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

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


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


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

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


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


● 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


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.


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


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


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


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


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


■■ 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

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


UPPER END COMPONENTSOF ENGINE INSPECTIONAND SERVICING

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.


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.


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.


⊙⊙ 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.


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.


Valve head radialrunout (IN. & EX.)

Service limit

0.03 mm (0.0012 in)


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


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.


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.


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.


⊙⊙ 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)


1st

2nd

Standard


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)


⊙⊙ 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


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


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)


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



⊙⊙ 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.


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


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


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.


⊙⊙ 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.


● 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)



⊙⊙ 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


⊙ 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

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 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 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


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


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


Engine overhaul

87


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


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

RX 125 D RX 125 SM RT 125 D · ServiceManual RX 125 D RX 125 SM RT 125 D Kun motor. Udgivet 2009...

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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...