. GENERAL INFORMATION 1ENGINE SERIAL NUMBER --- 1- 0 SPECIFICATION ----------------- 1- 1 TOOLS ----------------------------1-14 LUBRICATION POINTS --------1-16 SERVICE PRECAUTIONS ------ 1- 3 WIRING DIAGRAM--------------1-17 TORQUE VALUES--------------- 1-13 CABLE & HARNESS ROUTING- 1-22 1 TROUBLESHOOTING-----------1-24 ENGINE SERIAL NUMBER Location of Engine Serial Number 1-0
1. GENERAL INFORMATION SPECIFICATIONS Air cleaner type & No Lubrication oil capacity Fuel capacity Type Piston dia. Venturi dia.
1. GENERAL INFORMATION SPECIFICATIONS Air cleaner type & No Paper element, wet Lubrication oil 1.5 liters capacity Fuel capacity 10 liters Type ＰＢ Piston dia. Venturi dia. 14 equivalent Carburetor Ignition System Electrical Type Ignition timing Spark plug Spark plug gap Battery Capacity Clutch Type CDI 13.5° /2000rpm NGK BR6HSA 0.6_ 0.
1. GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets, Orings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. Use genuine parts and lubricants. When servicing the motorcycle, be sure to use special tools for removal and installation. After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.
1. GENERAL INFORMATION Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface.
1. GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. Check if any connector terminal is bending, protruding or loose.
1. GENERAL INFORMATION The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Snapping! Before connecting a terminal, check for damaged terminal cover or loose negative terminal. Check the double connector cover for proper coverage and installation. Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up.
1. GENERAL INFORMATION After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. When fixing the wire harnesses, do not make it contact the parts which will generate high heat. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws.
1. GENERAL INFORMATION Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. Do not break the sheath of wire. If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it. Do not press or squeeze the wire.
1. GENERAL INFORMATION After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. Be careful not to drop any parts.
1. GENERAL INFORMATION Symbols: The following symbols represent the servicing methods and cautions included in this service manual. Engine Oil Grease Gear Oil Special ＊ : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) : Use special tool.
1. GENERAL INFORMATION SERVICE INFORMATION ENGINE Item Cylinder head warpage Piston O.D.(5mm from bottom of piston skirt) Cylinder-to- piston clearance Piston pin hole I.D. Piston pin O.D. Piston-to-piston pin clearance Piston ring end gap (top/second) Connecting rod small end I.D. Cylinder bore Drive belt width Drive pulley collar O.D. Movable drive face ID. Weight roller O.D. Clutch outer I.D. Driven face spring free length Driven face O.D. Movable driven face I.D.
1. GENERAL INFORMATION FRAME Standard (mm) SH10BA SH10AA Item Axle shaft runout Front wheel rim runout Service Limit (mm) SH10BA SH10AA 0.2 0.2 200.0 200.0 182.8 182.8 2.0 2.0 Radial Axial Front shock absorber spring free length Rear wheel rim runout Brake drum I.D. Front/rear 110 110 111 111 Brake lining thickness Front/rear 4.0/4.0 4.0/4.0 2.0/2.0 2.0/2.0 Brake disk runout Front/rear 0.30 0.30 235.7 235.7 218.7 218.
1. GENERAL INFORMATION TORQUE VALUES ENGINE Item Cylinder head bolt Clutch drive plate nut Clutch outer nut Drive face nut Oil check bolt Engine mounting bolt Engine hanger bracket bolt Exhaust muffler joint lock nut Exhaust muffler lock bolt Spark plug Thread dia. (mm) BF7x115 10 NH10 NH12 10 BF10x95 BF10x50 NC6mm BF8x35 Torque (kg-m) 1.5_ 1.7 3.5_ 4.0 3.5_ 4.5 5.0_ 6.0 1.0_ 1.5 4.5_ 5.5 3.5_ 4.5 1.0_ 1.4 3.0_ 3.6 1.1_ 1.
1. GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No.
1. GENERAL INFORMATION Tool Name Tool No.
1. GENERAL INFORMATION LUBRICATION POINTS ENGINE NO. 1 2 3 4 5 6 Lubrication Points Crankcase sliding & movable parts Cylinder movable parts Transmission gear (final gear) Kick starter spindle bushing Drive pulley movable parts Starter pinion movable parts Lubricant JASO-FC or API-TC Remarks SAE-90# Grease Grease Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
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1. GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Fuel reaches carburetor Fuel does not reach carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground. Spark jumps Weak or no spark Test cylinder compression.
1. GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw. Fuel reaches carburetor Fuel does not reach carburetor Plug fouled or discolored Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground. Plug not fouled or discolored Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground.
1. GENERAL INFORMATION Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks. No air leak Air leaks Not clogged Clogged Broken cable Dirty auto bystarter Faulty auto bystarter Clogged Not Clogged Faulty auto bystarter Remove auto bystarter connecting wire and check if bypass fuel line is clogged. Connect auto bystarter wire to battery. Wait for 5 minutes, then connect a hose to fuel enriching circuit and then blow the hose with mouth.
1. GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation. Engine speed increases Engine speed does not increase sufficiently Clogged air cleaner Clogged fuel filter Clogged exhaust muffler Faulty auto bystarter Faulty charcoal canister Check ignition timing (using a timing light). Correct timing Incorrect timing Faulty CDI unit Faulty A.C.
1. GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Correct timing Incorrect timing Correctly adjusted Incorrectly adjusted Faulty CDI unit Faulty A.C. generator Check carburetor air screw adjustment. Mixture too rich (turn screw out) Mixture too lean (turn screw in) Check carburetor gasket for air leaks.
1. GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Correct timing Faulty CDI unit Incorrect timing Loose A.C.G. stator Faulty A.C. generator Check auto fuel valve for fuel supply. Fuel flows freely Fuel flow restricted Empty fuel tank Clogged fuel tube or filter Clogged charcoal canister Check carburetor jets for clogging.
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1. GENERAL INFORMATION OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Signals operate properly Connect indicator light bulb to battery for bulb inspection.
1. GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Remove fuel unit and check operation of pointer by moving float up and down. Check operation of pointer by opening and shorting fuel unit terminal on wire harness side.
1. GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by applying brake. Stoplight comes on Check battery circuit by operating turn signals. Check operation of starter relay by depressing starter button.
