RX 125 D RX 125 SM RT 125 D · ServiceManual RX 125 D RX 125 SM RT 125 D Kun motor. Udgivet 2009...
Transcript of RX 125 D RX 125 SM RT 125 D · ServiceManual RX 125 D RX 125 SM RT 125 D Kun motor. Udgivet 2009...
ServiceManual
RX 125 DRX 125 SMRT 125 DKun motor. Udgivet 2009
Holtvej 8-10, Høruphav6470 SydalsTelefon: +45 73 15 11 00Fax: +45 73 15 11 01
E-mail: [email protected]: 27 73 31 07
FOREWORD
This manual contains an introductory description onHYOSUNG 『 』,『 』& 『 』and procedures for its inspection /service and overhaul of its engine components.It covers the differences from 『 』&
『 』’s engine and please refer to theservice manual of 『 (99000-94610)』and 『 (99000-97100)』 for others which arenot covered in this manual.Other information considered as generally known isnot included.Read GENERAL INFORMATION section tofamiliarize yourself with outline of the vehicle andMAINTENANCE and other sections to use as a guidefor proper inspection and service.This manual will help you know the vehicle better sothat you can assure your customers of your optimumand quick service.
SERVICING INFORMATION
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE
ENGINE 3
2
7
This manual has been prepared on the basisof the latest specification at the time ofpublication.If modification has been made since then,difference may exist between the content ofthis manual and the actual vehicle.Illustrations in this manual are used to showthe basic principles of operation and workprocedures. They may not represent the actual vehicleexactly in detail.
WARNINGThis manual is intended for those who haveenough knowledge and skills for servicingHYOSUNG vehicles. Without such knowledge andskills, you should not attempt servicing by relyingon this manual only.Instead, please contact your nearby authorizedHYOSUNG motorcycle dealer.
COPYRIGHT S&T Motors Co., Ltd.
NOTE『 』model :
2
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARELOOKING FOR :
1. The text of this manual is divided into sections.2. As the title of these sections are listed on the previous
page as GROUP INDEX, select the section where you are looking for.
3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
4. On the first page of each section, its contents are listed.Find the item and page you need.
SYMBOLListed in the table below are the symbols indicating instructions and other information necessary for servicing.The meaning of each symbol is also included in the table.
Apply THREAD LOCK “1324”.
Apply or use brake fluid.
Measure in voltage range.
Measure in resistance range.
Measure in current range.
Use special tool.
Measure in continuity test range.
Measure in diode test range.
Torque control required.Data beside it indicates specified torque.
Apply oil. Use engine oil unless otherwise specified.
Apply SUPER GREASE “A”.
Apply SILICONE GREASE.
Apply MOLY PASTE.
Apply BOND “1215”.
Use fork oil.
DEFINITIONSYMBOL DEFINITIONSYMBOL
Apply SUPER GREASE “C”.
3
BL : Black with Blue tracer BBr : Black with Brown tracer
BG : Black with Green tracer BO : Black with Orange tracer
BR : Black with Red tracer BW : Black with White tracer
BY : Black with Yellow tracer LB : Blue with Black tracer
LG : Blue with Green tracer LR : Blue with Red tracer
LW : Blue with White tracer LY : Blue with Yellow tracer
BrB : Brown with Black tracer BrW : Brown with White tracer
GB : Green with Black tracer GR : Green with Red tracer
GY : Green with Yellow tracer GrB : Gray with Black tracer
GrR : Gray with Red tracer GrW : Gray with White tracer
OB : Orange with Black tracer OL : Orange with Blue tracer
OG : Orange with Green tracer OR : Orange with Red tracer
OW : Orange with White tracer OY : Orange with Yellow tracer
RB : Red with Black tracer RW : Red with White tracer
WB : White with Black tracer WL : White with Blue tracer
WR : White with Red tracer YB : Yellow with Black tracer
YL : Yellow with Blue tracer YG : Yellow with Green tracer
YR : Yellow with Red tracer
B : Black Gr : Gray Sb : Light blue
L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red
WIRE COLOR
4
5
GENERAL INFORMATION
EXTERIOR PHOTOGRAPH ………………………………………… 6 (1-3)
EXTERIOR ILLUSTRATION ~~ ₩₩………………………… 7 (1-7-1)
EXTERIOR ILLUSTRATION ~~ ₩₩……………………… 8 (1-7-2)
EXTERIOR ILLUSTRATION ~~ ₩₩……………………… 9 (1-7-3)
SPECIFICATIONS ………………………………………………………10 (1-8)
CONTENTS 1
6
1-3 GENERAL INFORMATION
EXTERIOR PHOTOGRAPH
7
GENERAL INFORMATION 1-7-1
EXTERIOR ILLUSTRATION~~ ₩₩
390
315
840
940
945
1,12
51,
060
230
1,350
2,085
405
79
0
660
715
725 80
0865
Rearreflector
Brake / Tail lamp
Rear turn signal lamp
License plate lamp
Front turn signal lamp
Passenger footrests
Head lamp
(HE
IGH
T)
(WHEEL BASE)
(LENGTH)
(WID
TH)
8
1-7-2 GENERAL INFORMATION
EXTERIOR ILLUSTRATION~~ ₩₩87
5
720
295
810 41
0
1,01
0
1,06
5
1,16
0
1,10
0
1,4252,190
320
840
865
124cm3
Rearreflector
Brake / Tail lamp
Rear turn signal lampLicense plate lamp
Front turn signal lamp
Passenger footrests
Head lamp
(HE
IGH
T)
(WHEEL BASE)
(LENGTH)
(WID
TH)
9
GENERAL INFORMATION 1-7-3
EXTERIOR ILLUSTRATION~~ ₩₩
Rearreflector
Brake / Tail lamp
Rear turn signal lampLicense plate lamp
Front turn signal lamp
Passenger footrests
Head lamp
(HE
IGH
T)
(WHEEL BASE)
(LENGTH)
(WID
TH)
10
1-8 GENERAL INFORMATION
2,085 mm (82.1 in)
840 mm (33.1 in)
1,125 mm (44.3 in)
1,350 mm (53.2 in)
230 mm (9.1 in)
135 kg (298 lbs)
2,190 mm (86.2 in)
←1,160 mm (45.7 in)
1,425 mm (56.1 in)
295 mm (11.6 in)
130 kg (287 lbs)
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Mass
I T E M
SPECIFICATIONS
⊙⊙ DIMENSIONS AND MASS
Four-stroke, DOHC, Air & oil cooled
1 cylinder
57.0 mm (2.24 in)
48.8 mm (1.92 in)
124.5 ㎤ (7.6 in3 )
Carburetor
Electric starter
Wet sump
←
←←←←←←←
←
←←←←←←←
Type
Number of cylinder
Bore
Stroke
Piston displacement
Fuel system
Starter system
Lubrication system
I T E M
⊙⊙ ENGINE
Wet multi-plate type
5-speed constant mesh
1-down, 4-up
3.500
2.750
1.786
1.368
1.046
0.913
428SO, 130 links
←←←←←←←←←
428H, 132 links
←←←←←←←←←
428H, 130 links
Clutch
Transmission
Gearshift pattern
Reduction ratio
1st
2nd
3rd
4th
5th
Drive chain
I T E M
⊙⊙ TRANSMISSION
2,175 mm (85.6 in)
←1,145 mm (45.1 in)
1,415 mm (55.7 in)
275 mm (10.8 in)
←
Gear ratio
11
GENERAL INFORMATION 1-9
NOTEThe specifications are subject to change without notice.
Telescopic type
Swingarm type
47˚(right & left)
25˚84 mm (3.31 in)
Disk brake
Drum brake
130/80 - 18M/C 66P
180/80 - 14M/C 78P
160 mm (6.3 in)
←←
45˚(right & left)
27.5˚94 mm (3.70 in)
←←
2.75 - 21 45P
4.10 - 18M/C 59P
250 mm (9.8 in)
←←←27˚
88 mm (3.47 in)
←Disk brake
110/70 - 17M/C 58H
130/70 - 17M/C 62H
←
Front suspension
Rear suspension
Steering angle
Caster
Trail
Front brake
Rear brake
Front tire size
Rear tire size
Front fork stroke
I T E M
⊙⊙ CHASSIS
I T E M
⊙⊙ ELECTRICAL
9.0 ℓ850 ㎖950 ㎖
1,200 ㎖215 ± 2.5 cc
8.0 ℓ←←←
443 ± 2.5 cc
←←←←←
Fuel tank
Engine oil
Front fork oil capacity (One side)
Oil change
Oil and filter change
Engine overhaul
I T E M
⊙⊙ CAPACITIES
Ignition type
Ignition timing
Spark plugBatteryFuse
Head lamp
Turn signal lampBrake / Tail lamp
License plate lampIllumination lamp
High beam indicator lampTurn signal indicator lamp(right & left)
Neutral indicator lamp
“CDI”type
6˚B.T.D.C. at 1,900 rpmand 27˚B.T.D.C. at 4,250 rpm
CR8E12 V 6 Ah (MF)
15 A12 V - HS1 : 35 W ×112 V - HS1 : 35 W ×1
12 V - W5 W × 112 V - RY10 W × 412 V - P21/5 W × 1
12 V - W5 W × 1LED type
12 V - 1.7 W × 112 V - 1.7 W × 212 V - 1.7 W × 1
←
←
←←←
12 V - H4 : 60 W ×112 V - H4 : 55 W ×1
←←←←←←←←
←
←
←←←←←←←←←←←←←
HILO
Position
LED : Light Emitting Diode
12
13
2
2 PERIODIC MAINTENANCE
MAINTENANCE PROCEDURES …………………………………14 (2-3)
CYLINDER HEAD COVER BOLTS,
CYLINDER HEAD && CYLINDER BASE NUTS,
EXHAUST PIPE NUTS AND MUFFLER BOLTS …………………14 (2-3)
AIR CLEANER …………………………………………………………15 (2-5-1)
VALVE CLEARANCE……………………………………………………18 (2-6-1)
SPARK PLUG ……………………………………………………………20 (2-7)
ENGINE OIL ……………………………………………………………21 (2-8)
ENGINE OIL FILTER ……………………………………………………22 (2-9)
CARBURETOR …………………………………………………………23 (2-10)
COMPRESSION PRESSURE CHECK ………………………………24 (2-19)
OIL PRESSURE CHECK ………………………………………………25 (2-20)
CONTENTS
14
2-3 PERIODIC MAINTENANCE
● Tighten the exhaust pipe nuts ④ , mufflerconnecting bolt ⑤, and muffler mounting bolts ⑥,⑦ to the specified torque.
● Tighten the cylinder head cover bolts ① to thespecified torque.
CYLINDER HEAD COVER BOLTS,CYLINDER HEAD & CYLINDERBASE NUTS, EXHAUST PIPE NUTS AND MUFFLER BOLTS
Tighten Initial at 1,000 km and Every 4,000 kmthereafter.
Exhaust pipe nut : 18 ~ 28 N··m (1.8 ~ 2.8 kgf··m)
Muffler connecting bolt : 18 ~ 28 N··m (1.8 ~ 2.8 kgf··m)
Muffler mounting bolt : 18 ~ 28 N··m (1.8 ~ 2.8 kgf··m)
Cylinder head cover bolt: 12 ~ 16 N··m (1.2 ~ 1.6 kgf··m)
■■ CYLINDER HEAD COVER BOLT
● Tighten the cylinder head base buts ② andcylinder base nuts ③ to the specified torque.
Cylinder head base nut: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)
Cylinder base nut: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)
■■ CYLINDER HEAD & CYLINDER BASENUT
■■ EXHAUST PIPE NUTS & MUFFLERBOLTS
MAINTENANCE PROCEDURES
This section describes the servicing procedures foreach item.
① ①
③
⑦
②
⑥
⑤
④
Inspect Interval
15
PERIODIC MAINTENANCE 2-5-1
AIR CLEANER
If the air cleaner is clogged with dust, intakeresistance wil l be increased, with a resultantdecrease in power output and an increase in fuelconsumption.
Check and clean the air cleaner element in thefollowing manner :
■■● Remove the seat and right side cover.● Remove the six screws ① and remove the air
cleaner case cover.
● Take off the air cleaner element ②.
Clean the air cleaner element for the follwing : ● Fill a washing pan of a proper size with a non-
flammable cleaning solvent . Immerse the aircleaner element in the cleaning solvent and washit.
● Gently squeeze the air cleaner element betweenthe palms of both hands to remove the excesssolvent : do not twist or wring the element or it willdevelop tears.
● Immerse the element in HYOSUNG genuine oil, and then squeeze out the excess oil leaving
the element slightly wet. ● Reinstall the cleaned or new air cleaner element
in the reverse order of removal.
Clean Every 3,000 km,Replace Every 12,000 km.
①
②
Inspect Interval
■■ &
16
2-5-2 PERIODIC MAINTENANCE
CAUTIONInspect the air cleaner element for tears. A torn element must be replaced.If driving under dusty conditions, clean the aircleaner element more frequently. The surestway to accelerate engine wear is to operate theengine without the element or with tornelement. Make sure that the air cleaner elementis in good condition at all times. Life of theengine depends largely on this component!
8
8
● Remove the seat.● The air cleaner is located under the seat.● Remove the four air cleaner element bolts ②.● Pull up the air cleaner element ③. ③
①
②
②
※※ AIR CLEANER OIL DRAIN TUBE
Inspect the air cleaner oil drain tube ① and drainwater and oil at the periodic interval.The air cleaner oil drain tube ① is located beneaththe air cleaner case.
②
17
PERIODIC MAINTENANCE 2-5-3
8
8
Clean the air cleaner element for the following :● When the air cleaner element clean with the air gun,
necessarily blow at the inside by compressed air.● Carefully examine the air cleaner element for tears
during cleaning. Replace it with a new one if it is torn.● Assemble the element completely or damage
severely the engine.● Be careful not to allow water to go inside the air clea-
ner element.
CAUTIONMore frequent servicing may be performed onmotorcycles that are used under severeconditions, also clean the air cleaner elementwhen replacing the engine oil to prevent damageof the engine.
①
※※ AIR CLEANER OIL DRAIN TUBE
Inspect the air cleaner oil drain tube ① and drainwater and oil at the periodic interval.The air cleaner oil drain tube ① is located beneaththe air cleaner case.
18
2-6-1 PERIODIC MAINTENANCE
Excessive valve clearance results in valve noise andinsufficient valve clearance results in valve damageand reduced power.Check the intake and exhaust valve clearances atthe distances indicated above and adjust the valveclearances to specification, if necessary.
● Remove the seat and fuel tank.● Remove the spark plug.
VALVE CLEARANCE
Inspect Initial 1,000 km and Every 4,000 kmthereafter.
● Remove the cylinder head cover ①.The valve clearance specification is different for bothintake and exhaust valves.Valve clearance adjustment must be checked andadjusted :1) at the time of periodic inspection,2) when the valve mechanism is serviced, and3) when the camshafts are removed for servicing.
● Remove the magneto cover plug ② and valvetiming inspection plug ③.
NOTEThe piston must be at top dead center (TDC)on the compression stroke in order to check oradjust the valve clearance.The valve clearance should only be checkedwhen the engine is cold.
③
②
①
Inspect Interval
19
PERIODIC MAINTENANCE 2-6-2
● To inspect the valve clearance, insert a thicknessgauge between the tappet and the camshaft.
0.1 ∼ 0.2 mm (0.004 ~ 0.008 in)
0.2 ∼ 0.3 mm (0.008 ~ 0.012 in)
IN.
EX.
Standard (When cold)Valve clearance
Thickness gauge : 09900-20806
● Rotate the magneto rotor clockwise or counter-clockwise with a socket wrench to set the piston atTDC on the compression stroke. (Rotate the magneto rotor until the “T” index markon the magneto rotor is aligned with the trianglemark ① on the crankcase.)
● If the clearance is out of specification, first removethe cam chain tension adjuster, camshaft housing,camshaft.To install the tappet shim at original position,record the shim NO. and clearance to present by“A”, “B”, “C”, “D” mark on the cylinder head.
Select the tappet that agree with tappet clearance(vertical line) and shim NO.(horizontal line) as referto the tappet shim selection chart. (Refer to page 90·91)
Adjust valve timing, install the camshaft housing andthe cam chain tension adjuster.After the crankshaft rotate about 10 times, measurethe valve clearance.If the clearance be not correct, adjust the standardclearance as the same manner above.● In case of valve adjustment which is not the tappet
shim selection chart, please follow instructions ofexample in the below.For example, the intake clearance is 0.4 and theshim is 170 (1.70 mm), select 195 (1.95 mm) ofthe shim which 170 (1.70 mm) of the shim add upthe excess clearance 0.25 mm when adjust withthe standard 0.15 as the intake standard clearance0.1∼ 0.2 mm.
CAUTIONIf you don’t rotate the crankshaft about 10 timesbefore measuring the valve clearance, there is nomeaning of valve clearance.
①
20
2-7 PERIODIC MAINTENANCE
0.7 ∼ 0.8 mm (0.028 ~ 0.032 in)Spark plug gap
0.7 ~0.8 mm(0.028 ~0.032 in)
■■ CARBON DEPOSITSCheck to see if there are carbon deposits on thespark plug. If carbon is deposited, remove it using a wire or pinwith a pointed end.
● Disconnect the spark plug cap ① and remove thespark plug.
SPARK PLUG
CR7E
CR8E
CR9E
Hot type
Standard type
Cold type
SPARK PLUG SPECIFICATIONTYPE
Clean Initial 1,000 km and Every 4,000 km thereafter.Replace Every 8,000 km.
■■ SPARK PLUG GAPMeasure the spark plug gap using a thicknessgauge.If the spark plug gap is out of specification, adjust thegap.
■■ ELECTRODECheck to see the worn or burnt condition of the elec-trodes.If it is extremly worn or burnt, replace the spark plugwith a new one.And also replace the spark plug if it has a brokeninsulator, damaged thread, etc.
Thickness gauge : 09900-20806
CAUTIONTo avoid damaging the cylinder head threads ;first, finger tighten the spark plug, and thentighten it to the specified torque using the sparkplug wrench.
Inspect Interval
①
21
PERIODIC MAINTENANCE 2-8
● Insert the spark plug and finger tighten it to thecylinder head and then tighten it to the specifiedtorque.
Spark plug : 20 ~ 25 N··m (2.0 ~ 2.5 kgf··m)
Necessary amount of engine oil
Oil change
Oil and filter change
Engine overhaul
Engine oil type SAE 10W/40API Over SL
850 ㎖
950 ㎖
1,200 ㎖
ENGINE OIL
Inspect IntervalReplace Initial 1,000 km and Every 4,000 kmthereafter.
Engine oil should be changed while the engine iswarm. Engine oil filter replacement at the above intervals,should be together with the engine oil change.● Keep the motorcycle upright.● Place an oil pan below the engine, and drain the
engine oil by removing the engine oil filler plug ①and drain plug ②.
● Reinstall the drain plug gasket and engine oildrain plug ②.
● Tighten the drain plug ② to the specified torque,and pour fresh engine oil through the engine oilfiller hole. Use an engine oil that meets the APIservice classification of Over SL and that has aviscosity rating of SAE 10W/40.
● Install the engine oil filler plug ①.● Start up the engine and allow it to run for a few
minutes at idling speed.● Turn off the engine and wait about three minutes,
and then check the engine oil level through theengine oil level lens.If the level is below mark “F”, add engine oil to“F”level. If the level is above mark “F”, drainengine oil to “F”level. The motorcycle must be ina level position for accurate measurement.
Engine oil drain plug: 25 ~ 30 N·m (2.5 ~ 3.0 kgf·m)
②
①
22
2-9 PERIODIC MAINTENANCE
①
CAUTIONNever operate the motorcycle if the engine oil levelis below the “Lower line mark (L)”in the engineoil level lens. Never fill the engine oil above the“Upper line mark (F)”.Engine oil level being most suitable about 1 mmunder the “Upper line mark (F)”of the engine oillevel lens. In case of the engine oil pouring inexcessively, the engine output being madeinsufficient.Be careful not to pour the engine oil excessivelyinto the engine.
CAUTIONNecessarily, confirm and clean the oil strainer ①①when replace the engine oil (specially, when first replacement).
CAUTIONMore frequent servicing may be performed on mo-torcycles that are used under severe conditions.
ENGINE OIL FILTER
● Drain the engine oil as described in the engine oil replacement procedure.
● Remove the oil filter cap ② by removing the threenuts.
● Remove the oil filter ③.● Install the new O-ring ④.
● Install the new oil filter.● Install the new O-ring ⑤ and spring ⑥ to the oil filter
cap.● Install the oil filter cap ②.
Inspect IntervalReplace Initial 1,000 km and Every 4,000 kmthereafter.
CAUTIONBefore installing the oil filter cap, apply engineoil lightly to the new O-ring ⑤⑤.
②
②
⑥⑤
③④
23
PERIODIC MAINTENANCE 2-10
LUSTER MATERIAL
HYOSUNG
16510H05240
INSERTEDDIRECTION⇦
OUTSIDE⇦
■ OIL FILTER INSTALLATION
CAUTIONWhen installing the oil filter, necessarily,“HYOSUNG”character and “16510H05240”part’s
NO. is installed toward the outside, otherwise candamage the engine.
WARNINGEngine oil and exhaust pipes can be hot enough toburn you.Wait until the engine oil drain plug and exhaustpipes are cool enough to touch with bare handsbefore draining oil.
● Add new engine oil and check the engine oillevel as described in the engine oil replacementprocedure.
CAUTIONONLY USE A GENUINE HYOSUNG MOTORCYCLEENGINE OIL FILTER. Other manufacturer’sengine oil filters may differ filtering performanceand durability which may lead to engine damageor oil leaks.
● Connect an engine tachometer to the high tensioncord.Start up the engine and set its speed at anywhereof the specified value by turning throttle stopscrew ①.
1,400 ∼ 1,500 rpmEngine idle speed
1,400 ∼ 1,600 rpmEngine idle speed
Engine tachometer : 09900-26006
CARBURETOR
■■ IDLE SPEED
Inspect IntervalInspect Initial 1,000 km and Every 4,000 kmthereafter.
CAUTIONMake this inspection when the engine is hot.
①
&
24
2-19 PERIODIC MAINTENANCE
Low compression pressure can indicate some of thefollowing conditions :● Excessively worn cylinder wall● Worn-down piston or piston rings● Piston rings stuck in grooves● Poor valve seating● Ruptured or otherwise defective cylinder head
gasket
Remove the related parts and test the compressionpressure in the following manner :
● Fit the compression gauge in the spark plug hole.Make sure that the connection is tightened.
● Keep the throttle grip in the full-opened position.● Press the starter switch and crank the engine for a
few seconds. Record the maximum gauge readingas the cylinder compression.
● Remove the spark plug.
■■ COMPRESSION TEST PROCEDURE
COMPRESSION PRESSURE CHECK
The compression of a cylinder is a good indicator ofits internal condition.The decision to overhaul the cylinder is often basedon the results of a compression test. Periodicmaintenance records kept at your dealership shouldinclude compression reading for each maintenanceservice.
NOTEBefore testing the engine for compressionpressure, make sure that the cylinder headbolts are tightened to the specified torquevalues and valves are properly adjusted.Have the engine warmed up by idling beforetesting.Be sure that the battery used is in fully-charged condition.
NOTEWhen the compression pressure goes belowspecification, check the engine for conditionslisted above.
WARNINGThe hot engine can burn you. Wait until the engine are cool enough to touch.
Compression gauge : 09915-64511
Standard
Service limit
14 ~ 16 kgf/㎠
12 kgf/㎠
Compression pressure
25
PERIODIC MAINTENANCE 2-20
■■ HIGH OIL PRESSURE● Engine oil viscosity is too high● Clogged oil passage way● Combination of the above items
■■ OIL PRESSURE TEST PROCEDURECheck the engine oil pressure in the following manner :● Remove the oil check plug ① and install the oil
pressure gauge and adapter into the oil check plugremoved position.
● Connect an engine tachometer.● Warm up the engine as follows :
Summer : 10 min. at 2,000 rpm.Winter : 20 min. at 2,000 rpm.
● After warming up, increase the engine speedto 3,000 rpm. (with the engine tachometer), andread the oil pressure gauge.
Engine tachometer : 09900-26006Oil pressure gauge : 09915-74511
■■ LOW OIL PRESSURE● Clogged oil filter● Oil leakage from the oil passage way● Damaged O-ring● Defective oil pump● Combination of the above items
OIL PRESSURE CHECKCheck the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.
If the engine oil pressure is lower or higher than the specification, the following causes may be considered.
0.4 ~ 0.6 kgf/㎠(at 60 ℃·3,000 rpm)
Standard
Oil pressure
①
26
27
ENGINE
ENGINE REMOVAL AND REMOUNTING ……………………… 28 (3-5)
ENGINE REMOUNTING ……………………………………………… 28 (3-5)
UPPER END COMPONENTS OF ENGINE DISASSEMBLY 29 (3-6)
UPPER END COMPONENTS OF ENGINE INSPECTION
AND SERVICING ……………………………………………………… 34 (3-11)
UPPER END COMPONENTS OF ENGINE REASSEMBLY 44(3-21)
LEFT END COMPONENTS OF ENGINE DISASSEMBLY 54 (3-31)
RIGHT END COMPONENTS OF ENGINE DISASSEMBLY 57 (3-34)
LOWER END COMPONENTS OF ENGINE DISASSEMBLY 60 (3-37)
LOWER END COMPONENTS OF ENGINE INSPECTION
AND SERVICING ……………………………………………………… 63 (3-40)
LOWER END COMPONENTS OF ENGINE REASSEMBLY 66 (3-43)
RIGHT END COMPONENTS OF ENGINE REASSEMBLY 71 (3-48)
LEFT END COMPONENTS OF ENGINE REASSEMBLY 75 (3-52)
3
CONTENTS
CAUTIONMark an identification of assembly location on each removed part so that each will be restored to theoriginal position during reassembly.Wash clean and dry the removed parts before inspecting and measuring.Oil the rotating or sliding parts before assembly.Make sure to use the correct type of lubricant where specified.Check that each rotating or sliding part moves or operates smoothly after assembly.Make sure to follow the bolt tightening order where specified.If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the boltsand check that the tightening margin is equal in each bolt.
28
3-5 ENGINE
ENGINE REMOVAL ANDREMOUNTING
ENGINE REMOUNTINGRemount the engine in the reverse order of removal.● Temporarily fasten the engine mounting bracket
before inserting the engine mounting bolts.
● Tighten the engine mounting bolts and nuts to thespecified torque.
■■ INSTALLING POSITION FOR CLUTCHRELEASE ARM
● Align the clutch release arm slit surface with thenotch mark on the clutch release camshaft.
Engine mounting bolt (M10) ①①: 48 ~ 72 N··m (4.8 ~ 7.2 kgf··m)
Engine mounting bolt (M8) ②②,, ③③,, ④④: 22 ~ 33 N··m (2.2 ~ 3.3 kgf··m)
● Tighten the engine mounting bracket bolts and nutsto the specified torque.
Engine mounting bracket bolt (M8) ⑤⑤: 22 ~ 33 N··m (2.2 ~ 3.3 kgf··m)
Notch Mark
Slit
②
③
①
④
⑤
29
ENGINE 3-6
UPPER END COMPONENTSOF ENGINE DISASSEMBLY
● Drain the engine oil by removing the drain plug ①located on the bottom of the engine.
● Remove the magneto cover plug ② and the timinginspection plug ③.
● Remove the cylinder head cover ④ by removingthe four wrench bolts.
● Bring the piston at TDC (Top Dead Center).
NOTEIf only the upper end components of theengine is repaired, there is no necessary toremove the engine from the frame.Remove the seat and fuel tank so that theupper end components of the engine isdisassemble.
CAUTIONAlign the ““T””index mark on the magneto rotorwith the triangle mark ⑤⑤ on the magneto cover asturn the crankshaft clockwise or counter-clockwise.
①
②
③
④
⑤
30
3-7 ENGINE
● Remove the cam chain tension adjuster ①.
● Remove the cam chain guide NO.2 ②.
● Remove the camshaft housings ③.
● Remove the dowel pins, intake camshaft andexhaust camshaft.
NOTEDo not drop the dowel pins and cam chain intothe crankcase.
①
②
③③
31
ENGINE 3-8
● Remove the camshaft C-rings ①.
● Loosen the three cylinder head bolts.
● Loosen the three cylinder head base nuts.
● Remove the cam chain guide NO.1.
①
32
3-9 ENGINE
● Remove the tappet and the shim.
● Compress the valve spring by using the specialtools.
● Take out the valve cotter ① from the valve stem.● Remove the valve spring retainer ②.
CAUTION
Draw out the tappet and shim with the strongmagnet not to be scratched.
CAUTIONThe tappet and shim should be lined so that eachwill be restored to the original position duringreassembly.
Valve spring compressor : 09916-14510
Valve spring compressor attachment: 09916H35C00
①②
33
ENGINE 3-10
● Pull out the valve ① from the other side.
● Remove the two cylinder base nuts and thecylinder.
● Place a clean rag over the cylinder base toprevent the piston pin circlips from dropping intothe crankcase.Remove the piston pin circlips with the long-nosepliers.
● Remove the piston pin by using the special tool.
CAUTION
If tapping with the plastic hammer is necessary,pay attention to break the fins.
Piston pin puller : 09910-34510
①
34
3-11 ENGINE
Thickness gauge : 09900-20806
UPPER END COMPONENTSOF ENGINE INSPECTIONAND SERVICING
Cylinder head distortion
Cylinder head distortion
Service limit
0.05 mm (0.002 in)
⊙⊙ CYLINDER HEAD DISTORTIONDecarbonize in combustion chamber.Check the gasket surface of the cylinder head fordistortion using a straightedge and thickness gauge.Take clearance reading at several places asindicated. If any clearance reading exceeds the service limit,replace the cylinder head with a new one.
⊙⊙ VALVE FACE WEARVisually inspect each valve face for wear or damage.If any abnormal wear is found, replace the respectivevalve with a new one. The thickness of the valve facedecreases as the face wears. Measure the valvehead thickness . If the valve head thickness is notwithin the specified value, replace the valve with anew one.
Cylinder head distortion
Valve head thickness(IN. & EX.)
Service limit
0.5 mm (0.02 in)
Vernier calipers : 09900-20101
⊙⊙ VALVE STEM RUNOUTCheck the valve stem for abnormal wear or bend.Support the valve using a V-blocks and measure thevalve stem runout using the dial gauge, as shown.If the service limit is exceeded or abnormal conditionexists, replace the valve with a new one.
Cylinder head distortion
Valve stem runout(IN. & EX.)
Service limit
0.05 mm (0.002 in)
Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304
35
ENGINE 3-12
Camshaft runout(IN. & EX.)
Service limit
0.10 mm (0.004 in)
⊙⊙ CAMSHAFT RUNOUTSupport the camshaft using a V-blocks and measurethe camshaft runout using the dial gauge. If therunout exceeds the service l imit, replace thecamshaft with a new one.
Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304
⊙⊙ CAMSHAFTThe camshaft should be checked for runout and alsofor wear of cams and journals if the engine has beennoted to produce abnormal noise or vibration or alack of out-put power. Any of these abnormality couldbe caused by a worn camshaft.
VALVE TIMING DIAGRAM
Cam height
Intake cam
Exhaust cam 34.12 mm (1.343 in)
34.17 mm (1.345 in)
Service limit
⊙⊙ CAMSHAFT WEARWorn-down cams are often the cause of mistimedvalve operation resulting in reduced output power.The limit of cam wear is specified for both intake andexhaust cams in terms of cam height , which is tobe measured with a micrometer. Replace camshaftsif found it worn down to the limit.
Micrometer(25~50 mm) : 09900-20202
Intake open(B.T.D.C)
TDC (0。。)
Exhaust close(A.T.D.C)
Exhaust open(B.B.D.C)
Intake close(A.B.D.C)
17。
14。
45。
48。
90。270。
BDC (180。。)
36
3-13 ENGINE
Valve clearance
0.2 ~ 0.3 mm(0.008 ~ 0.012 in)
0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
Standard (When cold)
⊙⊙ TAPPET & SHIM WEARWhen measuring the valve clearance, the clearance should be within the standard range.
Exhaust valve
Intake valve
● Inspect the tappet for wear and scratch.If modification or scratch is present, replace thetappet.
● When you checked the valve clearance, if thevalve clearance is wide please replace the presentshim into thick one, if the valve clearance isnarrow please replace the present shim into thinshim. (Refer to page 90·91)
⊙⊙ SHIM KINDThere are 41 kinds of shim which thickness isincreased by each 0.025 mm from 1.20 mm to 2.20mm.
Thickness gauge : 09900-20806
37
ENGINE 3-14
⊙⊙ VALVE HEAD RADIALRUNOUT
Support the valve using a V-block and measure thevalve head radial runout using the dial gauge, asshown. If the runout exceeds the service limit,replace the valve with a new one.
Cylinder head distortion
Valve head radialrunout (IN. & EX.)
Service limit
0.03 mm (0.0012 in)
Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304
Valve stem deflection
0.35 mm(0.014 in)
0.35 mm(0.014 in)
Service limit
⊙⊙ VALVE STEM DEFLECTIONLift the valve about 10 mm (0.39 in) from the valveseat. Measure the valve stem deflection in twodirections, “X” and “Y”, perpendicular to each other.Position the dial gauge as shown.If the deflection exceeds the service limit, determinewhether the valve or the guide should be replacedwith a new one.
EX.
IN.
Dial gauge : 09900-20606Magnetic stand : 09900-20701
⊙⊙ VALVE STEM DIAMETERMeasure the valve stem outside diameter using themicrometer.If the diameter measured exceeds the standard,replace the valve.
Micrometer(0~25 mm) : 09900-20201
Valve stem diameter
IN.
EX.
4.475 ~ 4.490 mm(0.1762 ~ 0.1768 in)
4.455 ~ 4.470 mm(0.1754 ~ 0.1760 in)
Standard
38
Cylinder head distortion
Valve spring freelength (IN. & EX.)
Service limit
37.80 mm (1.488 in)
Cylinder head distortionValve spring tension(IN. & EX.)
Standard
⊙⊙ VALVE SPRINGThe force of the coil spring keeps the valve seat tight.A weakened spring results in reduced engine poweroutput and often accounts for the chattering noisecoming from the valve mechanism.Check the valve springs for proper strength bymeasuring their free length and also by the forcerequired to compress them. If the spring length isless than the service limit or if the force required tocompress the valve spring is not within specification,replace the valve spring.
Vernier calipers : 09900-20101
12.1 ~ 13.9 kgf(26.68 ~ 30.64 lbs)
at length 33.7 mm (1.33 in)
3-15 ENGINE
Cylinder distortionService limit
0.05 mm (0.002 in)
⊙⊙ CYLINDER DISTORTIONCheck the gasketed surface of the cylinder fordistortion using a straightedge and thickness gauge,taking a clearance reading at several places asindicated. If the largest reading at any posit ion of thestraightedge exceeds the limit, replace the cylinder.
Thickness gauge : 09900-20806
39
ENGINE 3-16
57.000 ~ 57.015 mm(2.2441 ~ 2.2447 in)
57.080 mm(2.2472 in)
Cylinder bore
⊙⊙ CYLINDER BOREMeasure the cylinder bore diameter at six place. If any one of the measurements exceeds the limit,overhaul the cylinder and replace the cylinder.
Cylinder gauge set : 09900-20508
Standard Service limit
⊙⊙ PISTON DIAMETERINSPECTION
Measure the outside diameter of the piston in thedirection perpendicular to the piston pin axis at theheight from the skirt as shown in the illustration usinga micrometer.If the measurement is found less than the servicelimit, replace the piston.
⊙⊙ PISTON TO CYLINDERCLEARANCE
To determine the piston to cylinder clearance,calculate the difference between the cylinder boreand outside diameter of the piston.
15 mm (0.6 in)
0.120 mm(0.0047 in)
Micrometer(50 ~ 75 mm) : 09900-20203
Piston diameterService limit
56.880 mm (2.2394 in)
Standard Service limitPiston tocylinder
clearance0.050 ~ 0.060 mm
(0.0020 ~ 0.0024 in)
40
3-17 ENGINE
Service limit
0.180 mm (0.007 in)
0.150 mm (0.006 in)
Piston ring-groove clearance
1st
2nd
⊙⊙ PISTON RING TO GROOVECLEARANCE INSPECTION
Remove carbon deposit both from the piston ring andits groove.Fit the piston ring into the groove. With the ring com-pressed and lifted up, measure the clearance on the bottom side of the ring using a thickness gauge.If any clearance reading exceeds the service limt,replace both the piston and piston rings.
StandardPiston ring thickness
StandardPiston ring groove width
Oil
2nd
1st
2.01 ~ 2.03 mm(0.079 ~ 0.080 in)
1.01 ~ 1.03 mm(0.040 ~ 0.041 in)
1.01 ~ 1.03 mm(0.040 ~ 0.041 in)
2nd
1st
0.970 ~ 0.990 mm(0.0382 ~ 0.0390 in)
0.970 ~ 0.990 mm(0.0382 ~ 0.0390 in)
Micrometer(0~25 mm) : 09900-20201Thickness gauge : 09900-20806
41
ENGINE 3-18
⊙⊙ PISTON RING FREE END GAPINSPECTION
Before installing the piston rings, measure the freeend gap of each ring using vernier calipers. If the gapis less than the service limit, replace the ring.
Vernier calipers : 09900-20101
⊙⊙ PISTON RING END GAPINSPECTION (Assembly condition)
Insert the piston ring squarely into the cylinder usingthe piston head.Measure the end gap with a thickness gauge.If the gap exceeds the service limit, replace thepiston ring with a new one.
Piston ring end gap (Assembly condition)
1st
2nd
Service limit
0.50 mm (0.020 in)
0.50 mm (0.020 in)
Piston ring end gap (Assembly condition)
1st
2nd
Standard
Thickness gauge : 0990-20806
Service limitPiston ring free end gap
1st
2nd
5.7 mm (0.224 in)
4.6 mm (0.181 in)
0.20 ~ 0.32 mm(0.008 ~ 0.013 in)
0.20 ~ 0.32 mm(0.008 ~ 0.013 in)
42
⊙⊙ CONROD SMALL END INSIDEDIAMETER INSPECTION
Using a dial calipers, measure the conrod small end inside diameter both in vertical and horizontaldirections. If any of the measurements exceeds the service limit,replace the conrod.
15.006 ~ 15.014 mm(0.5908 ~ 0.5911 in)
15.040 mm(0.5921 in)
Conrod smallend I.D.
Dial calipers : 09900-20605
3-19 ENGINE
⊙⊙ PISTON PIN HOLE BOREUsing a dial calipers, measure the piston pin holebore both the vertical and horizontal directions.If the measurement exceeds the service limit, replace the piston with a new one.
Dial calipers : 09900-20605
Piston pin hole bore
Service limit
15.030 mm (0.5917 in)
Piston pin diameterService limit
14.980 mm (0.5898 in)
⊙⊙ PISTON PIN DIAMETERINSPECTION
Using a micrometer, measure the piston pin outsidediameter at three position, both the ends and thecenter.If any of the measurements is founds less than theservice limit, replace the pin with a new one.
Micrometer(0~25 mm) : 09900-20201
Standard Service limit
43
ENGINE 3-20
⊙⊙ CONROD DEFLECTIONINSPECTION
Wear on the big end of the conrod can be estimatedby checking the movement of the small end of theconrod.Turn the conrod and see if it moves smoothly without play and noise. This method can also be used tocheck the extent of wear on the parts of the conrod’sbig end.
Conrod deflectionService limit
3.0 mm (0.12 in)
Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304
⊙⊙ CONROD BIG END SIDECLEARANCE INSPECTION
Push the big end of the conrod to one side andmeasure the side clearance using a thickness gauge.If the clearance exceeds the service limit, replace thecrankshaft assembly with a new one or bring thedeflection and the side clearance within the servicelimit by replacing the worn parts (conrod, big endbearing, crankshaft, crank pin, etc.) with new ones.
Standard
1.00 mm(0.040 in)
Conrod bigend side
clearance
Thickness gauge : 09900-20806
0.10 ~ 0.45 mm(0.004 ~ 0.018 in)
Service limit
⊙⊙ CRANKSHAFT RUNOUTINSPECTION
With the right and left crank journals supported usinga V-block, turn the crankshaft slowly. At this time,measure the crankshaft end runout using a dialgauge. If the runout exceeds the service limit,replace the crankshaft with a new one.
Crankshaft runout0.05 mm (0.002 in)
Service limit
Dial gauge : 09900-20606Magnetic stand : 09900-20701V-block : 09900-21304
44
⊙⊙ PISTON RING● Install the oil ring first, the 2nd ring second, and
the 1st ring last.
NOTEThe 1st ①① and 2nd ②② piston rings differ inshape.The 1st and 2nd piston rings should beinstalled with the mark facing up.
● First, install a spacer ③ into the oil ring groove,and then install the two side rails ④. The spacerand side rails do not have a designated top andbottom. They can be installed in any position.
CAUTIONWhen installing the spacer, be careful not to allowits two ends to overlap in the groove.
● Position the piston ring gaps as shown. Beforeinserting the piston into its cylinder, check that thegaps are properly positioned.
⑤ 2nd ring and lower side rail⑥ Upper side rail⑦ 1st ring and spacer
EX
⑥⑤
⑦IN
①
②
INCORRECT
CORRECT
UPPER END COMPONENTSOF ENGINE REASSEMBLY
3-21 ENGINE
45
ENGINE 3-22
⊙⊙ PISTON AND CYLINDER● Apply MOLY PASTE on the piston pin and small
end of the conrod.
● Apply the engine oil to the sliding surface of thepiston and big end of the conrod.
● Install the dowel pins ② and new gasket onto thecrankcase.
● Place a clean rag over the cylinder base toprevent the piston pin circlip from dropping intothe crankcase, and then fit the piston pin circlipwith the long-nose pliers.
● Hold each piston ring with the piston ring sectionspositioned correctly and put it into the cylinder.Make sure that the piston rings are caught by thecylinder skirt.
● Tighten the cylinder base nut ③ to the specifiedtorque.
MOLY PASTE
NOTEInstall the piston with the punch mark ①① on thepiston head facing toward the exhaust side.
NOTEWhen mounting the cylinder, after attaching thecam chain, keep the cam chain taut. The cam chain must not be caught between thecam chain sprocket and crankcase when thecrankshaft is rotated.
CAUTIONUse a new piston pin circlip to prevent circlipfailure with a bent one.
CAUTIONUse a new gasket to prevent oil leakage.
②
Cylinder base nut: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)
③
①
46
⊙⊙ VALVE AND SPRING● Apply MOLY PASTE to the valve as shown, and
then insert them into the valve guides.
● Put on the valve spring retainer ①, and using thevalve spring compressor, press down the spring,fit the cotter halves to the stem end, and releasethe valve spring compressor to allow the cotter ②to wedge in between retainer and stem.Be sure that the rounded lip ③ of the cotter fitssnugly into the groove ④ in the stem end.
● Install the valve spring with the smaller pitch facing the cylinder head.
CAUTIONWhen inserting each valve into the valve guides,make sure not to damage the lip of the oil seal.
MOLY PASTE
Cylinder headdirection
Valve spring compressor : 09916-14510Valve spring compressor attachment
: 09916H35C00
CAUTIONAfter installing the valve cotter, tap the valvestem end by using the plastic hammer at 2~3times for assembly of the valve and cotter. ①
②
③④
3-23 ENGINE
47
ENGINE 3-24
● Install the dowel pins ① and new gasket.
CAUTIONUse a new cylinder head gasket to prevent gasleakage.
⊙⊙ CYLINDER HEAD● Install the cylinder head ②.● With the cylinder head snugly seated on the
cylinder, secure it by tightening the bolts indiagonal stages. Tighten the cylinder head boltsdiagonally to the specified torque.
NOTEApply engine oil to the threaded parts of thecylinder head bolts and its washers.Be sure to install the washer with rounded sidefacing up.Pay caution to prevent the cam chain fromdropping into the crankcase.
Cylinder head bolt : 21 ~ 25 N··m (2.1 ~ 2.5 kgf··m)
● After tightening the cylinder head bolts to thespecification, tighten the cylinder head base nuts③ to the specified torque.
Cylinder head base nut: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)
①
②
● Install the tappet and shim.
CAUTIONWith the tappet fitted, it should be replaced if itdoesn’t turn smoothly by the hand.
③
48
Tappet
Shim
CAUTIONThe tappet and shim should be installed at theoriginal position when removed.If otherwise, it is difficult to adjust the valve clear-ance.
● With pulling up the cam chain, align the “T”indexmark of the magneto rotor into the triangle mark① of the magneto cover to turn the crankshaft.
● Fit the cam chain guide NO.1.
CAUTIONIf turn the crankshaft without pulling up the camchain, the cam chain may be fallen off between thecrankcase and cam chain drive sprocket.
3-25 ENGINE
①
49
ENGINE 3-26
● Install the camshaft C-rings ①.
● Tighten the camshaft sprocket bolts to thespecified torque.
● When installing the camshaft and camshaftsprocket, apply a small quantity of the THREADLOCK “1324” to the thread portion of thecamshaft sprocket bolts.
①
Camshaft sprocket bot: 10 ~ 12 N··m (1.0 ~ 1.2 kgf··m)
THREAD LOCK “1324”
⊙⊙ CAMSHAFT ASSEMBLY● Distinguish the “EX”mark for the exhaust
camshaft, the “IN”mark for the intake camshaft.
IN EX
● Apply the engine oil to the camshaft bearings.
● Install the exhaust camshaft first, following theintake camshaft.
CAUTIONDo not rotate the magneto rotor while doing thisoperate.
50
3↑
16 Pins
2↑
● The other arrow marked “2” ② should now bepointing straight up. Starting from the roller pinthat is directly above the arrow marked “2” ②,count out 16 roller pins (from the exhaustcamshaft side going towards the intake camshaftside).Engage the 16th roller pin on the cam chain withthe arrow marked “3” ③ on the intake sprocket.Refer to the following photograph and illustrations.
3-27 ENGINE
● With the “T” index mark on the magneto rotor isaligned with the triangle mark on the magnetocover, hold the camshaft steady and lightly pull upthe cam chain to remove any slack between thecam chain sprocket and exhaust camshaftsprocket.
● The exhaust camshaft sprocket has an arrowmarked “1” ①. Turn the exhaust camshaft so thatthe arrow marked “1” ① is aligned with the gasketsurface of the cylinder head. Engage the camchain with the exhaust camshaft sprocket.
② ③
①
Exhaust Intake
2↑
1←
3↑
1←①
②③
51
ENGINE 3-28
16 Pins
Notch mark
EXHAUST INTAKE
NOTEThe cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft housings and cam chain tensioner are secured.
①
② ③
Camshaft housing bolt : 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
Cam chain tension adjuster mountingbolt : 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
● Tighten the camshaft housing bolt with thespecified torque.
● If turn the lock shaft handle ① of the cam chaintension adjuster in clockwise ( ) direction, thepushrod is inserted in.Turn the mechanical spring continually until thehandle is turned to the end.
● Fix the cam chain tension adjuster into thecylinder block.
● Tighten the cam chain tension adjuster mountingbolt with the specified torque.
● Each camshaft housing is punched with “A”“B”“C”“D”.
Put on the housing “A”to the “A”of headsurface, the housing “B”to the “B”, the housing“C”to the “C”and the housing “D”to the “D”asthat “A”“B”“C”“D”is punched also to thecylinder head upper surface.
● Fix the four camshaft housing and cam chainguide NO.2 by tightening of the bolt in order.Install each bolt diagonally by using the wrench pulling the shaft down.
Tighten the bolt of each camshaft housing with thesame torque.
CAUTIONIf get damaged the cylinder head or surface ofcamshaft housing thrust, produce an result thatthe camshaft housing not was tightened.
CAUTIONThe camshaft housing bolt is made of the special material.This bolt is superior at the degree of hardness more than the different high tension bolt.Pay special caution that the different type of bolt should not be used.This bolt head is punched the ““9””mark.
52
3-29 ENGINE
①
53
ENGINE 3-30
● Get out the pushrod for the front to turn the lockshaft handle of the cam chain tension adjuster in counter-clockwise ( ).
● Apply BOND “1215”to the surface of the cylinderhead cover packing block.
BOND “1215”
● Tighten the cylinder head cover bolts ① with thespecified torque.
Cylinder head cover bolt : 12 ~ 16 N·m (1.2 ~ 1.6 kgf·m)
● Turn the crankshaft about 10 times clockwise orcounter-clockwise on the basis of the magnetorotor.
● If the valve clearance is within standard aftermeasured the valve clearance, begin the nextoperation.If it is out of standard, adjust the valve clearancewithin standard limit after disassembled thecamshaft and replaced the proper shim.
CAUTIONIf you don’’t rotate the crankshaft about 10times before measuring the valve clearance,there is no meaning in valve clearance.
① ①
Valve clearance
IN.
EX.
Standard (When cold)
0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
0.2 ~ 0.3 mm (0.008 ~ 0.012 in)
Thickness gauge : 09900-20806
LEFT END COMPONENTS OFENGINE DISASSEMBLY
● Disconnect the magneto couplers.
● Remove the engine guard ①.● Remove the engine sprocket cover ②.
● Remove the magneto cover ③.
● Remove the starter idle gear shaft ④ and starteridle gear ⑤.
⑤
②
③
①
④
54
3-31 ENGINE
55
ENGINE 3-32
● With the magneto rotor held immovable, loosenthe rotor nut ①.
● Remove the magneto rotor ② by using the specialtool.
● Remove the key.● Remove the starter clutch gear ③.
● Remove the starter one way clutch.
Rotor remover : 09930-30162
①
②
③
● The starter one way clutch is constituted as shownin the right illustration.
● Separate the stator and magneto cover byremoving the stator screws.
● Remove the gear position switch by removing thescrews.
● Remove the switch contact ① and its spring ②.
● Flatten the lock washer, and then remove theengine sprocket nut.
● Remove the engine sprocket.
CAUTIONBe careful not to lose the O-ring, switch contact andits spring.
56
3-33 ENGINE
② ①
57
ENGINE 3-34
● Drain the engine oil by removing the drain plug ①located on the bottom of the engine.
● Remove the engine guard ②.● Remove the clutch cover bolts and oil filter cap
nuts, and detach the clutch cover by tapping witha plastic hammer.
● Remove the clutch spring mounting boltsdiagonally while holding the primary driven gear,and remove the clutch pressure plate.
● Remove the clutch drive plates and driven plates.
RIGHT END COMPONENTSOF ENGINE DISASSEMBLY
②
①
58
● Remove the thrust washer ①, thrust bearing ②,clutch push piece ③ and clutch push rod ④.
● Flatten the lock washer ⑤.● With the crankshaft held immovable, remove the
primary drive gear nut ⑥.
● Flatten the lock washer.● With the clutch sleeve hub held immovable using
the special tool, remove the clutch sleeve hub nut.
● Remove the clutch sleeve hub and thrust washer.● Take off the primary driven gear assembly ⑦.
CAUTIONThe primary drive gear nut ⑥⑥ has a left-hand thread.If turning it counter-clockwise ( ), it may causedamage.
Clutch sleeve hub holder: 09920-53710
⑦
①②③
⑥
⑤
④
3-35 ENGINE
59
ENGINE 3-36
● Remove the circlip ① and oil pump driven gear ②.● Remove the primary drive NO.2 gear ③ and
primary drive gear.
● Loosen the oil pump screws, and then remove theoil pump ④.
● Draw out the gearshift shaft ⑤.
● Loosen the four screws, and then remove the gearshift pawl lifter ⑥ and gear shift cam guide ⑦.
● Take off the gear shift cam driven gear ⑧.
CAUTIONWhen removing the gear shift cam driven gear ⑧⑧, becareful not to lose the gear shift pawl ⑨⑨, pin ⑩⑩ andreturn spring ⑪⑪.
⑨⑩⑪
⑪⑩⑨
⑧
Primary drive gear
Primary driveNO.2 gear
Spring ① ②
④
⑤
⑥
⑦
③
60
⊙⊙ CRANKCASE● Remove the oil strainer cap ①.● Remove the gear shift cam stopper plug ②,
washer ③, spring ④ and neutral cam stopper ⑤.
● Remove the engine oil strainer by loosening thescrews.
● Separate the crankcase into left and right halvesusing the special tool.
● Loosen the crankcase bolts.
⑤④③②
NOTEFit the crankcase separator, so that the toolarms are in parallel with the side of crankcase.The crankshaft and transmission componentsshould remain in the left crankcase half.This is necessary because the gear shift camstopper is mounted on the left crankcase halfand will be damaged if the transmissioncomponents remain in the right half.
Crankcase separator : 09920-13120
①
②
LOWER END COMPONENTSOF ENGINE DISASSEMBLY
3-37 ENGINE
61
ENGINE 3-38
● Remove the gear shift arm stopper spring ①.
● Draw out the gear shift fork shaft NO.1 & NO.2.
● Take off the gear shift cam ② and gear shift forkNO.1 & NO.2.
● Remove the driveshaft assembly ③ andcountershaft assembly ④.
⊙⊙ TRANSMISSION
①
②
③④
62
● Remove the crankshaft using the special tool.
⊙⊙ CRANKSHAFT
● Remove the retainer, oil seals and bearings, rightand left.
● Remove the clutch release camshaft.
⊙⊙ OIL SEAL AND BEARING
Crankcase separator : 09920-13120
3-39 ENGINE
63
ENGINE 3-40
LOWER END COMPONENTSOF ENGINE INSPECTIONAND SERVICING
Service limit
0.1 mm (0.004 in)
Clutch driven plate distortion
Service limit
2.6 mm (0.102 in)
Thickness of clutchdrive plate
Thickness gauge : 09900-20806
Vernier calipers : 09900-20101
⊙⊙ CLUTCH DRIVEN PLATESMeasure each clutch driven plate for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set.
⊙⊙ CLUTCH SPRING FREELENGTH
Measure the free length of each clutch spring using thevernier calipers. If any spring is not within the servicelimit, replace all of the spring.
Vernier calipers : 09900-20101
Service limitClutch spring free length 29.5 mm (1.161 in)
⊙⊙ CLUTCH DRIVE PLATESMeasure the thickness and claw width of the clutchdrive plates using the vernier calipers. If the clutch drive plate is not within the the servicelimit, replace the clutch plates as a set.
Thickness of clutchdrive plate
Standard
2.9 ~ 3.1 mm(0.114 ~ 0.122 in)
Service limit
11.0 mm (0.433 in)
Claw width of clutchdrive plate
Claw width of clutchdrive plate
Standard
11.8 ~ 12.0 mm(0.465 ~ 0.472 in)
64
⊙⊙ CLUTCH RELEASE BEARINGInspect the clutch release bearing for anyabnormality, especially cracks. When removing thebearing from the clutch, decide whether it can bereused or if it should be replaced.Smooth engagement and disengagement of theclutch depends on the condition of this bearing.
⊙⊙ GEAR SHIFT FORK & GEARUsing a thickness gauge, check the clearancebetween the groove of its gear and gear shift fork.The clearance for each of the three gear shift forksplays an important role in the smoothness andpositiveness of shifting action.If the checked clearance is noted to exceed the limitspecified, replace the fork or its gear, or both.
Service limit
0.50 mm(0.020 in)
Standard
0.10 ~ 0.30 mm(0.004 ~ 0.012 in)
Vernier calipers : 09900-20101Thickness gauge : 09900-20806
Shift fork-grooveclearance
Shift fork groove width Standard
NO.3
NO.1 & NO.2
5.50 ~ 5.60 mm(0.217 ~ 0.221 in)
5.00 ~ 5.10 mm(0.197 ~ 0.201 in)
Shift fork thickness Standard
NO.3
NO.1 & NO.2
5.30 ~ 5.40 mm(0.209 ~ 0.213 in)
4.80 ~ 4.90 mm(0.189 ~ 0.193 in)
3-41 ENGINE
65
ENGINE 3-42
①⑥
②
③
④
⑤
⊙⊙ PRIMARY DRIVEN GEAR
The primary driven gear is composed the followingparts :① Primary driven gear ④ Rivet② Plate ⑤ Washer③ Clutch housing ⑥ Spring
If the tension of the inner spring of the primary drivengear is not working, get a play and noise between thegear and spring.If necessary, replace the primary driven gearassembly with a new one.
⊙⊙ CAM CHAIN 20-PITCH LENGTH
Pull the cam chain tight to remove any slack, thenusing the vernier caliper, measure the 20-pitch (21pins) length of the cam chain. If it measures than the limits, replace the cam chain.
⊙⊙ STARTER CLUTCH BEARINGInspect the bearing for any abnormality, particularlycracks, to decide whether it can reused or should bereplaced.
129.9 mm (5.11 in)
Cam chain 20-pitchlength
⊙⊙ CRANKCASE BEARINGRotate the bearing inner race by finger to inspect forabnormal play, noise and smooth rotation while thebearings are in the crankcase.Replace the bearing if there is anything unusual.
Play
Play
Service limit
66
LOWER END COMPONENTS OF ENGINE REASSEMBLY⊙⊙ CRANKSHAFT
● Inspect the between the webs referring to thebelow figure when rebuilding the crankshaft.
● When mounting the crankshaft in the crankcase, itis necessary to pull its left end into the crankcase.
53.0 ± 0.1 mm(2.087 ± 0.004 in)
Width between websCrankshaft installer : 09910-32812Conrod holder : 09910-2011553.0 ± 0.1 mm
(2.087 ± 0.004 in)
3-43 ENGINE
Standard
67
ENGINE 3-44
⊙⊙ TRANSMISSION
CAUTIONNever fit the crankshaft into the crankcase bystriking it with a plastic hammer.Always use the special tool, otherwise crankshaftalignment accuracy will be affected.
CAUTIONNever reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.When installing a new circlip, do not expand the end gap larger than required to slip the circlip over theshaft.After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
68
⊙⊙ COUNTERSHAFT■■ MOUNTING 2ND DRIVE GEAR● Press-fit 2nd drive gear into the countershaft.
Before reassembling, coat the internal face of the2nd drive gear with THREAD LOCK “1324”andinstall it so that the length is as shown in thefigure.
+0.1
-0.2Countershaft length
(Low to 2nd)
mm88.0
+0.004
-0.008in3.465
THREAD LOCK “1324”
NOTE
When reassembling the bearing retainer, apply a small quantity of THREAD LOCK ““1324””to the threadedparts of the bearing retainer screws.In reassembling the transmission, attention must be given to the locations and positions of washers andcirclips. The cross sectional view shows the correct position of the gears, washers and circlips.
CAUTIONThis procedure may be performed only twicebefore shaft replacement is required.
( )
3-45 ENGINE
Washers and circlips thickness1.2 mm 1.0 mm1.0 mm 0.5 mm1.0 mm
THREAD LOCK “1324”
69
ENGINE 3-46
● Fit the gear shift cam on the crankcase.Position the gear shift cam as shown in the figureso that the gear shift fork can be installed easily.
⊙⊙ GEAR SHIFT CAM AND FORK
70
● After the gear shift arm stopper and gear shiftforks have been fitted, hook the gear shift armstopper spring into the crankcase.
CAUTIONTwo kinds of the gear shift forks, ①① and ②②, areused. They resemble each other very closely inexternal appearance and configuration.Carefully examine as shown in the illustration forcorrect installing positions and directions.
⊙⊙ CRANKCASEWhen reassembling the crankcase pay attention tothe following.● Coat SUPER GREASE “A”to the lip of oil seals.
SUPER GREASE ““A””● Remove the sealant material on the fitting surface
of right and left halves of the crankcase andthoroughly remove the oil stains.
● Fit the dowel pins on the left side of thecrankcase.
● Apply the engine oil to the big end of thecrankshaft conrod and all parts of the transmissiongears.
● Apply BOND “1215”uniformly to the fittingsurface of the left side of the crankcase, and afterwaiting a few minutes, fit the right half on the lefthalf.
● Tighten the crankcase bolts to the specifiedtorque.
● After the crankcase bolts have been tightened,check if the driveshaft and countershaft rotatesmoothly.
BOND ““1215””
Crankcase bolt : 9 ~ 13 N··m (0.9 ~ 1.3 kgf··m)
NOTETightening the crankcase bolts, tighten each boltlittle by little diagonally.
3-47 ENGINE
71
ENGINE 3-48
5th
4th
3rd
2nd
N
Low
A�A� A�
A� A�A�
CAUTIONAfter the gear shift cam driven gear, gear shiftcam guide, gear shift shaft and neutral camstopper have been fitted, confirm that gearchange is normal while rotating thecountershaft and driveshaft. If gear change isnot obtained, it means that assembly of gearsor installation of gear shift fork is incorrect. Ifthis is the case, disassemble and trace themistake.
● If a large resistance is felt to rotation, try to freethe shafts by tapping the driveshaft orcountershaft with a plastic hammer as shown inthe figure.
⊙⊙ GEAR SHIFT CAM DRIVEN GEAR
● When installing the gear shift pawls into the gearshift cam driven gear, the large shoulder mustface to the outside as shown.
● Next, install the gear shift cam guide and gearshift pawl lifter. Apply a small quantity of THREADLOCK “1324”to the threaded parts of thesecuring screws.
THREAD LOCK “1324”
⊙⊙ GAER SHIFT SHAFTWhen installing the gear shift shaft, match the centerteeth of the gear on the gear shift shaft with thecenter teeth on the gear shift cam driven gear asshown.
RIGHT END COMPONENTSOF ENGINE REASSEMBLY
72
Align index markto the slot
Primary drive NO.2 gear
⊙⊙ OIL PUMP AND PRIMARYDRIVE GEAR
● Install the primary drive gear and primary driveNO.2 gear, and fit the key in the key slot on thecrankshaft completely.
● Before mounting the oil pump, apply engine oil tothe sliding surfaces of the case, outer rotor, innerrotor and shaft.
● Apply a small quantity of THREAD LOCK “1324”to the threaded parts of the oil pump mountingscrews.
● Tightening the oil pump mounting screws to thespecified toruqe.
THREAD LOCK “1324”
● Fit the oil pump driven gear ① and install thecirclip ②.
CAUTIONAfter mounting the oil pump in the crankcase,rotate the oil pump driven gear by hand to see ifit turns smoothly.
CAUTIONWhen installing the primary drive NO. 2 gear,align the index mark on the gear to the key slotas show in the illustration.
Oil pump mounting screw: 5 ~ 7 N··m (0.5 ~ 0.7 kgf··m)
3-49 ENGINE
①
②
73
ENGINE 3-50
CAUTIONThe primary drive gear nut is a left-hand threadnut.
● Be sure to lock the nut by firmly bending thetongue of the washer.
Assemble the clutch in the reverse order ofdisassembly. Pay attention to the following points :● When inserting the spacer on the countershaft,
apply a small quantity of engine oil to both insideand outside of the spacer.
● Tighten the clutch sleeve hub nut using thespecial tool to the specified torque.
Clutch sleeve hub holder: 09920-53710
Clutch sleeve hub nut : 30 ~ 50 N··m (3.0 ~ 5.0 kgf··m)
● With the clutch sleeve hub held immovable, installthe primary drive gear washer and nut, tighten theprimary drive gear nut to the specified torque andbend up to the washer.
Primary drive gear nut: 40 ~ 60 N··m (4.0 ~ 6.0 kgf··m)
⊙⊙ CLUTCH
74
1/4
1/2
Part without groove of primary driven gear
Clutch driveplate groove
● Install the clutch drive plates and driven platesone by one into the clutch sleeve hub.
CAUTIONThe groove of the first installed clutch drive platein five drive plates is inserted between the partwithout the groove of the primary driven gear.
● Insert the clutch push rod in the countershaft.
● Install the clutch push piece, thrust bearing andthrust washer to the countershaft.
● Install the clutch pressure plate.● Tighten the clutch spring set bolts.
CAUTIONInsert the longer side of the clutch push rodtoward the inside.
NOTETighten the clutch spring set bolts diagonally.
⊙⊙ CLUTCH RELEASEADJUSTER SCREW
● Loosen the adjuster nut, and turn clutch releaseadjuster screw to feel high resistance.
● From that position, turn out the clutch releaseadjuster 1/4 ~ 1/2 turn, and tighten adjuster nut.
Inside←←
Outside→→
Longer Shorter
3-51 ENGINE
75
ENGINE 3-52
● Install the clutch cover, and tighten the clutchcover bolts securely.
⊙⊙ GEAR SHIFT CAM STOPPERPLUG
● Insert the cam neutral stopper ①, spring ② andwasher ③.
● Tighten the gear shift cam stopper plug ④ to thespecified torque.
⊙⊙ OIL DRAIN PLUG● Tighten the engine oil drain plug ⑤ to the
specified torque.
LEFT END COMPONENTS OFENGINE REASSEMBLY
⊙⊙ STATOR● Apply a small quantity of THREAD LOCK “1324”
to the thread parts of screws.
Engine oil drain plug: 25 ~ 30 N··m (2.5 ~ 3.0 kgf··m)
Gear shift cam stopper plug: 20 ~ 25 N··m (2.0 ~ 2.5 kgf··m)
THREAD LOCK “1324”
THREAD LOCK “1324”
⊙⊙ STARTER CLUTCH● When installing the starter clutch and rotor, apply
the THREAD LOCK “1324”to the bolts andtighten to the specified torque.
Starter clutch bolt : 15 ~ 20 N·m (1.5 ~2.0 kgf·m)
①
②
④ ⑤
③
76
THREAD LOCK “1324”
⊙ MAGNETO ROTOR● Fit the key into the key slot on the crankshaft.● With the magneto rotor, install the starter clutch on
the crankshaft.● Apply a small quantity of THREAD LOCK “1324”to
the threaded parts of crankshaft.
● Hold the magneto rotor, and tighten the magnetorotor bolt ① to the specified torque.
⊙ STARTER IDLE GEAR ANDMOTOR
● Install the starter idle gear ②.
● Install the starter motor ③.
Magneto rotor bolt : 56 ~ 60 N·m (5.6 ~ 6.0 kgf·m)
3-53 ENGINE
②
③
①
77
ENGINE 3-54
O-ring
Oil seal⊙⊙ DRIVESHAFT OIL SEAL AND ENGINE SPROCKET
⊙⊙ GEAR POSITION SWITCH● Install the spring ① and contact ②.● Apply SUPER GREASE “A” to the O-ring and
install the gear position switch.
SUPER GREASE ““A””
● Install the magneto cover ③ and engine sprocketcover ④.
● Install the engine guard ⑤.
● Tighten the engine sprocket nut to the specifiedtorque and bend up the lock washer.
Rotor holder : 09930-40113Engine sprocket nut
: 80 ~ 100 N··m (8.0 ~ 10.0 kgf··m)
CAUTIONAlways replace the driveshaft oil seal with anew one every disassembly to prevent oilleakage. Also grease the oil seal lip.On installation, refer to the figure, for correctposition and direction.Replace the engine sprocket O-ring with a newone every disassembly.
①
④③
⑤
②
78
79
SERVICING INFORMATION
TIGHTENING TORQUE………………………………………………… 80 (7-11)
SERVICE DATA…………………………………………………………… 81 (7-13)
WIRING DIAGRAM ~~ ₩₩………………………………………88 (7-22-1)
WIRING DIAGRAM ~~ & ₩₩…………………89 (7-22-2)
CONTENTS
7
80
7-11 SERVICING INFORMATION
ITEM
Camshaft sprocket bolt
Camshaft housing bolt
Cam chain tension adjuster mounting bolt
Clutch sleeve hub nut
Crankcase bolt
Cylinder head base nut
Cylinder head bolt
Cylinder head cover bolt
Cylinder base nut
Engine mounting bolt (M10)
Engine mounting bolt (M8)
Engine mounting bracket bolt (M8)
Engine oil drain plug
Engine sprocket nut
Exhaust pipe nut
Gear shift cam stopper plug
Magneto rotor nut
Muffler connecting bolt
Muffler mounting bolt
Oil cooler bolt
Oil pump mounting screw
Primary drive gear nut
Spark plug
Starter clutch bolt
1.0 ~ 1.2
0.8 ~ 1.2
0.8 ~ 1.2
3.0 ~ 5.0
0.9 ~ 1.3
0.7 ~ 1.1
2.1 ~ 2.5
1.2 ~ 1.6
0.7 ~ 1.1
4.8 ~ 7.2
2.2 ~ 3.3
2.2 ~ 3.3
2.5 ~ 3.0
8.0 ~ 10.0
1.8 ~ 2.8
2.0 ~ 2.5
5.6 ~ 6.0
1.8 ~ 2.8
1.8 ~ 2.8
2.0 ~ 2.5
0.5 ~ 0.7
4.0 ~ 6.0
2.0 ~ 2.5
1.5 ~ 2.0
kgf·m
10 ~ 12
8 ~ 12
8 ~ 12
30 ~ 50
9 ~ 13
7 ~ 11
21 ~ 25
12 ~ 16
7 ~ 11
48 ~ 72
22 ~ 33
22 ~ 33
25 ~ 30
80 ~ 100
18 ~ 28
20 ~ 25
56 ~ 60
18 ~ 28
18 ~ 28
20 ~ 25
5 ~ 7
40 ~ 60
20 ~ 25
15 ~ 20
N·m
⊙ ENGINE
TIGHTENING TORQUE
81
SERVICING INFORMATION 7-13
SERVICE DATA
⊙⊙ VALVE + GUIDE Unit : mm (in)
ITEM STANDARD LIMIT
22.0 (0.87)
19.0 (0.75)
0.1 ~ 0.2 (0.004 ~ 0.008)
0.2 ~ 0.3 (0.008 ~ 0.012)
0.010 ~ 0.037 (0.0004 ~ 0.0015)
0.030 ~ 0.057 (0.0012 ~ 0.0022)
———
4.500 ~ 4.512 (0.1771 ~ 0.1776)
4.475 ~ 4.490 (0.1762 ~ 0.1768)
4.455 ~ 4.470 (0.1754 ~ 0.1760)
———
———
45°
———
———
———
12.1 ~ 13.9 kgf (26.68 ~ 30.64 lbs)at length 33.7 mm (1.33 in)
12.1 ~ 13.9 kgf (26.68 ~ 30.64 lbs)at length 33.7 mm (1.33 in)
0.9 ~ 1.1 (0.035 ~ 0.043)
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN.
EX.
IN.
EX.
———
———
———
———
———
———
0.35 (0.014)
———
———
———
0.05 (0.002)
0.50 (0.02)
———
0.03 (0.0012)
37.80 (1.488)
37.80 (1.488)
———
———
Valve diam.
Valve clearance (When cold)
Valve guide to valve stem clearance
Valve stem deflection
Valve guide I.D.
Valve stem O.D.
Valve stem runout
Valve head thickness
Valve seat width
Valve seat angle
Valve head radial runout
Valve spring free length
Valve spring tension
ITEM STANDARD LIMIT
Camshaft runout
Cylinder head distortion
Cylinder head cover distortion
Cam chain pin (Arrow “3”)
Cam chain 20-pitch length
34.47 ~ 34.51 (1.357 ~ 1.359)
34.42 ~ 34.46 (1.355 ~ 1.356)
———
IN.
EX.
IN. & EX.
34.17 (1.345)
34.12 (1.343)
0.10 (0.004)
0.05 (0.002)
0.05 (0.002)
———
129.9 (5.11)
⊙⊙ CAMSHAFT + CYLINDER HEAD Unit : mm (in)
Cam height
———
———
16th pin
———
82
7-14 SERVICING INFORMATION
ITEM STANDARD LIMIT
14 ~ 16 kgf/cm2
0.050 ~ 0.060 (0.0020 ~ 0.0024)
57.000 ~ 57.015 (2.2441 ~ 2.2447)
56.945 ~ 56.960 (2.2419 ~ 2.2425)(Measure at 15 mm (0.6 in) from the skirt end)
15.002 ~ 15.008 (0.5906 ~ 0.5909)
14.994 ~ 15.000 (0.5903 ~ 0.5906)
12 kgf/cm2
0.120 (0.0047)
57.080 (2.2472)
56.880 (2.2394)
0.05 (0.002)
5.7 (0.224)
4.6 (0.181)
0.50 (0.020)
0.50 (0.020)
0.180 (0.007)
0.150 (0.006)
———
———
———
———
———
15.030 (0.5917)
14.980 (0.5898)
Approx 7.2 (0.284)
Approx 5.8 (0.228)
0.20 ~ 0.32 (0.008 ~ 0.013)
0.20 ~ 0.32 (0.008 ~ 0.013)
———
———
1.01 ~ 1.03 (0.040 ~ 0.041)
1.01 ~ 1.03 (0.040 ~ 0.041)
2.01 ~ 2.03 (0.079 ~ 0.080)
0.970 ~ 0.990 (0.0382 ~ 0.0390)
0.970 ~ 0.990 (0.0382 ~ 0.0390)
1st
2nd
1st
2nd
1st
2nd
1st
2nd
Oil
1st
2nd
———
Compression pressure
Piston to cylinder clearance
Cylinder bore
Piston diameter
Cylinder distortion
Piston ring free end gap
Piston ring end gap (Assembly condition)
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Piston pin hole bore
Piston pin O.D.
⊙⊙ CYLINDER + PISTON + PISTON RING Unit : mm (in)
Oil pressure
Oil pump reduction ratio
0.4 ~ 0.6 kgf/cm2
(at 60℃, 3,000 rpm)
2.00 (36/15)
———
———
ITEM STANDARD NOTE
⊙⊙ OIL PUMP
⊙⊙ CONROD + CRANKSHAFT Unit : mm (in)
ITEM STANDARD LIMIT
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
15.006 ~ 15.014 (0.5908 ~ 0.5911)
———
0.10 ~ 0.45 (0.004 ~ 0.018)
15.95 ~ 16.00 (0.628 ~ 0.630)
53.0 ± 0.1 (2.087 ± 0.004)
———
15.040 (0.5921)
3.0 (0.12)
1.00 (0.040)
———
———
0.05 (0.002)
⊙⊙ CLUTCH Unit : mm (in)
Unit : mm (in)
83
SERVICING INFORMATION 7-15
ITEM STANDARD LIMIT
Clutch cable play
Clutch drive plate thickness
Clutch drive plate claw width
Clutch driven plate distortion
Clutch spring free length
———
2.6 (0.102)
11.0 (0.433)
0.1 (0.004)
29.5 (1.161)
4 (0.16)
2.9 ~ 3.1 (0.114 ~ 0.122)
11.8 ~ 12.0 (0.465 ~ 0.472)
———
———
Reduction ratio
Gear ratio
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain ( )
Drive chain ( )
Drive chain ( )
Drive chain slack ( )
Drive chain slack( & )
3.500 (70/20)
5.00 ~ 5.10 (0.197 ~ 0.201)
5.50 ~ 5.60 (0.217 ~ 0.221)
4.80 ~ 4.90 (0.189 ~ 0.193)
5.30 ~ 5.40 (0.209 ~ 0.213)
20 ~ 30 (0.79 ~ 1.18)
50 ~ 60 (1.97 ~ 2.36)
———
———
———
———
———
———
0.5 (0.020)
———
———
———
———
———
———
256.5 (10.10)
———
———
256.5 (10.10)
———
———
256.5 (10.10)
ITEM STANDARD LIMIT
⊙⊙ TRANSMISSION + DRIVE CHAIN
2.750 (33/12)
1.786 (25/14)
1.368 (26/19)
1.046 (23/22)
0.913 (21/23)
428SO
130 LINKS
254.0 (10.00)
1st
2nd
3rd
4th
5th
Type
Links
20-pitch length
428H
132 LINKS
254.0 (10.00)
428H
130 LINKS
254.0 (10.00)
Type
Links
20-pitch length
Type
Links
20-pitch length
NO.1 & NO.2
NO.3
NO.1 & NO.2
NO.3
0.10 ~ 0.30 (0.004 ~ 0.012)
84
7-16-1 SERVICING INFORMATION
Unit : mm (in)⊙⊙ CARBURETOR ~~ ₩₩
ITEM
Piston valve type
ф 24
1,400 ~ 1,600 rpm
12.5 (0.492)
# 102
# 100
A1FC
ф 2.6
# 38
# 3
ф 0.9
ф 2.0
MAX # 500
# 120
0.5∼1.0 (0.02∼0.04)
SPECIFICATION
Carburetor type
Bore size
Idle rpm
Float height
Main jet (M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(P.J.)
(TH.V.)
(V.S.)
(P.A.J.)
Main air jet
Jet needle
Pilot jet
Throttle valve
Pilot outlet
Valve seat
Starter jet
Pilot air jet
Throttle cable play
Needle jet
85
SERVICING INFORMATION 7-16-2
Unit : mm (in)⊙⊙ CARBURETOR ~~ & ₩₩
ITEM
Piston valve type
ф 24
1,400 ~ 1,500 rpm
12.5 (0.492)
# 98
# 90
ф 2.6
A1FC-2nd
# 38
# 3
ф 0.9
ф 2.0
MAX # 500
# 150
0.5∼1.0 (0.02∼0.04)
SPECIFICATION
Carburetor type
Bore size
Idle rpm
Float height
Main jet (M.J.)
(M.A.J.)
(J.N.)
(N.J.)
(P.J.)
(TH.V.)
(V.S.)
(P.A.J.)
Main air jet
Jet needle
Pilot jet
Throttle valve
Pilot outlet
Valve seat
Starter jet
Pilot air jet
Throttle cable play
Needle jet
86
7-16-3 SERVICING INFORMATION
NOTE
Fuel type
Fuel tank capacity ( )
Fuel tank capacity
( & )
Engine oil
Engine oil capacity
9.0 ℓ
8.0 ℓ
API Over SL (SAE 10W/40)
Gasoline used should be graded 91 octane or higher.An unleaded gasoline is recommened.
850 ㎖
950 ㎖
1,200 ㎖
ITEM SPECIFICATION
⊙⊙ FUEL + OIL
Oil change
Oil and filter change
Engine overhaul
87
SERVICING INFORMATION 7-17
Type
Capacity
Standard electrolyte S.G.
⊙ ELECTRICAL
CR8E
0.7 ~ 0.8 (0.028 ~ 0.032)
CR7E
CR8E
CR9E
YTX7A-BS
12V 6Ah
15A
ITEM STANDARD
BTDC 6°/ 1,900 rpm ~ 27°/ 4,250 rpm
NOTE
1.320 at 20℃ (68℉)
Unit : mm (in)
Ignition timing
Spark plug
Battery
Fuse size
Type
Gap
Hot type
Standard type
Cold type
88
7-22-1 SERVICING INFORMATION
WIRING DIAGRAM ~~ ₩₩
89
SERVICING INFORMATION 7-22-2
WIRING DIAGRAM ~~ & ₩₩
90
SH
IM N
o.
HO
W T
O U
SE
TH
E C
HA
RT
1. M
easu
re th
e ta
ppet
cle
aran
ce.(W
hen
cold
)2.
Mea
sure
the
shim
thic
knes
s at
pre
sent
.3.
Loo
k fo
r mee
ting
spac
e in
that
hor
izon
tal l
ine
for t
hick
ness
and
ver
tical
line
for c
lear
ance
.
(EX
AM
PLE
)W
hen
the
tapp
et c
lear
ance
is 0
.23
mm
and
the
shim
thic
knes
s at
pre
sent
is 1
.70
mm
, the
shi
m
thic
knes
s sh
ould
be
used
1.8
0 m
m.
TAP
PE
T S
HIM
SE
LEC
TIO
N C
HA
RT
(IN.)
Spe
cifie
d cl
eara
nce
- Adj
ustm
ent u
nnec
essa
ry
1.20
1.20
0.00
~ 0
.04
0.05
~ 0
.09
0.10
~ 0
.20
0.21
~ 0
.25
0.26
~ 0
.30
0.31
~ 0
.35
0.36
~ 0
.40
0.41
~ 0
.45
0.46
~ 0
.50
0.51
~ 0
.55
0.56
~ 0
.60
0.61
~ 0
.65
0.66
~ 0
.70
0.71
~ 0
.75
0.76
~ 0
.80
0.81
~ 0
.85
0.86
~ 0
.90
0.91
~ 0
.95
0.96
~ 1
.00
1.01
~ 1
.05
1.06
~ 1
.10
1.11
~ 1
.15
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
1.20
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.20
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.95
2.00
2.05
2.10
2.15
2.20
2.00
2.05
2.10
2.15
2.20
2.05
2.10
2.15
2.20
2.10
2.15
2.20
2.15
2.20
2.20
SHIM
THICK
NESS
AT PR
ESEN
T(m
m)
MEA
SUR
ING
TA
PPET
C
LEAR
ANC
E (m
m)
120
1.25
125
1.30
130
1.35
135
1.40
140
1.45
145
1.50
150
1.55
155
1.60
160
1.65
165
1.70
170
1.75
175
1.80
180
1.85
185
1.90
190
1.95
195
2.00
200
2.05
205
2.10
210
2.15
215
2.20
220
91
SH
IM N
o.
TAP
PE
T S
HIM
SE
LEC
TIO
N C
HA
RT
(EX
.)
Spe
cifie
d cl
eara
nce
- Adj
ustm
ent u
nnec
essa
ry
1.20
1.20
0.05
~ 0
.09
0.10
~ 0
.14
0.15
~ 0
.19
0.20
~ 0
.30
0.31
~ 0
.35
0.36
~ 0
.40
0.41
~ 0
.45
0.46
~ 0
.50
0.51
~ 0
.55
0.56
~ 0
.60
0.61
~ 0
.65
0.66
~ 0
.70
0.71
~ 0
.75
0.76
~ 0
.80
0.81
~ 0
.85
0.86
~ 0
.90
0.91
~ 0
.95
0.96
~ 1
.00
1.01
~ 1
.05
1.06
~ 1
.10
1.11
~ 1
.15
1.16
~ 1
.20
1.21
~ 1
.25
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
1.20
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
1.20
1.25
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
1.30
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.20
1.35
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.40
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.45
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.50
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.55
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.60
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.65
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.70
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.90
1.95
2.00
2.05
2.10
2.15
2.20
1.95
2.00
2.05
2.10
2.15
2.20
2.00
2.05
2.10
2.15
2.20
2.05
2.10
2.15
2.20
2.10
2.15
2.20
2.15
2.20
2.20
SHIM
THICK
NESS
AT PR
ESEN
T(m
m)
MEA
SUR
ING
TA
PPET
C
LEAR
ANC
E (m
m)
120
1.25
125
1.30
130
1.35
135
1.40
140
1.45
145
1.50
150
1.55
155
1.60
160
1.65
165
1.70
170
1.75
175
1.80
180
1.85
185
1.90
190
1.95
195
2.00
200
2.05
205
2.10
210
2.15
215
2.20
220
HO
W T
O U
SE
TH
E C
HA
RT
1. M
easu
re th
e ta
ppet
cle
aran
ce.(W
hen
cold
)2.
Mea
sure
the
shim
thic
knes
s at
pre
sent
.3.
Loo
k fo
r mee
ting
spac
e in
that
hor
izon
tal l
ine
for t
hick
ness
and
ver
tical
line
for c
lear
ance
.
(EX
AM
PLE
)W
hen
the
tapp
et c
lear
ance
is 0
.33
mm
and
the
shim
thic
knes
s at
pre
sent
is 1
.70
mm
, the
shi
m
thic
knes
s sh
ould
be
used
1.8
0 m
m.
Prepared by
1st Ed. JUN. 2009.
Manual No. 99000HR7810
Printed in Korea
SERVICE MANUAL
99000HR7810
SE
RV
ICE
MA
NU
AL
S&T Motors Co., Ltd.
ENGINE