Bleed air from the oil inlet line first,then bleed air from the oil outlet line.

∞Never run the engine in a closed area.∞Do not increase the engine speed at

will.

Oil Pump

Oil Outlet Line Intake Manifold

Oil Tube

Oil Outlet Line


4-6

OIL TANK

OIL TANK REMOVAL

Remove the met-in box. (12-5)Remove the frame body cover. (12-5)Remove the rear carrier. (12-5)Remove the two bolts, four nuts attachingthe stay comp fuel tank.Remove the oil meter connector.Remove the two bolts attaching the oil tank.Disconnect the oil inlet line.Drain the oil inside the oil tank into a cleancontainer.Remove the oil tank.The installation sequence is the reverse ofremoval.

∞Connect the oil line properly.∞Bleed air from the oil pump after

installation.∞The oil tube clip (at the oil tank side)

must be locked from inside of the oiltube joint.

Oil Meter

BoltsWire Connector

5. ENGINE REMOVAL/INSTALLATION

5-0

5

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ENGINE REMOVAL/INSTALLATION__________________________________________________________________________________


ENGINE REMOVAL................................................................. 5-2

ENGINE INSTALLATION........................................................ 5-4

5


5-1

SERVICE INFORMATION


∞Parts requiring engine removal for servicing:

Crankcase

Crankshaft

TORQUE VALUES

Engine mounting bolt 4.5 5.5kg-m

Rear shock absorber lower mount bolt 2.4 3.0kg-m

Engine hanger bracket bolt 3.5 4.5kg-m

4.5 5.5kg-m

3.5 4.5kg-m

4.5 5.5kg-m


5-2

ENGINE REMOVAL

Remove the frame body cover. (12-5)Remove the two bolts attaching the aircleaner case.Loosen the band between the air cleaner andcarburetor to remove the air cleaner case.Remove the carburetor cap.

Disconnect the oil pump control cable fromthe pump body.Disconnect the oil inlet line from the oilpump.

Disconnect the auto bystarter, A.C.generator and starter motor wire connectors.

Remove the spark plug cap.

After the oil inlet line is disconnected,plug the oil line opening to prevent oilfrom flowing out.

Carburetor Cap

Oil Inlet Line Oil Pump ControlCable

Band

Air Cleaner Case

AC Generator Wire Connector

Spark Plug Cap

Bolt


5-3

Remove the rear brake adjusting nut anddisconnect the brake cable from thecrankcase.Remove the rear brake cable clamp and rearbrake cable.Remove the cooling air tube band on the leftcrankcase cover and disconnect the coolingair tube.Remove the rear shock absorber lowermount bolt.

Remove the right and left engine mountingnuts.Take out the right and left engine mountingbolts.Lift the frame upward to separate it fromthe engine and be careful not to damage therear fender.

ENGINE HANGER BRACKET REMOVAL

Remove the engine hanger bracket bolt andengine hanger bracket.The installation sequence is the reserve ofremoval.

Torque: 3.5 4.5kg-m

Engine Mounting Nuts

Rear Brake Cable Clamp

Rear Shock Absorber Lower Mount Bolt

Engine Hanger Bracket Bolt

Engine Hanger Bracket


5-4

ENGINE HANGER BRACKET

INSPECTION

Inspect the stopper rubbers and bushingsfor damage and replace with new ones ifnecessary.

ENGINE INSTALLATION

Install the engine in the reverse order ofremoval.

Torque Values:

Engine mounting bolt : 4.5 5.5kg-m

Rear shock absorber lower mount bolt:: 2.4 3.0kg-m

Perform the following inspections andadjustments after installation.

∞ Throttle cable

∞ Oil pump control cable (3-11)

∞ Rear brake cable (3-5)

∞ Oil pump bleeding (3-11)

Cables and wires should be routedproperly.

Bushings

Engine Hanger

Stopper Rubbers

6. CYLINDER HEAD/CYLINDER/PISTON

6-0

6

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CYLINDER HEAD/CYLINDER/PISTON__________________________________________________________________________________



CYLINDER HEAD.................................................................... 6-3

CYLINDER/PISTON................................................................. 6-6

6


6-1

Torque: 1.5 1.7kg-m

Torque: 0.8 1.2kg-m

Torque: 1.1 1.7kg-m(cold)


6-2

SERVICE INFORMATION


∞The cylinder head, cylinder and piston can be serviced with the engine installed in the frame.

∞Before disassembly, clean the engine to prevent dust from entering the engine.

∞Remove all gasket material from the mating surfaces.

∞Do not use a driver to pry between the cylinder and cylinder head, cylinder and crankcase.

∞Do not damage the cylinder inside and the piston surface.

∞After disassembly, clean the removed parts before inspection. When assembling, apply thespecified engine oil to movable parts.

SPECIFICATIONS Standard (mm) Service Limit (mm)

Item BA10AB.AC.50 BA10AB.AC 50

Cylinder head warpage ⎯ 0.10

Piston O.D.(5mm from bottom of piston 38.970 38.955 38.90

Cylinder-to- piston clearance 0.10

Piston pin hole I.D. 12.002 12.008 12.03

Piston pin O.D. 11.994 12.0 11.98

Piston-to-piston pin clearance ← ←

Piston ring end gap (top/second) 0.10 0.25 0.40

Connecting rod small end I.D. 17.005 17.017 17.03

Cylinder bore 39.0 39.025 39.05

TORQUE VALUES

Cylinder head bolt 1.5 1.7kg-m

Exhaust muffler joint lock nut 1.0 1.4kg-m

Exhaust muffler lock bolt 3.0 3.6kg-m

Spark plug 1.1 1.7kg-m

TROUBLESHOOTING

Compression too low, hard startingor poor performance at low speed Abnormal noisy piston

∞Leaking cylinder head gasket ∞ Worn cylinder and piston∞Loose spark plug ∞ Worn piston pin or piston pin hole∞Worn, stuck or broken piston and piston rings ∞ Worn connecting rod small end bearing∞Worn or damaged cylinder and piston

Compression too high, overheatingor knocking Abnormal noisy piston rings

∞Excessive carbon build-up in cylinder head ∞ Worn, stuck or broken piston ringsor on piston head ∞ Worn or damaged cylinder


6-3

CYLINDER HEAD

REMOVAL

Remove the rear carrier.Remove the frame body cover. (12-5)

Remove the spark plug cap.Remove the three bolts attaching the fancover to remove the fan cover.Remove the two joint lock nuts on the frontof the exhaust muffler and then remove thetwo exhaust muffler lock bolts.Remove the bolt attaching the engine hoodto remove the engine hood.The installation sequence is the reverse ofremoval.

Remove the spark plug.Remove the cylinder head bolts and thecylinder head.

Remove the cylinder head gasket.

Loosen the bolts diagonally in 2 or 3times.

Cylinder head Bolts

Spark Plug Cap

Fan Cover/Engine Hood

Bolts

When installing the exhaust muffler,first tighten the two nuts on the frontand then tighten the two bolts.

Cylinder Head

Spark Plug


6-4

COMBUSTION CHAMBERDECABONIZING

Remove the carbon deposits from thecombustion chamber

CYLINDER HEAD INSPECTION

Check the cylinder head for warpage with astraight edge and feeler gauge.

Service Limit:

BA10AB.AC.50: 0.10mm replace if over

CYLINDER HEAD INSTALLATION

Install the cylinder head on the cylinderproperly.

Install a new cylinder head gasket onto thecylinder.

Avoid damaging the combustion cham-ber wall and cylinder mating surface.

Be careful not to damage the matingsurfaces.

Cylinder head Gasket

Combustion Chamber

Mating Surface


6-5

Cylinder Head Bolts Installation

Install and tighten the cylinder head boltsdiagonally in 2 or 3 times.

Torque: 1.5 1.7kg-m

Install the spark plug.

Torque: 1.1 1.7kg-m

Engine Hood Installation

Install the engine hood. (6-3)Install the spark plug cap. (6-3)

Perform the following inspections afterinstallation:

∞ Compression test

∞ Abnormal engine noise

∞ Cylinder air leaks

Cylinder head Bolts

Bolts

Bolt

Cylinder Head

Spark Plug

Spark Plug

Engine Hood


6-6

CYLINDER/PISTON

CYLINDER REMOVAL

Remove the met-in box and seat.Remove the frame body cover.Remove the cylinder head.Remove the two exhaust muffler joint locknuts and two exhaust muffler lock bolts.Remove the exhaust muffler.Remove the cylinder.Remove the cylinder gasket.

PISTON REMOVAL

Remove the piston pin clip to remove thepiston pin and piston.

Spread each piston ring and remove bylifting it up at a point just opposite the gap.Remove the expander.

∞Do not damage or scratch the piston.

∞Do not apply side force to theconnect-ing rod when removing thepiston pin.

∞Place clean shop towels in the crank-case to keep the piston pin clip fromfalling into the crankcase.

Do not pry between the cylinder andcrankcase or strike the fins.

Piston Pin Clip

Exhaust Muffler LockBolts

Joint Lock Nuts

Piston Piston Pin

Cylinder


6-7

CYLINDER/PISTON INSPECTION

Check the cylinder and piston for wear ordamage.Clean carbon deposits from the exhaustport area.

Measure the cylinder bore at three levels ofA, B and C in both X and Y directions.Avoid the port area. Take the maximumfigure measured to determine the cylinderbore.

Service Limit:


Inspect the top of the cylinder for warpage.

Service Limit:


Be careful not to damage the cylinderinside wall.


6-8

Measure the piston O.D. at a point 5mmfrom the bottom of the piston skirt.

Service Limit:

BA10AB.AC.50: 38.90mm replace if below

Measure the piston-to-cylinder clearance.

Service Limit:


Measure the piston pin hole I.D.

Service Limit:


Measure the piston pin O.D.

Service Limit:


Measure the piston-to-piston pin clearance.

Service Limit:


The cylinder has an A mark or no markon it. When replacing the cylinder witha new one, use a cylinder having thesame mark as the old one.

A Mark


6-9

PISTON RING INSPECTION

Measure each piston ring end gap.

Service Limits: Top/Second


CONNECTING ROD SMALL ENDINSPECTION

Install the piston pin and bearing in theconnecting rod small end and check forexcessive play.Measure the connecting road small end I.D.

Service Limit:


PISTON/CYLINDER INSTALLATION

First install the expander in the second ringgroove.Then install the top and second rings intheir respective ring grooves.The piston rings should be pressed into thegrooves with even force.After installation, check and make sure thateach ring is flush with the piston at severalpoints around the ring.A ring that will not compress means thatthe ring groove has carbon deposits in it andshould be cleaned.

Set each piston ring squarely into thecylinder using the piston and measurethe end gap.

<Small End I.D. Measurement>

Expander

Top Ring (1st Ring)

Piston

Second Ring


6-10

Install a new cylinder gasket on the matingsurface between the cylinder and crankcase.

Make sure that the ring end gaps are alignedwith the piston ring pins in the ringgrooves.

Lubricate the cylinder inside and pistonrings with engine oil and install the pistoninto the cylinder while compressing thepiston rings.

Install the cylinder head.

Torque: 1.5 1.7kg-m

Install the exhaust muffler and tighten theexhaust muffler joint lock nuts.

Torque: 1.0 1.4kg-m

Tighten the exhaust muffler lock bolts.

Torque: 3.0 3.6kg-m

Install the frame covers.

Install the met-in box.

The installation sequence is the reverse ofremoval .

Be careful not to damage the piston.

Cylinder Gasket

Ring Pins

7. A.C. GENERATOR

7-0

7

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A.C. GENERATOR__________________________________________________________________________________


A.C. GENERATOR REMOVAL................................................. 7-3

A.C. GENERATOR INSTALLATION ........................................ 7-4

7

7. A.C. GENERATOR

7-1

Torque: 3.5 4.0kg-m

Torque: 0.8 1.2kg-m

Torque: 0.6 1.0kg-m

Torque: 0.8 1.2kg-m

7. A.C. GENERATOR

7-2

SERVICE INFORMATION


∞All A.C. generator maintenance and inspection can be made with the engine installed.

∞Refer to Section 15 for A.C. generator inspection.

TORQUE VALUE

Flywheel nut : 3.5 4.0kg-m

SPECIAL TOOLS

Flywheel puller

Universal holder

7. A.C. GENERATOR

7-3

A.C. GENERATOR REMOVAL

Remove the three bolts attaching the fancover to remove the fan cover.

Remove the cooling fan by removing thefour bolts.

Hold the flywheel with an universal holderand then remove the 10mm flywheel nut.

Fan Cover Bolts

Bolt

Nut

Universal Holder

Cooling Fan

7. A.C. GENERATOR

7-4

Remove the A.C. generator flywheel usingthe flywheel puller.

Remove the A.C. generator wire connector.

Remove the two pulser coil bolts and pulsercoil from the right crankcase.Remove the pulser coil wire clamp from theright crankcase.Remove the two bolts attaching the A.C.generator stator.

A.C. GENERATOR INSTALLATION

Install the A.C. generator stator and pulsercoil wire clamp onto the right crankcase,and then install the pulser coil.

Be careful not to damage the discon-nected wire.

Lock Nut Wrench

A.C. Generator Wire Connector

Stator

Flywheel Puller

Pulser Coil

Wire Clamp

7. A.C. GENERATOR

7-5

Connect the A.C. generator wire connector.

Clean the taper hole in the flywheel off anyburrs and dirt.Install the woodruff key in the crankshaftkeyway.

Install the flywheel onto the crankshaftwith the flywheel groove aligned with thecrankshaft woodruff key.Hold the flywheel with the universal holderand install the 10mm flywheel flange nut.

Torque: 3.5 4.0kg-m

Start the engine and check the ignitiontiming. (3-8)Install other removed parts in the reserveorder of removal.

A.C. Generator Wire Connector

Woodruff Key

Universal Holder

8. KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY

8-0

8

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__________________________________________________________________________________

KICK STARTER/DRIVE PULLEY/

CLUTCH/DRIVEN PULLEY__________________________________________________________________________________

SERVICE INFORMATION........................................................ 8- 3

TROUBLESHOOTING.............................................................. 8- 3

KICK STARTER....................................................................... 8- 4

DRIVE BELT ........................................................................... 8- 8

DRIVE PULLEY....................................................................... 8-10

STARTER ONE-WAY CLUTCH DRIVE GEAR ......................... 8-12

CLUTCH/DRIVEN PULLEY ..................................................... 8-15

8


8-1

MODEL BA10AB.AC.

Torque:3.5 4.5kg-m

Torque:5.0 6.0kg-m

Torque:3.5 4.0kg-m


8-2

SERVICE INFORMATION


∞Avoid getting grease and oil on the drive belt and pulley faces.

SPECIFICATIONS BA10AB.AC.50

Item Standard (mm) Service Limit (mm)

Drive pulley collar O.D. 20.01 20.025 24.24

Movable drive face I.D. 20.035 20.085 19.97

Weight roller O.D. 13.0 12.4

Clutch outer I.D. 107 107.2 107.5

Driven face spring free length 87.9 82.6

Driven face O.D. 33.965 33.985 33.94

Movable driven face I.D. 34.0 34.25 34.06

Drive belt width 18 17

TORQUE VALUES

Drive face nut 3.5 4.0kg-m

Clutch outer nut 3.5 4.5kg-m

Clutch drive plate nut 5.0 6.0kg-m

SPECIAL TOOLS

Lock nut wrench, 39mm Universal holder

Clutch spring compressor Lock nut socket wrench, 32mm

Bearing outer driver 37x40mm Bearing driver pilot, 17mm

One-way clutch puller Outer driver, 24x26mm

TROUBLESHOOTINGPoor performance at high speed or

Engine starts but motorcycle won‘t move lack of power

∞Worn drive belt ∞ Worn drive belt∞Broken ramp plate ∞ Weak driven face spring∞Worn or damaged clutch lining ∞ Worn weight roller

∞ Faulty driven face

Engine stalls or motorcycle creeps

∞Broken clutch weight spring


8-3

KICK STARTER

LEFT CRANKCASE COVER REMOVAL

Remove the drive belt cooling air tubeconnector circlip.Remove the nine left crankcase cover bolts,left crankcase cover and dowel pins.Inspect the left crankcase cover seal rubberfor damage or deterioration.

KICK STARTER SPINDLE REMOVAL

Remove the kick lever from the kick starterspindle.Remove the circlip and washer from thekick starter spindle.

Slightly rotate the kick starter spindle toremove the kick starter driven gear togetherwith the friction spring.

Left Crankcase CoverBolt

Friction Spring

Kick Starter Driven Gear

Kick Starter Spindle

Washer Circlip


8-4

Remove the kick starter spindle and returnspring from the left crankcase cover.Remove the kick starter spindle bushing.

KICK STARTER SPINDLE INSPECTION

Inspect the kick starter spindle and gear forwear or damage.Inspect the return spring for weakness ordamage.Inspect the kick starter spindle bushing forwear or damage.

Check the kick starter driven gear for wearor damage.Check the friction spring for wear ordamage.

Kick Starter Spindle

Return Spring

Spindle

Plastic Bushing Spindle Bushing

Return Spring

Friction Spring



8-5

Inspect the kick starter spindle and drivengear forcing parts for wear or damage.

KICK STARTER INSTALLATION

Install the kick starter spindle bushing andreturn spring onto the left crankcase cover.

Properly install the kick starter driven gearand friction spring as the figure shown.

If the hooks of the return spring can notbe installed properly, use a screw driverto press them into their locationsrespectively.

Kick Starter Spindle Forcing Part

Kick Starter Driven Gear Forcing Part

Friction SpringKick Starter Spindle

Friction Spring



8-6

First install the washer and then the circliponto the kick starter spindle.Install the kick lever.

LEFT CRANKCASE COVERINSTALLATION

First install the dowel pins and then the sealrubber.

Install the left crankcase cover and tightenthe ten bolts diagonally.Connect the drive belt cooling air tube andinstall the circlip.

Left Crankcase Cover

Rear Brake Cable Clamp

Seal Rubber

Dowel Pins

Washer Circlip

For drum brake, note the location of thebrake cable clamp and install the rearbrake cable in place with the clamp.


8-7

DRIVE BELT

Remove the left crankcase cover.

INSPECTION

Check the drive belt for cracks, separationor abnormal or excessive wear.Measure the drive belt width.

Service Limit:


REPLACEMENT

Remove the ten left crankcase cover boltsand left crankcase cover. (8-4)Hold the clutch outer with the universalholder and remove the 10mm clutch outernut and clutch outer.

Hold the drive pulley with the holder andremove the 12mm drive face nut.Remove the starting ratchet.Remove the drive pulley face.

Use specified genuine parts for replace-ment.

Clutch Outer

Drive Face Nut

Drive Face

Universal Holder

Clutch Outer Nut

Ratchet


8-8

Remove the drive belt from the clutch/driven pulley.

DRIVE BELT INSTALLATION

Turn the driven pulley clockwise and lift itup to expand the drive belt groove and theninstall a new drive belt.

Set the drive belt on the drive pulley.Install the drive pulley face, starting ratchetand 12mm washer, then tighten the driveface nut.

Torque: 3.5 4.0kg-m

Clutch/Driven Pulley

Drive Belt

Drive Belt

Drive Pulley Face

12mm Washer

Drive Belt

Starting Ratchet

Drive Face Nut

When installing the drive face nut, makesure that the tooth spaces of the drivepulley face and starting ratchet alignwith the teeth of the crankshaft.


8-9

DRIVE PULLEY

REMOVAL

Hold the drive pulley with the holder andremove the 12mm drive face nut.Remove the starting ratchet, 12mm washerand drive pulley face.

MOVABLE DRIVE FACEDISASSEMBLY

Remove the movable drive face and drivepulley collar from the crankshaft.

Remove the ramp plate.

Movable Drive Face

Ramp Plate

Drive Pulley Collar

12mm Drive Face Nut

Starting RatchetDrive Pulley Face


8-10

Remove the weight rollers.

MOVABLE DRIVE FACE INSPECTION

Check each weight roller for wear ordamage.Measure each roller O.D.

Service Limit:


DRIVE PULLEY INSTALLATION

Install the drive pulley collar and movabledrive face onto the crankshaft.

Weight Roller

Movable Drive Face

Drive Pulley Collar


8-11

Install the drive belt on the crankshaft.Install the drive face, starting ratchet andwasher, then tighten the 12mm drive facenut.

Torque: 3.5 4.0kg-m

STARTER PINIONREMOVAL

Remove the left crankcase cover. (8-4)Remove the drive pulley. (8-8)Remove the starter pinion.

INSPECTION

Inspect the starter pinion seat for wear.Inspect the starter pinion for smoothoperation.Inspect the starter pinion shaft forcingparts for wear and damage.

INSTALLATION

Apply a small amount of grease to thestarter pinion teeth.Install the starter pinion in the reverse orderof removal.

Keep grease or oil off the drive belt anddrive pulley faces.

Drive Face Nut Starting Ratchet

Drive Pulley Face

Starter Pinion

Shaft Forcing Parts

Starter Pinion


8-12

CLUTCH/DRIVEN PULLEY

CLUTCH/DRIVEN PULLEY REMOVAL

Remove the drive pulley. (8-8)Hold the clutch outer with the universalholder and remove the 10mm clutch outernut.Remove the clutch outer.

Remove the clutch/driven pulley.Remove the drive belt from theclutch/driven pulley.

CLUTCH/DRIVEN PULLEY DIS-ASSEMBLY

Compress the clutch/driven pulley springwith the clutch spring compressor andremove the 28mm drive plate nut.Remove the driven face spring.


Universal Holder Clutch Outer

10mm Clutch Outer Nut

Clutch Spring Compressor

Lock Nut Wrench, 39mm


8-13

Remove the seal collar.

Pull out the guide roller pins from thedriven pulley and then remove the O-ringsand oil seal from the driven pulley.

CLUTCH/DRIVEN PULLEYINSPECTION

Inspect the clutch outer for wear or damage.Measure the clutch outer I.D.

Service Limit:


Seal Collar

Oil Seal

O-rings Guide Roller Pin

Driven Pulley


8-14

Check the clutch shoes for wear or damage.Measure the clutch lining thickness.

Service Limit: 2.0mm replace if below

Measure the driven face spring free length.

Service Limit:


Check the driven face assembly for wear ordamage.Measure the driven face O.D.


Check the movable driven face for wear ordamage.Measure the movable driven face I.D.


Check the guide roller pins for steppedwear.


8-15

DRIVEN PULLEY FACE BEARINGREPLACEMENT

Check the needle bearings in the driven faceand replace them if they have excessiveplay, damage or abnormal noise.Drive the inner bearing out of the drivenpulley face.

Remove the snap ring and drive the outerbearing out of the driven face.

Drive a new outer bearing into the drivenface with the sealed end facing up.Seat the snap ring in its groove.

Snap Ring

Bearing Outer Driver, 37x40mm

Inner Bearing

Outer Bearing

Pack all bearing cavities with5.0 5.6g grease.

Specified grease: 230 Heat-resistantgrease


8-16

Drive in a new needle bearing into the

driven face with the mark facing up.

CLUTCH/DRIVEN PULLEY ASSEMBLY

First install the movable driven face ontothe driven face. Then, install the guideroller pins, O-rings and a new oil seal.

Install the seal collar.

Seal Collar

Oil Seal

O-rings Guide Roller Pin

Driven Pulley

Bearing Driver Pilot

Outer Driver, 24x26mm


8-17

Set the driven pulley, driven face spring andclutch assembly onto the clutch springcompressor. Compress the tool and installthe 28mm drive plate nut.Tighten the 28mm nut to the specifiedtorque.

Torque: 5.0 6.0kg-m

CLUTCH/DRIVEN PULLEY

INSTALLATION

Install the drive belt on the clutch/drivenpulley and then install the clutch/drivenpulley onto the drive shaft.

Install the clutch outer.Hold the clutch outer with the universalholder.Install and tighten the 10mm clutch outernut.

Torque: 3.5 4.5kg-m

Install the left crankcase cover. (8-7)

Universal Holder

Clutch Outer


9. FINAL REDUCTION

9-0

9

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__________________________________________________________________________________

FINAL REDUCTION__________________________________________________________________________________



FINAL REDUCTION DISASSEMBLY....................................... 9-3

FINAL REDUCTION INSPECTION........................................... 9-3

FINAL REDUCTION ASSEMBLY............................................. 9-6

9

9. FINAL REDUCTION

9-1

9. FINAL REDUCTION

9-2

SERVICE INFORMATION

Specified Oil: SAE90#

At disassembly: 0.12 liter

At change: 0.1 liter

SPECIAL TOOLS



Crankcase assembly collar

Crankcase assembly shaft

Bearing outer driver, 37x40mm

Bearing outer driver, 32x35mm

Bearing driver pilot, 17mm



Bearing outer driver handle A

TROUBLESHOOTING

Engine starts but motorcycle won‘t move

∞Damaged transmission

∞Seized or burnt transmission

Abnormal noise

∞Worn, seized or chipped gears

∞Worn bearing

Oil leaks

∞Oil level too high

∞Worn or damaged oil seal

9. FINAL REDUCTION

9-3

FINAL REDUCTION DISAS-SEMBLY

Remove the rear wheel. (14-3)Remove the left crankcase cover. (8-4)Remove the clutch/driven pulley. (8-15)Drain the transmission gear oil into a cleancontainer.Remove the transmission case coverattaching bolts.Remove the transmission case cover.Remove the gasket and dowel pins.

Remove the final gear and countershaft.

FINAL REDUCTION INSPECTION

Inspect the countershaft and gear for wear

or damage.

Dowel Pin

Final Shaft

Final Gear

Countershaft

Dowel PinCountershaft

Driver shift

Driver shift

9. FINAL REDUCTION

9-4

Inspect the final gear and final shaft forwear, damage or seizure.

Check the left crankcase bearings forexcessive play and inspect the oil seal forwear or damage.

Inspect the drive shaft and gear for wear ordamage.Check the transmission case cover bearingsfor excessive play and inspect the finalshaft bearing oil seal for wear or damage.

Do not remove the transmission casecover except for necessary part replace-ment. When replacing the drive shaft,also replace the bearing and oil seal.

Oil SealDrive Shaft Bearing

Final Shaft Bearing

Drive Shaft Bearing

Countershaft Bearing

9. FINAL REDUCTION

9-5

BEARING REPLACEMENT

(Transmission Case Cover)

Remove the transmission case coverbearings using the bearing remover.Remove the final shaft oil seal.

Drive new bearings into the transmissioncase cover.

BEARING REPLACEMENT (Left

Crankcase Cover)

Remove the drive shaft.Remove the drive shaft oil seal.Remove the left crankcase bearings usingthe bearing remover.

Drive Shaft Bearing

Bearing Outer Driver, 32x35mm

Bearing Remover Set

Bearing Remover Set, 12mm

Bearing Outer Driver Handle A

9. FINAL REDUCTION

9-6

Drive new bearings into the left crankcase.Install a new drive shaft oil seal.

FINAL REDUCTION ASSEMBLY

Install the drive shaft into the leftcrankcase.

Install the final gear and final shaft into theleft crankcase.

Drive Shaft

Bearing Outer Driver

9. FINAL REDUCTION

9-7

Install the countershaft and gear into the leftcrankcase.Install the resin washer onto the counter-shaft.Install the dowel pins and a new gasket.

Install the transmission case cover.

Install and tighten the transmission casecover bolts.Install the clutch/driven pulley. (8-20)Install other removed parts in the reverseorder of removal.

Resin Washer Countershaft

Transmission Case Cover

Bolts

Dowel Pins

9. FINAL REDUCTION

9-8

After installation, fill the transmission casewith the specified oil.

Specified Gear Oil: SAE90#

Oil Capacity: at disassembly: 0.12 literat change: 0.09 liter

Install and tighten the oil check bolt.

Torque: 1.0 1.5kg-m

Start the engine and check for oil leaks.Check the oil level from the oil check bolthole and add the specified oil to the properlevel if the oil level is low.

∞Place the motorcycle on its main standon level ground.

∞Check the sealing washer for wear ordamage.

Drain Bolt

Oil Check Bolt Hole/Filler

10. CRANKCASE/CRANKSHAFT

10-0

10

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CRANKCASE/CRANKSHAFT__________________________________________________________________________________



CRANKCASE SEPARATION .................................................... 10-3

CRANKSHAFT REMOVAL....................................................... 10-3

CRANKSHAFT INSPECTION ................................................... 10-4

CRANKSHAFT INSTALLATION.............................................. 10-5

CRANKCASE ASSEMBLY ....................................................... 10-7


10-1

Torque: 0.8 1.2kg-m


10-2

SERVICE INFORMATION


∞This section covers crankcase separation to service the crankshaft.

∞The following parts must be removed before separating the crankcase.

Engine (Section 5) Driven pulley (Section 9)

Carburetor (Section 11) A.C. generator (Section 7)

Oil pump (Section 4) Cylinder head/cylinder (Section 6)

Reed valve (Section 11)

∞When the left crankcase must be replaced, remove the following part in addition to the above.

Final reduction removal

∞Special tools must be used for crankshaft and crankcase assembly. When separating thecrankcase, the bearing will remain in the crankcase and it should be removed. When, assembling,drive a new bearing into the crankcase and install a new oil seal.

SPECIFICATIONSBA10AB.AC.50


Connecting rod big end sideclearance ⎯ 0.60

Connecting rod big end radialclearance ⎯ 0.04

Crankshaft runout A/B ⎯ 0.15/0.10

SPECIAL TOOLS

Crankcase puller Bearing outer driver handle A

Universal bearing puller Bearing outer driver, 42x47mm

Crankcase assembly collar Bearing driver pilot, 20mm

Crankcase assembly tool Bearing outer driver, 37x40mm


TROUBLESHOOTING

Abnormal engine noise

∞Excessive crank journal bearing play

∞Excessive crankpin bearing play

∞Excessive transmission bearing play


10-3

CRANKCASE SEPARATION

Remove the crankcase attaching bolts.

Attach the crankcase puller on the rightcrankcase and remove the right crankcasefrom the left crankcase.

CRANKSHAFT REMOVAL

Attach the crankcase puller on the leftcrankcase and remove the crankshaft fromthe left crankcase.

When removing the crankshaft, do itslowly and gently.

Crankcase Puller

Crankcase Puller


10-4

Remove the remaining bearing on thecrankshaft side using the universal bearingpuller.

CRANKSHAFT INSPECTION

Measure the connecting rod big end sideclearance.

Service Limit: 0.6mm replace if over

Measure the connecting rod big end radialclearance at two points in the X and Ydirections.


When separating the crankcase, the oilseals must be removed. Replace the oilseals with new ones.

Universal Bearing Puller


10-5

Measure the crankshaft runout.

Service Limit

A B

0.150mmreplace if over

0.100mmreplace if over

Check the crankshaft bearings for excessiveplay. The bearings must be replaced if theyare noisy or have excessive play.

CRANKSHAFT INSTALLATION

Wash the crankshaft in cleaning solvent andthen check for cracks or other faults.

∞After check, apply clean engine oil toall moving and sliding parts.

∞Remove all gasket material from thecrankcase mating surfaces. Dress anyroughness or irregularities with an oilstone.

Axial

PlayPlay

Radial


10-6

Drive a new crankshaft bearing into theright crankcase.

Drive a new crankshaft bearing into the leftcrankcase.

Install the crankshaft into the left crankcase.


∞Apply KYMCO ULTRA motor oil ormolybdenum disulfide to the crank-shaft bearings and connecting rod bigend.

∞Apply grease to the lip of the oil sealand then install it.


Bearing Outer Driver, 37x40mmBearing Driver Pilot, 17mm

Bearing Outer Driver, 42x47mmPilot, 20mm

Crankcase Assembly Tool

Crankcase Assembly Collar


10-7

CRANKCASE ASSEMBLY

Install the dowel pins and a new gasket tothe crankcase mating surface.

Assemble the crankcase halves.

The distance between the right crankcase oilseal and crankcase surface is about 12.5±0.5mm.

When installing the oil seal, be careful topress it with even force.

Dowel Pins






10-8

The distance between the left crankcase oilseal and crankcase surface is about 1.0mm.

Install and tighten the crankcase attachingbolts.

After assembly, check the crankshaftfor smooth operation.

Oil Seal

1.0mm

11. CARBURETOR

11-0

11

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__________________________________________________________________________________

CARBURETOR__________________________________________________________________________________



THROTTLE VALVE DISASSEMBLY ....................................... 11- 3

THROTTLE VALVE INSTALLATION...................................... 11- 4

CARBURETOR REMOVAL....................................................... 11- 5

AUTO BYSTARTER................................................................. 11- 6

FLOAT CHAMBER................................................................... 11- 8

FLOAT LEVEL INSPECTION .................................................. 11-10

CARBURETOR INSTALLATION.............................................. 11-11

AIR SCREW ADJUSTMENT ..................................................... 11-11

REED VALVE.......................................................................... 11-12

FUEL TANK ............................................................................ 11-13

11. CARBURETOR

11-1

11. CARBURETOR

11-2

SERVICE INFORMATION


ïWhen working with gasoline, keep away from sparks and flames..ïNote the locations of O-rings when disassembling and replace them with new ones during

assembly.ïAll cables, fuel lines and wires must be routed and secured at correct locations.ïBleed air from the oil lines whenever they are disconnected.

SPECIFICATIONS BA10AB.AC.

Venturi dia. 14mm

Identification number PB058

Float level 8.6mm

Main jet #85

Slow jet #35

Air screw opening 1º ± Ω

Idle speed 2000±100rpm

Throttle grip free play 2 6mm

SPECIAL TOOL

Float level gauge

TROUBLESHOOTING

Engine does not start Lean mixture

∞No fuel in tank ∞ Clogged fuel jets ∞ Faulty float valve

∞Too much fuel getting to cylinder ∞ Clogged fuel cap vent ∞ Float level too low

∞Clogged fuel filter ∞ Clogged fuel filter ∞ Clogged air cleaner

∞Clogged air cleaner ∞ Bent, kinked or restricted fuel line

Engine idles roughly, stalls or runs poorly Rich mixture

∞Incorrect idle speed ∞ Clogged air cleaner ∞ Faulty float valve

∞Ignition malfunction ∞ Intake air leaks ∞ Float level too high

∞Compression too low ∞ Fuel contaminated ∞ Clogged air jets

∞Incorrectly adjusted air screw ∞ Faulty reed valve

∞Incorrect float level ∞ Clogged fuel jets

A

11. CARBURETOR

11-3

THROTTLE VALVE DIS-ASSEMBLY

Remove the rear carrier. (12-5)Remove the met-in box. (12-4)Loosen the carburetor cap and remove thethrottle valve.

Disconnect the throttle cable from thethrottle valve.

Remove the throttle valve spring, carburetorcap and rubber seal.

Carburetor Cap

Throttle Valve

Rubber Seal Carburetor Cap

Spring

11. CARBURETOR

11-4

Remove the jet needle by removing theneedle clip.Check the jet needle and throttle valve forwear or damage.

THROTTLE VALVE INSTALLA-TION

Install the jet needle on the throttle valveand secure with the needle clip.

Install the rubber seal on the throttle cableand then install the carburetor cap andthrottle valve spring.

Connect the throttle cable to the throttlevalve.

Carburetor Cap

Throttle Valve

Rubber Seal

Throttle Cable

Throttle Valve Spring

Needle Retainer2nd Notch (STD)

ThrottleValve

Jet Needle

Needle Clip

11. CARBURETOR

11-5

Install the throttle valve by aligning thegroove in the throttle valve with the throttlestop screw.

Tighten the carburetor cap.After installation, perform the followingadjustments and inspections.

∞ Throttle cable free play (3-12)

∞ Idle speed adjustment (3-11)

Install the met-in box.

CARBURETOR REMOVAL

Remove the met-in box. (12-4)Remove the air cleaner by removing the aircleaner band screw and attaching bolts.Disconnect the fuel tube.Loosen the drain bolt to drain fuel from thecarburetor.Disconnect the auto bystarter wireconnector.Remove the two carburetor lock nuts.

Carburetor Cap

Drain Bolt

Throttle Cable

Throttle Stop Screw

Groove

Fuel Tube

Band

Auto Bystarter

11. CARBURETOR

11-6

Remove the carburetor.

AUTO BYSTARTER

AUTO BYSTARTER INSPECTION

Measure the resistance between the autobystarter wire terminals.Resistance: 5Ω (10 minutes minimumafter stopping the engine)

If the resistance exceeds 5Ω, replace theauto bystarter with a new one.

After the engine stops for 30 minutes,connect a hose to the fuel enriching circuitand blow the hose with mouth.If air cannot be blown into the hose(clogged), the auto bystarter is faulty.Replace it with a new one.

Nut

11. CARBURETOR

11-7

Connect the auto bystarter yellow wire tothe battery positive (+) terminal and green/black wire to the battery negative (-)terminal and wait 5 minutes.Connect a hose to the fuel enriching circuitand blow the hose with mouth.If air can be blown into the hose, the autobystarter is faulty and replace it with a newone.

AUTO BYSTARTER REMOVAL

Remove the auto bystarter cover.Remove the two auto bystarter set platescrews to remove the auto bystarter.

Check the auto bystarter valve and needlefor wear or damage.Check the O-ring for wear or damage.

Auto Bystarter

Screws

O-ring

Set Plate

Bystarter ValveBystarterNeedle

11. CARBURETOR

11-8

AUTO BYSTARTER INSTALLATION

Install the auto bystarter into the carburetorbody until it bottoms..Install the set plate and then tighten the twoscrews.

FLOAT CHAMBER

Remove the two float chamber screws andthe float chamber.

Remove the screw and O-ring.Remove the float pin, float and float valve.

Auto Bystarter

Float

O-ring

Set Plate

Float Pin

Screws

Screws

11. CARBURETOR

11-9

FLOAT/FLOAT VALVE INSPECTION

Inspect the float for damage or fuel insidethe float.Check the float valve seat for wear ordamage.

JETS/SCREWS REMOVAL

Before removing the throttle stop screw orair screw, record the number of rotationsuntil it seats lightly. Then, remove them.

Remove the main jet and needle jet holder.

CARBURETOR PASSAGES CLEANING

Blow compressed air through all passagesof the carburetor body with an air gun.

Do not force the air screw against itsseat to prevent damage.

Float Valve

Float Seat

Main Jet

Throttle Stop Screw Air Screw

11. CARBURETOR

11-10

FLOAT CHAMBER ASSEMBLY

Install the main jet and needle jet holder.

Install the air screw and throttle stop screwaccording to the rotations recorded.

Install the float valve, float and float pin.Tighten the float screw securely.

FLOAT LEVEL INSPECTION

Slightly tilt the carburetor and measure thefloat level with the float valve justconnecting the float arm.

Float Level: 8.6mm

Replace the float if the level is out of thespecified level range.Install the O-ring.Check the operation of the float and installthe float chamber.Tighten the screws.

If the air screw must be replaced, be sureto perform the air screw adjustmentagain.

Air ScrewThrottle Stop Screw

Needle Jet holder

Float Pin

Main Jet

11. CARBURETOR

11-11

CARBURETOR INSTALLATION

Check the carburetor insulator and O-ringfor wear or damage.Install the carburetor and insulator onto theintake manifold and tighten the two locknuts.Connect the fuel tube and auto bystarterwire connector.

Install the carburetor cap. (11-4)Install the air cleaner onto the carburetorand tighten the band screw.Install the met-in box. (12-4)

AIR SCREW ADJUSTMENT


Turn the air screw clockwise until it seatslightly and back it to the specification given.

Air Screw Opening:

BA10AB.AC.50: 1º ± Ω turns

Start the engine and turn the air screw in orout slowly to obtain the highest enginespeed.

Turn the throttle stop screw to obtain thespecified idle speed.

Idle Speed:

BA10AB.AC.50 : 2000±100rpm

Slightly increase the engine speed and makesure that the engine does not miss or runerratic.If the adjustment of the air screw within therange of ±Ω turn makes no difference to theengine performance, check other relateditems.

When installation, do not allow foreignparticles to enter the carburetor.

Route the auto bystarter wire correctlyand properly.

Warm up the engine before air screwadjustment.

Do not force the air screw against itsseat to prevent damage.

Air Screw

Throttle Stop Screw

O-rings

Insulator

Carburetor Cap Band

Fuel Tube

Air Cleaner Case

11. CARBURETOR

11-12

REED VALVE

REMOVAL

Remove the rear carrier.Remove the frame body cover.Remove the four intake manifold bolts andgasket.Remove the reed valve and gasket.

INSPECTION

Check the reed valve for damaged or weakreeds.Check the reed valve seat for cracks, damageor clearance between the seat and reed.Replace the valve if necessary.

INSTALLATION

Install the reed valve in the reverse order ofremoval.

∞Install a new gasket with the gasketindentation aligned with the reedvalve.

∞After installation, check for intake airleaks.

Bolts

Do not disassemble or bend the reedstopper. To do so can cause loss ofengine power and engine damage. If anyof the stopper, reed or valve seat isfaulty, replace them as a unit.

Reeds

Intake Manifold

Reed Valve Seat

Reed Stopper

11. CARBURETOR

11-13

FUEL TANK

REMOVAL

Remove the met-in box. (12-4)Remove the frame body cover. (12-5)Remove the rear carrier. (12-5)Disconnect the fuel tube and vacuum tubeat the auto fuel valve.Disconnect the fuel unit wire connector.Remove the fuel tank mounting bolts andfuel tank.Inspect the fuel unit. (16-2)Replace the fuel unit if necessary. (16-2)

Fuel Unit

Fuel TubeVacuum Tube

Fuel Tank

Auto Fuel Valve

Fuel Tank Cap

12. FRAME COVERS

12-0

12

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__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

FRAME COVERS

__________________________________________________________________________________


FRAME COVERS REMOVAL/INSTALLATION ........................ 12-3

12

12. FRAME COVERS

12-1

ASSEMBLY DRAWING

12. FRAME COVERS

12-2

SERVICE INFORMATION

∞When removing frame covers, use care not to pull them by force because the cover joint clawsmay be damaged.

Items Related for Removal

∞Handlebar front cover Headlight wire

∞Front cover

∞Handlebar rear cover Speedometer cable and instrument lightwire connectors, etc.

∞Frame body cover Met-in box, rear carrier,rear fender.

∞Floor board frame body cover.

∞Front tool box Front cover, battery, floor board .

12. FRAME COVERS

12-3

FRAME COVERS REMOVAL

FRONT COVER REMOVAL

Remove the screw the front cover.Remove the two screws on the back of thefront cover.Push the two inside claws of the downsidefront cover to float the front cover.Remove the front cover downward.The installation sequence is the reverse ofremoval.

HANDLEBAR FRONT/REAR COVER

REMOVAL

First remove the one screws attaching thehandlebar front cover.Remove the handlebar front cover.Disconnect the headlight wire connector.

Remove the handlebar rear cover:Remove the four screws and bolt attaching thehandlebar rear cover.Disconnect the speedometer cable andinstrument light wire connectors.Remove the handlebar rear cover.The installation sequence is the reverse ofremoval.

Front Cover Screws

Screws

During removal, be careful not to pullthe joint claws forcibly.

Handlebar Rear Cover

Front Tool BoxScrew

Screws

Screws

12. FRAME COVERS

12-4

FLOOR BOARD REMOVAL

Remove the rear carrier. (12-5)Remove the frame body cover. (12-6)Remove the front cover. (12-3)Remove the four bolts attaching and six screwsthe floor board to remove the floor board.The installation sequence is the reverse ofremoval.

FRONT TOOL BOX REMOVAL

Remove the rear carrier. (12-5)Remove the frame body cover. (12-6)Remove the floor board. (12-4)Open the front tool box and remove thebattery.Remove the switch covers.Remove the nut attaching and six screws thefront tool box.Remove the front tool boxThe installation sequence is the reverse ofremoval.

BOTTOM COVER REMOVAL

Remove the flood board. (12-4)Remove the three screws each side ofthe bottom cover.Remove the bolt attaching the side stand.Remove the bottom cover.The installation sequence is the reverse ofremoval.

Screws

Battery

Floor Board

Nut

Bolts

Front Tool Box

Bottom Cover

When removing the battery, firstdisconnect the battery negative (-) cableand then the positive (+) cable.When taking the front tool box, pullthem up and backward from downsidenot to damage the claws.

screws

Bolt

12. FRAME COVERS

12-5

MET-IN BOX REMOVAL:

Open the seat.Remove the two bolts, two nuts attaching themet-in box.Remove the oil tank cap, rubber packing andfuel tank cap.Remove the met-in box.The installation sequence is the reverse ofremoval .

REAR CARRIER REMOVAL

Remove the three bolts attaching the rearcarrier.Remove the rear carrier.The installation sequence is the reverse ofremoval.

REAR FENDER REMOVAL

Remove the two screws the rear fender.Remove the rear fender.The installation sequence is the reverse ofremoval.

Rear Carrier

Bolts

Met-in Box

Boltsfuel tank capNuts

Rubber Packing Oil Tank Cap

Screws Rear Fender

12. FRAME COVERS

12-6

FRAME BODY COVER REMOVAL

Remove the rear carrier. (12-5)

Remove the rear fender. (12-5)


Remove the rear brake cable.

Remove the bolt attaching the front center coverof the frame body cover.

Remove the frame body cover.

The installation sequence is the reverse ofremoval.

FRONT FENDER REMOVAL

Remove the floor board. (12-4)

Remove the front tool box.(12-4)

Remove the handlebar. (13-3)

Remove the front fork. (13-19)

Remove two bolts attaching each side of thefront fender.Remove the front fender.The installation sequence is the reverse ofremoval.

FRONT LOWER COVERS REMOVAL

Remove the rear brake cable.

Remove the frame body cover. (12-5)

Remove the front tool box.(12-4)

Remove the handlebar. (13-3)

Remove the front fork. (13-19)

First remove the front cover. (12-3)Remove the right and left bottom coverremoving the two screws for each rail.Remove the two bolts attaching each of theright and left front lower covers.Remove the front lower covers.The installation sequence is the reverse ofremoval.

Bolts

Front Fender

Bolt

Bolts Front Lower Cover

frame body

13. STEERING HANDLEBAR/FRONT WHEEL/FRONTBRAKE/FRONT SHOCK ABSORBER/FRONT FORK

13-0

13

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__________________________________________________________________________________

STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK__________________________________________________________________________________



STEERING HANDLEBAR ........................................................ 13- 3

FRONT WHEEL ....................................................................... 13- 5

FRONT BRAKE (DRUM BRAKE) ............................................. 13- 9

FRONT BRAKE (DISK BRAKE) ............................................... 13-12

FRONT SHOCK ABSORBER..................................................... 13-20

FRONT FORK .......................................................................... 13-23

13


13-1

4.5kg-m

2.7kg-m

6.0kg-m

3.3kg-m


13-2

SERVICE INFORMATION

SPECIFICATIONS


Axle shaft runout ⎯ 0.2

Radial ⎯ 2.0Front wheel rim runout

Axial ⎯ 2.0

Front shock absorber spring free length 200 182.8

Brake disk thickness 35 3.8 3.0

Brake disk runout ⎯ 0.30

Brake master cylinder I.D. 12.700 12.743 12.75

Brake master cylinder piston O.D. 12.657 12.684 12.64

Brake caliper piston O.D. 25.400 25.405 25.45

Brake caliper piston I.D. 25.318 25.368 25.30

TORQUE VALUES

Handlebar lock nut 4.0 5.0kg-m Front damper nut 1.5 3.0kg-mSteering stem lock nut 8.0 12.0kg-m Front axle nut 5.0 7.0kg-mSteering top cone race 0.5 1.3kg-m Brake arm bolt 0.4 0.7kg-m

SPECIAL TOOLS

Lock nut wrench Driver handle ALock nut socket wrench Outer driver, 37x40mmOuter driver, 28x30mm Pilot, 10mmRear shock absorber remover Bearing pullerRear shock absorber compressor Snap ring pliers (close)Ball race remover Damper compressor

TROUBLESHOOTINGHard steering (heavy) ∞ Contaminated brake disk or disk pad∞Excessively tightened steering stem top ∞ Worn brake bushing

cone race ∞ Worn brake master cylinder piston oil seal∞Broken steering balls ∞ Clogged brake fluid line∞Insufficient tire pressure ∞ Deformed brake diskSteers to one side or does not track straight ∞ Unevenly worn brake caliper∞Broken clutch weight spring Front wheel wobbling∞Bent front fork ∞ Bent rim∞Bent front axle or uneven tire ∞ Loose front axlePoor brake performance ∞ Bent spoke plate∞Incorrectly adjusted brake ∞ Faulty tire∞Worn brake linings ∞ Improperly tightened axle nut∞Contaminated brake lining surface Soft front shock absorber∞Worn brake cam ∞ Weak shock springs∞Worn brake drum ∞ Insufficient damper oil∞Poorly connected brake arm Front shock absorber noisePoor brake performance (disk brake) ∞ Slider bending∞Air in brake system ∞ Loose fork fasteners∞Deteriorated brake fluid ∞ Lack of lubrication


13-3

STEERING HANDLEBAR

REMOVAL

Remove the handlebar front and rear covers.(12-3)Remove two bolts attaching the left brakelever holder.Remove two bolts attaching the brakemaster cylinder (disk brake) to the rightbrake lever.

Remove the two right handlebar switchhousing bolts and separate the housing.Disconnect the throttle cable and thenremove the throttle pipe from thehandlebar.

Remove the handlebar lock nut to removethe handlebar.


Bolts

Bolts

Nut

Throttle Pipe

Throttle Cable

Bolts

Handlebar

Bolt


13-4

INSTALLATION

Install the handlebar, aligning the tabs of thehandlebar with the grooves in the steeringstem.Install and tighten the handlebar lock nut.

Torque: 4.5 5.0kg-m

Lubricate the throttle pipe front end withgrease.Install the throttle grip and connect thethrottle cable.

The installation sequence is the reverse ofremoval.Install the rear brake lever holder.Install the front brake master cylinder (diskbrake).


Bolts

Tab/Groove

Holders

Throttle Cable

Bolts


13-5

FRONT WHEEL

REMOVAL

(DISK BRAKE)Jack the motorcycle front wheel off theground.Remove the speedometer cable set screwand disconnect the speedometer cable.Remove the front axle nut and pull out theaxle.Remove the front wheel.Remove the brake panel side collar.

INSPECTION

Set the axle in V blocks and measure therunout.The actual runout is _ of the total indicatorreading.

Service Limit: 0.2mm replace if over.

Check the wheel rim runout.

Service Limits:

Radial:2.0mm replace if over

Axial:2.0mm replace if over

Axle Nut

Speedometer Cable


13-6

Turn the wheel bearings and replace them ifthey have excessive play or noise.

DISASSEMBLYRemove the dust seal.

Remove the wheel bearings and distancecollar.

Bearing Puller

Dust Seal

Play

Radial

Pilot

Axial

Play


13-7

ASSEMBLY

Pack all bearing cavities with grease.Drive in the left bearing .Install the distance collar.Drive in the right bearing.

Apply grease to the dust seal lip and install

the dust seal.Install the side collar.

Pilot

Dust Seal

Drive the bearing squarely with thesealed end facing out.

Side Collar

Grease

Grease


13-8

FRONT WHEEL INSTALLATION

(Disk Brake)

Install the front wheel, aligning thespeedometer gear tab with the front forkgroove.Connect the speedometer cable.

Torque: 5.0 7.0kg-m

HYDRAULIC BRAKE (FRONT BRAKE)

Brake Fluid Replacement/Air Bleeding

Check the brake fluid level on level ground.

Brake Fluid Bleeding

In order to avoid spill of brake fluid, connecta transparent hose to the bleed valve.

Fully apply the brake lever and then loosenthe brake caliper bleed valve to drain thebrake fluid until there is no air bubbles inthe brake fluid. Then, tighten the bleed valve.Repeat these steps until the brake system isfree of air.

Brake Fluid Refilling

Add DOT-3 brake fluid to the brake reservoir.

Make sure to bleed air from the brakesystem.

∞When bleeding, be careful not to allowair in the brake reservoir flowing intothe brake system.

∞When using a brake bleeder, follow themanufacturer‘s instructions.

∞Never use dirty or unspecified brakefluid or mix different brake fluids be-cause it will damage the brake system.

Bleed Valve

Front Brake Caliper

Lower Limit

Upper Limit

Axle NutTabGroove

∞When operating the brake lever, thebrake reservoir cap must be tightenedsecurely to avoid spill of brake fluid.

∞When servicing the brake system, useshop towels to cover plastic parts andcoated surfaces to avoid damagecaused by spill of brake fluid.

Brake fluid spilled on brake pads orbrake disk will reduce the braking effect.Clean the brake pads and brake diskwith a high quality brake degreaser.

Warning


13-9

Brake Pad/Disk Replacement

Remove the two bolts attaching the brakecaliper.Remove the brake caliper.Remove the brake pads.

Install the brake pads in the reverse order ofremoval.Torque: 1.5 2.0kg-m

Brake Disk

Measure the brake disk thickness.

Service Limit: 3.0mm

Measure the brake disk runout.


The brake pads must be replaced as aset to ensure the balance of the brakedisk.

Keep grease or oil off the brake pads toavoid brake failure.

Front Brake Caliper

Front Brake Caliper

Brake Pads


13-10

BRAKE MASTER CYLINDER

Removal

First drain the brake fluid from thehydraulic brake system.

Disassembly

Remove the piston rubber cover and snapring from the brake master cylinder.

Remove the washer, main piston and springfrom the brake master cylinder.Clean the inside of the master cylinder andbrake reservoir with brake fluid.

∞When servicing the brake system, useshop towels to cover rubber andplastic parts and coated surfaces toavoid being contaminated by brakefluid.

∞When removing the brake fluid pipebolt, be sure to plug the pipe to avoidbrake fluid leakage.

Snap Ring Pliers (close)

Snap Ring

BoltsBrake Master Cylinder

Main Piston

Snap RingWasher

SpringMaster Cylinder


13-11

Inspection

Measure the brake master cylinder I.D.


Inspect the master cylinder for scratch orcrack.

Measure the brake master cylinder pistonO.D.


Before assembly, inspect the lst and 2ndrubber cups for wear.

Assembly

Before assembly, apply brake fluid to allremoved parts.Install the spring together with the 1strubber cup.

Install the main piston, spring and snapring.Install the rubber cover.Install the brake lever.

∞During assembly, the main piston andspring must be installed as a unitwithout exchange.

∞When assembling the piston, soak thecups in brake fluid for a while.

∞Install the cups with the cup lipsfacing the correct direction.


13-12

Place the brake master cylinder on thehandlebar and install the holder with “up”mark facing up. Be sure to align the punchmark with the holder joint.First tighten the upper bolt and then tightenthe lower bolt.

Torque: 1.0 1.4kg-m

Install the brake fluid pipe with theattaching bolt and two sealing washers.

Install the handlebar covers. (12-3)Fill the brake reservoir with recommendedbrake fluid to the upper limit and bleed airaccording to the method stated in 13-12.

BRAKE CALIPER (FRONT)

Removal

Remove the brake caliper. (13-13)Place a clean container under the brakecaliper and disconnect the brake fluid pipefrom the caliper.

BoltsPunch Mark

“Up” Mark

Bolt

Do not spill brake fluid on any coatedsurfaces.


13-13

Disassembly

Remove the brake caliper seat from thebrake caliper.

Remove the piston from the brake caliper.If necessary, use compressed air to squeezeout the piston through the brake fluid inletopening and place a shop towel under thecaliper to avoid contamination caused bythe removed piston.Check the piston cylinder for scratch orwear and replace if necessary.

Push the piston oil seal outward to removeit.Clean the oil seal groove with brake fluid.

Be careful not to damage the pistonsurface.

Brake Caliper Seat

Compressed Air

Piston Oil Seal


13-14

Check the piston for scratch or wear.

Measure the piston O.D. with amicrometer.


Check the caliper cylinder for scratch orwear and measure the cylinder bore.


Assembly

Clean all removed parts.Apply silicon grease to the piston and oilseal. Lubricate the brake caliper cylinderinside wall with brake fluid.Install the brake caliper piston with groovedside facing out.

Wipe off excessive brake fluid with a cleanshop towel. Apply silicon grease to thebrake caliper seat pin and caliper inside.Install the brake caliper seat.

Install the piston with its outer end3 5mm protruding beyond the brakecaliper.


13-15

Installation

Install the brake caliper and tighten the twobolts.

Torque: 2.9 3.5kg-m

Connect the brake fluid pipe to the brakecaliper and tighten the fluid pipe bolt.

Torque: 3.0 4.0kg-m

Fill the brake reservoir with recommendedbrake fluid and bleed air from the brakesystem. (13-12)

Bolts

Bolt


13-16

FRONT SHOCK ABSORBER

REMOVAL

Remove the front wheel. (13-5)Remove the front fender. (12-6)Remove the front shock absorber uppermount bolts.Loosen the lower mount bolts to removethe front shock absorbers.

LEFT FRONT SHOCK ABSORBERDISASSEMBLY

Remove the dust boot.Remove the circlip.

Use a vise to hold the front shock absorberand remove the shock absorber tube, hexbolt and copper washer from the frontshock absorber.

Front Shock AbsorberBolt/Washer

Circlip

Front Shock Absorber Mount Bolt

Dust Boot


13-17

Use a vise to hold the front shock absorbertube and remove the damper from the shockabsorber tube.

Measure the front shock absorber springfree length.

Service Limit: Right : 200mm

Left : 200mm

FRONT SHOCKABSORBER

ASSEMBLY

When holding the shock absorber tube,place a shop towel under it and do notapply too much force.

OilSeal

Damper Nut

AbsorberTube

DampingSpring

FrontShockAbsorber

Dust Seal

Front

Shock

Absorber

Spring

Damper

Circlip


13-18

Install the damping spring to the damperand then install them into the front shockabsorber tube.Install the front shock absorber spring andtighten the damper nut.

Use a vise to hold the front shock absorber.Tighten the hex bolt.(Apply locking agent to the washer andsocket hex bolt and install them together.)

Torque: 1.5 3.0kg-m

Specified Oil: ss#8

Oil Capacity: 61cc

Install the circlip.Install the dust boot.

Install the front shock absorber springwith the loosely wound coils facing up.

Damper Nut

Circlips

Front Shock Absorber

Bolt/Washer

Dust Boot


13-19

INSTALLATION

Install the front shock absorbers onto thesteering stem.Install and tighten the front shock absorberupper mount bolts.Tighten the lower mount bolts.Install the front fender.

Install the front wheel. (13-8)

FRONT FORK

REMOVAL

Remove the steering handlebar. (13-3)Disconnect the speedometer cable and frontbrake fluid pipe and remove the front brakecaliper.Remove the front wheel. (13-5)Hold the steering stem top cone race andremove the steering stem lock nut.

Remove the top cone race and remove thefront fork.

Inspect the ball races, cone races and steelballs for wear or damage. Replace ifnecessary.

Top Cone Race

Front Shock Absorber

Mount Bolts

Lock Nut Wrench

Be careful not to lose the steel balls (26on top race and 19 on bottom race).

Mount Bolts

Lock Nut Socket Wrench


13-20

BOTTOM CONE RACE REPLACEMENT

Remove the bottom cone race using a chisel.Drive a new bottom cone race into placewith a proper driver.

BALL RACE REPLACEMENT

Drive out the ball races.

Drive in new ball races.

Bottom Cone Race

Ball Race Remover

Be sure to drive the ball races into placecompletely.

Driver Handle A

Outer Driver, 37x40mm

Be careful not to damage the steeringstem and front fork.


13-21

INSTALLATION

Apply grease to top and bottom ball racesand install 26 steel balls on the top ball raceand 29 steel balls on the bottom ball race.Apply grease to the ball races again andthen install the front fork.

Apply grease to the top cone race andinstall it.Tighten the top cone race and then turn thesteering stem right and left several times tomake steel balls contact each other closely.

Install the steering stem lock nut and tightenit while holding the top cone race.

Torque: 8.0 12.0kg-m

Install the handlebar. (13-4)Install the speedometer cable.

Check that the steering stem rotatesfreely without vertical play.

Lock Nut Wrench

Top Cone Race

Lock Nut Socket Wrench

14. REAR WHEEL/REAR BRAKE/REARSHOCK ABSORBER

14-0

14

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__________________________________________________________________________________

REAR WHEEL/REAR BRAKE/REAR

SHOCK ABSORBER__________________________________________________________________________________



REAR WHEEL ......................................................................... 14-3

REAR BRAKE .......................................................................... 14-4

REAR SHOCK ABSORBER....................................................... 14-7

14


14-1

2.7kg-m

0.6kg-m11.0kg-m

1.2kg-m

4.0kg-m

2.5kg-m


14-2

SERVICE INFORMATION

SPECIFICATIONS


Rear wheel rim runout 2.0

Rear brake drum I.D. 110 111

Rear brake lining thickness 4.0 2.0

Rear shock absorber spring free length 235.7 218.7

TORQUE VALUES

Rear axle nut 11.0 13.0kg-m

Rear shock absorber upper mount bolt 3.5 4.5kg-m

Rear shock absorber lower mount bolt 2.4 3.0kg-m

Rear shock absorber lower joint nut 3.5 4.5kg-m (apply locking agent)

SPECIAL TOOL

Rear shock absorber remover

Rear shock absorber compressor

TROUBLESHOOTING

Rear wheel wobbling

∞Bent rim

∞Faulty tire

∞Axle not tightened properly

Soft rear shock absorber

∞Weak shock absorber spring

Poor brake performance

∞Brake not adjusted properly

∞Contaminated brake linings

∞Worn brake linings

∞Worn brake shoes at cam contacting area

∞Worn brake cam

∞Improper engagement between brake armand wear indicator plate


14-3

REAR WHEEL

REMOVAL

Remove the two exhaust muffler joint locknuts.Remove the two exhaust muffler lock bolts.Remove the exhaust muffler.Remove the rear axle nut to remove the rearwheel.

INSPECTION

Measure the rear wheel rim runout.

Service Limits:

Radial : 2.0mm replace if over

Axial : 2.0mm replace if over

INSTALLATION

Install the rear wheel and apply SAE30#engine oil to the axle threads. Then, tightenthe rear axle nut.

Torque values:

Rear axle nut: 11.0 13.0kg-m

Rear Axle Nut

Rear Axle Nut


14-4

REAR BRAKE

Remove the rear wheel. (14-3)Inspect the rear brake drum.Measure the rear brake drum I.D.


BRAKE LINING INSPECTION

Measure the brake lining thickness.


REAR BRAKE DISASSEMBLY

Remove the rear brake adjusting nut anddisconnect the rear brake cable.Remove the rear brake shoes.

Adjusting Nut

Brake Arm Brake Shoes

Keep oil or grease off the brake linings.


14-5

Remove the brake cam bolt to remove thebrake arm, wear indicator plate and felt seal.Remove the. brake arm.

REAR BRAKE ASSEMBLY

Apply grease to the anchor pin and brakeshoe moving parts.Apply grease to the brake cam and install it.

Apply engine oil to the felt seal and installit to the brake cam.Install the wear indicator plate.

Install the brake arm onto the brake cam.

Install and tighten the brake arm bolt.Install the brake arm return spring.Install the brake shoes.

Align the wide tooth of the wearindicator plate with the wide groove onthe brake cam.

Brake Arm Bolt Wear Indicator Plate

Brake Arm Brake Cam

Grease

Brake Arm

Punch MarkWear Indicator Plate

Align the punch mark on the brake armwith the scribed line on the brake cam.


14-6

Install the brake arm pin.Connect the brake cable and install theadjusting nut.Install the rear wheel. (14-3)Adjust the rear brake lever free play.

(3-4)

Brake Arm

Adjusting NutBrake Arm Pin

Brake Cable


14-7

REAR SHOCK ABSORBER

REMOVAL

Remove the front cover. (12-6)Remove the met-in box. (12-5)Remove the air cleaner case. (5-2)Remove the rear shock absorber upper andlower mount bolts to remove the rear shockabsorber.

DISASSEMBLY

Install the rear shock absorber compressoras the figure shown.

Compress the rear shock absorber spring.

Loosen the lower joint lock nut.Remove the lower joint.Remove the lock nut, rubber and damper.

Rear Shock Absorber Compressor

Lock Nut

Upper Mount Bolt

Install the rear shock absorber lowerjoint into the rear shock absorbercompressor.

Lower Mount Bolt

Rear Shock Absorber

Rear Shock Absorber Remover


14-8

INSPECTION

Inspect the damper rod for bending ordamage.Inspect the damper for oil leaks.

Inspect the damper rubber for deteriorationor damage.

Measure the rear shock absorber spring freelength.

Service Limit: 232mm replace if below

ASSEMBLY

Assemble the rear shock absorber in thereverse order of disassembly.

Tighten the lock nut.

Torque: 3.5 4.5kg-m

Spring

Damper RodDamper Rubber

∞Install the shock absorber spring withloosely wound coils facing down.

∞Apply locking agent to the lock nutthread and then install and tighten thelock nut.


14-9

INSTALLATION

Install the rear shock absorber.Install the rear shock absorber upper mountbolt and then install the lower mount bolt.

Torque:

Upper Mount Bolt: 3.5 4.5kg-m

Lower Mount Bolt: 2.4 3.0kg-m

Install the frame body cover. (12-5)

Upper Mount Bolt

Lower Mount Bolt

15. ELECTRICAL EQUIPMENT

15-0

15

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__________________________________________________________________________________

__________________________________________________________________________________

ELECTRICAL EQUIPMENT__________________________________________________________________________________



CHARGING SYSTEM............................................................... 15- 3

BATTERY................................................................................ 15- 4

IGNITION SYSTEM ................................................................. 15- 7

STARTING SYSTEM................................................................ 15-11

15


15-1

SERVICE INFORMATION


∞It is not necessary to check the battery electrolyte or fill with distilled water.

∞Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap..

∞Do not quick charge the battery. Quick charging should only be done in an emergency..

∞Charge the battery according to the charging current and time specified on the battery.

∞When charging, check the voltage (open voltage) with an electric tester.

∞When replacing the battery, do not use a traditional battery.

SPECIFICATIONS BA10AB.AC.

Capacity 12V4AH

Voltage 13.0 13.2V

Charging Standard 0.4A/5HBattery

current Quick 4A/0.5H

Spark plug (NGK) BR8HSA

Spark plug gap 0.6 0.7mm

Primary coil 0.2 0.3Ω

Secondary coil(with plug cap) 7.0 8.4KΩIgnition coil resistance

Secondary coil(without plug cap) 2.5 3.2KΩ

Pulser coil resistance (20 ) 80 160Ω

Ignition timing 8ϒ~14ϒ±1.5ϒBTDC/2000rpm

TROUBLESHOOTING

CHARGING SYSTEM

No power Intermittent power

∞Dead battery ∞ Loose battery cable connection

∞Disconnected battery cable ∞ Loose charging system connection

∞Fuse burned out ∞ Loose connection or short circuit in ignition system

∞Faulty ignition switch ∞ Loose connection or short circuit in lighting system

Low power Charging system failure

∞Weak battery ∞ Loose, broken or shorted wire or connector

∞Loose battery connection ∞ Faulty regulator/rectifier

∞Charging system failure ∞ Faulty A.C. generator

∞Faulty regulator/rectifier


15-2

IGNITION SYSTEM

No spark at plug Engine starts but turns poorly

∞Faulty spark plug ∞ Ignition primary circuit

∞Poorly connected, broken or shorted wire óFaulty ignition coil

óBetween A.C. generator and CDI unit óPoorly connected wire or connector

óBetween CDI unit and ignition coil ∞ Ignition secondary circuit

óBetween CDI unit and ignition switch óFaulty ignition coil

óBetween ignition coil and spark plug óFaulty spark plug

∞Faulty ignition switch óPoorly insulated plug cap

∞Faulty ignition coil ∞ Improper ignition timing

∞Faulty CDI unit óBattery voltage too low (6V max.)

∞Faulty A.C. generator óFaulty CDI unit

STARTING SYSTEM

Starter motor won‘t turn Lack of power

∞Fuse burned out ∞ Weak battery

∞Weak battery ∞ Loose wire or connection

∞Faulty ignition switch ∞ Foreign matter stuck in starter motor

∞Faulty starter switch or pinion

∞Faulty front or rear stop switch Starter motor rotates but engine does∞Faulty starter relay not start

∞Poorly connected, broken or shorted wire ∞ Faulty starter pinion

∞Faulty starter motor ∞ Starter motor rotates reversely

∞ Faulty starter clutch

∞ Weak battery


15-3

CHARGING SYSTEM

A.C. Generator

Dimmer Switch

Headlight Switch

Ignition Switch

Resistor

Battery

Y

W

5. 9Ω30W

Wire Harness B

G

R

W

G

R

Y

Y

Y

AutoBystarter

Fuse

Regulator/Rectifier

Ignition Switch

G/B

Resisto

r

Resisto

r

A.C

. Gen

erator

Pu

lser Co

il

10.2Ω5W

L/Y

G/B


15-4

BATTERY

BATTERY REMOVAL

Remove the front tool box cover.Disconnect the battery cables .

Remove the bolt and battery bracket.Remove the battery.The installation sequence is the reverse ofremoval.

BATTERY CHARGING (OPEN CIRCUITVOLTAGE) INSPECTION

Remove the battery cover and disconnectthe battery cables.Measure the voltage between the batteryterminals.Fully charged : 13.0V 13.2VUndercharged : 12.3V max.

CHARGING METHOD

Connect the charger positive (+) cable tothe battery positive (+) cable.Connect the charger negative (-) cable to thebattery negative (-) cable.

Charging current : Standard : 0.4AQuick : 4A

Charging time : Standard : 5 hoursQuick : 0.5 HOUR

After charging: Open circuit voltage: 12.8V min.

Front tool box Cover

First disconnect the battery negative (-)cable and then the positive (+) cable.

Battery charging inspection must beperformed with an electric tester.

∞Quick charging should only be done inan emergency.

∞During quick charging, the batterytemperature should not exceed45 .

∞Measure the voltage 30 minutes afterthe battery is charged.

∞ Keep flames and sparks awayfrom a charging battery.

∞ Turn power ON/OFF at thecharger, not at the battery terminals toprevent sparks near the battery.

∞ Charge the battery according tothe current specified on the batterysurface.

Power

Lamp

(Green)

Red

Black

Charging

Lamp

(Red)

Battery


15-5

PERFORMANCE TEST

Warm up the engine.Remove the floor mat and front tool boxcover.

Stop the engine and open the fuse box.Disconnect the wire lead from the fuseterminal. Connect an ammeter between thewire lead and fuse terminal as shown.Connect the battery positive (+) terminal tothe voltmeter positive (+) probe andbattery negative (-) terminal to thevoltmeter negative (-) probe.Start the engine, gradually increase enginespeed to test the output:

Position

RPMDay Night

2500 1.3A min. 1.0A min.

6000 2.0A min. 2.0A min.

Charging Limit Voltage: 14.5±0.5V/8000rpm

If the limit voltage is not within thespecified range, check the regulator/rectifier.

A.C. GENERATOR (CHARGINGCOIL) INSPECTION

Remove the met-in box. (12-4)Disconnect the A.C. generator connector.Measure the resistances between thecharging coil terminals (whiteñgreen) andlighting coil terminals (yellowñgreen).

Resistances:

Charging coil whiteñgreen 0.2 1.2Ω

Lighting coil yellowñgreen 0.3 1.0Ω

Refer to 7-3 for A.C. generator removal.

A.C. Generator Connector

Use a fully charged battery to check thecharging system output.

Inspect with the engine installed.


15-6

RESISTOR INSPECTION

Remove the frame front cover. (12-3)Measure the resistance between the resistorB pink wire and ground.Measure the resistance between the resistorA green/black wire and ground.

Resistances: Resistor A: 9.9 12.0Ω Resistor B: 5.6 7.2Ω

REGULATOR/RECTIFIERINSPECTION

Remove the front cover. (12-3)Disconnect the regulator/rectifier wirecoupler and remove the bolt to remove theregulator/rectifier.

Measure the resistances between theterminals.Replace the regulator/rectifier if the readingsare not within the specifications in the tablebelow.

Model Brand Range

SP-10D Sanwa KΩ

TH-5H Kowa 100Ω

Probe⊕

Probe(-) A (R) B (W) C (Y) D (G)

A (R) 20-35KΩ

B (W) 8-20KΩ

C (Y)

D (G) 6.5-35KΩ

∞Due to the semiconductor in circuit, itis necessary to use a specified testerfor accurate testing. Use of animproper tester in an improper rangemay give false readings.

∞Use a Sanwa Electric Tester (07208-0020000) or Kowa Electric Tester(TH-5H). The proper range fortesting is listed below.

Coupler

Faulty resistor is the cause of faultyoperation of the auto bystarter.

A (Red)C (Yellow)

D (Green) B (White)

Resister A Resister B

Regulator/Rectifier

Bolt


15-7

Ignition Coil

Pulser Coil

Ignition Switch

Spark Plug

A.C. Generator (Exciter Coil)

A.C. Generator

R

CDI Unit

IgnitionSwitch

SparkPlug

GY

B

G

Battery

Fuse7A

Regulator/Rectifier

W B

W

GRY

Pu

lser Co

il

L/Y Ig

nitio

n C

oil

B/Y

B/Y

L/Y

G G


15-8

IGNITION COIL INSPECTION

Continuity Test

Remove the met-in box. (12-4)Measure the resistance between the ignitioncoil primary coil terminals.

Resistance (20 ): 0.153 0.187Ω

Measure the secondary coil resistancebetween the spark plug cap and the primarycoil terminal as Figure A shown.

Resistance (20 ) (with plug cap):7.0 8.4KΩ

Measure the secondary coil resistancebetween the ignition coil terminal and theprimary coil terminal as Figure B shown.Resistance (20 ) (without plug cap):2.5 3.2KΩ

This test is to inspect the continuity ofignition coil.

Figure AFigure B

Ignition Coil

Green

Black


15-9

Performance Test

Remove the ignition coil.

Inspect the ignition coil with an ignition coiltester.

1. Turn the changeover switch to 12V andconnect the ignition coil to the tester.

2. Turn the power switch ON and check thespark from the watch window.

Good : Normal and continuous spark

Faulty : Weak or intermittent spark

A.C. GENERATOR

Exciter Coil/Pulser Coil Inspection

Remove the met-in box. (12-4)Disconnect the A.C. generator wireconnector.Measure the pulser coil resistance betweenthe blue/yellow wire and ground.

Resistance (20 ): 100 150Ω

This test is performed with the statorinstalled in the engine.

Follow the ignition coil tester manufac-turer‘s instructions.

Ignition Coil

AC 110V

6V/12VChangeoverSwitch

Ignition Coil Tester07508-0070100

Watch Window

Black

Black(-)

Red(+) Black(-)

Red(+)The test is performed at both conditionsthat the ignition coil is cold and hot.

Blue/Yellow


15-10

CDI UNIT INSPECTIONRemove the battery cover.Disconnect the CDI coupler and remove theCDI unit.

CDI CIRCUIT INSPECTIONMeasure the resistance between theterminals.Replace the CDI unit if the readings are notwithin the specifications in the table below.

Use the x KΩ range for the Sanwa Tester.

Use the x 100Ω range for the Kowa Tester.

Unit: KΩ

Probe⊕

(-)ProbeBlack

Blue/Yellow

Green Black/Yellow

Black 13~16

Blue/Yellow

33~40 18~22

Green 8~10

Black/Yellow

14~17 2.5~3.0

∞Due to the semiconductor in circuit, it isnecessary to use a specified tester foraccurate testing. Use of an impropertester in an improper range may givefalse readings.

∞Use a Sanwa Electric Tester or KowaElectric Tester (TH-5H).

∞In this table, “Needle swings thenreturns” indicates that there is a chargingcurrent applied to a condenser. The needlewill then remain at “ ” unless thecondenser is discharged.

CDI Unit

Blue/ Yellow

Green

Black

Black/ Yellow

Coupler


15-11

Starter Button

Starter Motor

Ignition Switch

G

G/Y

Ignition SwitchFuse7A

Stop Switch

R

G/Y

Y/RR/W

Front

Rear

Starter Button

Battery

Starter Motor

Stoplight

Starter Relay


15-12

STARTER RELAY INSPECTION

Remove the front cover.Disconnect the starter relay coupler andthen remove the starter relay.

Connect the starter relay green/yellowterminal to the 12V battery positive (+)terminal and the relay yellow/red terminalto the battery negative (-) terminal. Checkfor continuity between the starter relay redand red/white terminals. The relay isnormal if there is continuity.

STARTER MOTOR REMOVAL

Disconnect the starter motor cable.Remove the two bolts attaching the startermotor and remove the starter motor.The installation sequence is the reverse ofremoval.

Starter Relay

Green/Yellow

Starter Motor

Red/White

Bolts

Yellow/RedRed


15-13

STARTER MOTOR INSPECTION

Connect a battery across the starter motorand check for its operation.

1. Do not turn the starter motor for along time.

2. This inspection should be done with afully charged battery.

Battery

Starter Motor Battery (+) Terminal

16. INSTRUMENT/SWITCHES/LIGHTS

16-0

16

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

INSTRUMENT/SWITCHES/LIGHTS__________________________________________________________________________________



FUEL UNIT.............................................................................. 16-2

OIL METER ............................................................................. 16-3

SWITCHES .............................................................................. 16-5

STOP SWITCH INSPECTION/HORN ........................................ 16-6

BULB REPLACEMENT ............................................................ 16-7

INSTRUMENT/HEADLIGHT.................................................... 16-8

16


16-1

SERVICE INFORMATION


∞Wires should be connected to other wires of the same color. Couplers must be connected to othercouplers of the same color.

∞All plastic plugs have locking tabs that must be released before disconnecting, and must be alignedwhen reconnecting.

∞After installation of each switch, a continuity check must be performed.

TROUBLESHOOTING

Lights do not come on when ignition Motor oil indicator light does not come on

switch is “ON” (when motor oil is insufficient)

∞Burned bulb ∞ Fuse burned out

∞Faulty switch ∞ Dead battery

∞Broken or shorted wire ∞ Faulty ignition switch

∞Fuse burned out ∞ Faulty instrument∞Weak battery ∞ Faulty oil meter∞Poorly connected wire

∞Faulty winker Motor oil indicator light winks

∞ Loose wire connection

Light dims ∞ Broken wire

∞Faulty ignition coil ∞ Faulty oil meter

∞Wire or switch resistance too high

∞Faulty regulator/rectifier Fuel gauge pointer does not register

correctly

Headlight does not change when dimmer ∞ Disconnected wire or connector

switch is turn to Hi or Lo ∞ Broken wire

∞Faulty or burned bulb ∞ Faulty float

∞Faulty dimmer switch ∞ Faulty fuel unit

∞ Faulty instrument

Fuel gauge pointer fluctuates or swings

∞ Loose wire connection

∞ Faulty fuel unit

∞ Faulty instrument


16-2

FUEL UNIT

REMOVAL

Remove the frame body cover. (12-5)Disconnect the fuel unit wire connectors.Remove the three bolts attaching from thefuel unit retainer .

Remove the fuel unit.

INSPECTION

Remove the fuel unit.Measure the resistance between the fuelunit wire terminals with the float at upperand lower positions.

Wire Terminals Upper Lower

G Y/W 36Ω 700Ω

G L/W 550Ω 160Ω

Y/W L/W 600Ω 600Ω

FUEL GAUGE INSPECTION

Connect the fuel unit wire connectors andturn the ignition switch “ON”.

Check the fuel gauge needle for correctindication by moving the fuel unit float upand down.

Float Position Needle Position

Upper “F” (Full)

Lower “E” (Empty)

No Smoking!

Be careful not to bend or damage thefuel unit float arm.

Do not damage the fuel unit wire.

Before performing the following test,operate the turn signals to determinethat the battery circuit is normal.

Fuel Unit Wire

Fuel Unit

G

L/WY/W


16-3

INSTALLATION


OIL METER

INSPECTION

Remove the met-in box. (12-4)Remove the frame body cover. (12-4)Disconnect the oil meter wire connectorsand remove the oil meter. Keep the oilmeter float at the lower position.Measure the resistances between the wireterminals as Å and Ç shown in the leftfigure.

Wire Terminals Resistance

Green/Red(+) Black(-) 46Ω

Green(-) Black(+)

Oil Meter Operation Inspection

Connect the oil meter wire connectors andturn the ignition switch ON.Measure the resistance between the wireterminals with the float at upper position.

Green/Red(+) Black(-) About 300Ω

∞Align the groove on the fuel unit withthe flange on the fuel tank.

Light OFF

Light ONBefore performing the following test,operate the turn signals to determinethat the battery circuit is normal.

Oil Meter

Float

G/R

B

B

G

ÇÅ

Before removing the oil meter, be sure todrain the motor oil and do not allowsparks or flames near the working area.

G

Groove

Flange


16-4

Move the oil meter float up and down tosee if the oil indicator light will go out andcome on.

SWITCHES

IGNITION SWITCH INSPECTION

Remove the front cover. (12-3)Disconnect the ignition switch wirecouplers and check for continuity betweenthe wire terminals.

Color Red Black/White Green Black

Symbol BAT1 IG E BAT2

LOCK

OFF

ON

IGNITION SWITCH REPLACEMENT

Remove the front cover. (12-3)Disconnect the ignition switch wirecouplers.Remove the two mounting bolts and removethe ignition switch.The installation sequence is the reverse ofremoval.

Oil Indicator Light

Ignition Switch Coupler

Bolts

If the oil indicator light does not light,check for burned bulb, loose wire orconnector. After correction, check againaccording to the method mentionedabove.


16-5

HEADLIGHT SWITCH INSPECTION

Remove the handlebar front cover. (12-3)Disconnect the headlight switch wirecoupler and check for continuity betweenwire terminals.

Color Blue/White Yellow Brown Pink

Symbol HL CI TL RE

OFF

P

H

DIMMER SWITCH INSPECTION

Check for continuity between wireterminals.

Color Blue/White Blue White Black

Symbol HL HI LO BAT

HI

LO

PASSING

TURN SIGNAL SWITCHINSPECTION

Check for continuity between the wireterminals.

Color Light Blue Orange Gray

Symbol R L WR

R

L

Headlight Switch

Dimmer Switch

SBTurn Signal Switch O Gr

L

WB

L/W

Y BrP

L/W


16-6

STARTER SWITCH INSPECTION

Check for continuity between wireterminals.Push the starter button when measuring.

Color Yellow/Red Green

Symbol ST E

FREE

PUSH

HORN SWITCH INSPECTION

Check for continuity between wireterminals.Push the horn button when measuring.

Color Light Green Brown / Blue

Symbol HO BAT

FREE

PUSH

STOP SWITCH INSPECTION

Remove the handlebar front cover. (12-3)Disconnect the front and rear stop switchwire couplers.Check for continuity between the wireterminals when the front/rear brake lever isapplied.

Horn Switch

Br/L

Lg

Starter Switch

Y/RG


16-7

HORN INSPECTION

Remove the frame front cover. (12-3)Disconnect the horn wire couplers. Thehorn is normal if it sounds when a 12Vbattery is connected across the horn wireterminals.

FRONT TURN SIGNAL LIGHTREPLACEMENT


Remove the floor board. (12-4)

Remove the front tool box. (12-4)

Remove two screws attaching the turnsignal light shell and the bulb.Replace with new ones.

TAILLIGHT/STOPLIGHT/REAR TURNSIGNAL LIGHT BULB REPLACEMENT

Taillight Shell Removal:Remove two screws attaching the taillightshell.Remove the taillight shell and stop lightbulb.Remove screws attaching the rear turnsignal light.Remove the rear turn signal light bulbs.The installation sequence is the reverse ofremoval.

Taillight Shell

Screws

Turn Signal Light Bulb

Horn Terminal

Battery

Replace with new bulbs of the samespecifications.


16-8

INSTRUMENT

Instrument Bulbs Replacement

Remove the handlebar rear cover. (12-3)Remove the bulbs and replace with newones.

SPEEDOMETER REMOVAL

Disconnect the speedometer cable.Disconnect the speedometer wireconnector.Remove the three screws attaching thespeedometer.Remove the speedometer.The installation sequence is the reverse ofremoval.

HEADLIGHT

REMOVAL/BULB REPLACEMENT

Remove the handlebar front cover. (12-3)Remove the bulb sockets and bulbs.


Screws

∞The model adopts krypton gas bulb.When installing, do not directly touchthe bulb glass with fingers.

∞Use bulbs of the same specificationsfor replacement.

Coupler

Bulb Sockets

Wire Couplers

Bulb Sockets

specifications - scooter masters people 50-complete.pdf · specifications 1-0 1 ... this service...

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