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

RX 125 D RX 125 SM RT 125 D

Kun motor. Udgivet 2009

ServiceManual

D RX 125 SM RT 125 D Kun motor. Udgivet 2009 ServiceManual Downloaded from www.Manualslib.com manuals

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Downloaded from www.Manualslib.com manuals search engine Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11
Downloaded from www.Manualslib.com manuals search engine Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11

Holtvej 8-10, Høruphav 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01

E-mail: info@scanmi.dk www.scanmi.dk CVR: 27 73 31 07

FOREWORD

This manual contains an introductory description on HYOSUNG『 』,『 &『 』and procedures for its inspection / service and overhaul of its engine components. It covers the differences from『 』&

components. It covers the differences from 『 』 & 』 『 』 ’s engine and please
components. It covers the differences from 『 』 & 』 『 』 ’s engine and please

components. It covers the differences from 『 』 & 』 『 』 ’s engine and please

’s engine and please refer to the service manual of(99000- 94610)and

manual of 『 (99000 - 9 4 6 1 0 ) 』 a n d 『
manual of 『 (99000 - 9 4 6 1 0 ) 』 a n d 『

(99000-97100)for others which are not covered in this manual. Other information considered as generally known is not included. Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service.

can assure your customers of your optimum and quick service. This manual has been prepared on

This manual has been prepared on the basis of the latest specification at the time of publication. If modification has been made since then, difference may exist between the content of this manual and the actual vehicle. Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail.

WARNING

WARNING

This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby authorized HYOSUNG motorcycle dealer.

NOTE

model : model :

NOTE 』 model :

COPYRIGHT S&T Motors Co., Ltd.

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GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2
2

ENGINE

3

SERVICING INFORMATION

7
7
search engine GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 SERVICING INFORMATION 7

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR :

1. The text of this manual is divided into sections.

2. As the title of these sections 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.

its contents are listed. Find the item and page you need. SYMBOL Listed in the table

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK “ 1324 ”

Torque control required. Data beside it indicates specified torque.

Torque control required. Data beside it indicates specified torque. Apply THREAD LOCK “ 1324 ” .

Apply THREAD LOCK1324.

Apply oil. Use engine oil unless otherwise specified. Apply or use brake fluid.

Apply oil. Use engine oil unless otherwise specified.

Apply oil. Use engine oil unless otherwise specified. Apply or use brake fluid.

Apply or use brake fluid.

Apply SUPER GREASE “ A ” . Measure in voltage range.

Apply SUPER GREASEA.

Apply SUPER GREASE “ A ” . Measure in voltage range.

Measure in voltage range.

Apply SUPER GREASE “ C ” . Measure in resistance range.

Apply SUPER GREASEC.

Apply SUPER GREASE “ C ” . Measure in resistance range.

Measure in resistance range.

Apply SILICONE GREASE. Measure in current range.

Apply SILICONE GREASE.

Apply SILICONE GREASE. Measure in current range.

Measure in current range.

Apply MOLY PASTE. Measure in diode test range.

Apply MOLY PASTE.

Apply MOLY PASTE. Measure in diode test range.

Measure in diode test range.

Apply BOND “ 1215 ” . Measure in continuity test range.

Apply BOND1215.

Apply BOND “ 1215 ” . Measure in continuity test range.

Measure in continuity test range.

Use fork oil. Use special tool.

Use fork oil.

Use fork oil. Use special tool.

Use special tool.

2

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WIRE COLOR

B

: Black

Gr

: Gray

Sb

: Light blue

L

: Blue

Lg

: Light green

W

: White

Br

: Brown

O

: Orange

Y

: Yellow

G

: Green

R

: Red

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

 

3

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4

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GENERAL INFORMATION

CONTENTS

EXTERIOR PHOTOGRAPH ………………………………………… 6 (1-3)

EXTERIOR ILLUSTRATION~~ EXTERIOR ILLUSTRATION~~ EXTERIOR ILLUSTRATION~~

₩ ………………………… 7 (1-7-1) ………………………… 7 (1-7-1)

₩ ……………………… 8 (1-7-2) ……………………… 8 (1-7-2)

₩ ……………………… 9 (1-7-3) ……………………… 9 (1-7-3)

SPECIFICATIONS ………………………………………………………10 (1-8)

5

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1
1

1-3 GENERAL INFORMATION

EXTERIOR PHOTOGRAPH

1-3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH Downloaded from www.Manualslib.com manuals search engine 6
1-3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH Downloaded from www.Manualslib.com manuals search engine 6

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1-3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH Downloaded from www.Manualslib.com manuals search engine 6

6

GENERAL INFORMATION 1-7-1

EXTERIOR ILLUSTRATION~~

GENERAL INFORMATION 1-7-1 EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ Rear turn signal lamp Brake / Tail

Rear turn signal lamp

Brake / Tail lamp Rear License plate lamp reflector Front turn signal lamp Head lamp
Brake / Tail lamp
Rear
License plate lamp
reflector
Front turn signal lamp
Head lamp
Passenger footrests
1,350
(WHEEL BASE)
405
2,085
(LENGTH)
865
940
660
715
945
725
800
390
1,125
(HEIGHT)
1,060
230
790
315
840
(WIDTH)

7

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1-7-2 GENERAL INFORMATION

EXTERIOR ILLUSTRATION~~

1-7-2 GENERAL INFORMATION EXTERIOR ILLUSTRATION ~ ~ ₩ ₩ Brake / Tail lamp Rear reflector License

Brake / Tail lamp Rear reflector License plate lamp Rear turn signal lamp Front turn
Brake / Tail lamp
Rear
reflector
License plate lamp
Rear turn signal lamp
Front turn signal lamp
Head lamp
Passenger footrests
1,425
(WHEEL BASE)
2,190
(LENGTH)
3
124cm
875
1,010
720
1,065
810
865
1,160
(HEIGHT)
1,100
410
295
320
840
(WIDTH)

8

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GENERAL INFORMATION 1-7-3

(WIDTH)

(HEIGHT)

EXTERIOR ILLUSTRATION~~

Rear reflector License plate lamp

Front turn signal lamp

Brake / Tail lamp

Rear turn signal lamp

Head lamp

9

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(WHEEL BASE)

(LENGTH)

Passenger footrests

1-8 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND MASS

2,175 mm (85.6 in) ← 1,145 mm (45.1 in) 1,415 mm (55.7 in) ITEM Overall
2,175 mm (85.6 in) ← 1,145 mm (45.1 in) 1,415 mm (55.7 in) ITEM Overall
2,175 mm (85.6 in) ← 1,145 mm (45.1 in) 1,415 mm (55.7 in)

2,175 mm (85.6 in)

1,145 mm (45.1 in)

1,415 mm (55.7 in)

ITEM

ITEM

Overall length

2,085 mm (82.1 in)

2,190 mm (86.2 in)

Overall width

840 mm (33.1 in)

Overall height

1,125 mm (44.3 in)

1,160 mm (45.7 in)

Wheelbase

1,350 mm (53.2 in)

1,425 mm (56.1 in)

Wheelbase 1,350 mm (53.2 in) 1,425 mm (56.1 in) 275 mm (10.8 in) ← Ground clearance

275 mm (10.8 in)

Ground clearance

230

mm (9.1 in)

295 mm (11.6 in)

Mass

135

kg (298 lbs)

130 kg (287 lbs)

Ground clearance 230 mm (9.1 in) 295 mm (11.6 in) Mass 135 kg (298 lbs) 130
in) ← Ground clearance 230 mm (9.1 in) 295 mm (11.6 in) Mass 135 kg (298
in) Mass 135 kg (298 lbs) 130 kg (287 lbs) ⊙ ⊙ ENGINE ITEM Four-stroke, DOHC,

ENGINE

ITEM

ITEM
Four-stroke, DOHC, Air & oil cooled ← 1 cylinder ← 57.0 mm (2.24 in) 48.8
Four-stroke, DOHC, Air & oil cooled ← 1 cylinder ← 57.0 mm (2.24 in) 48.8
Four-stroke, DOHC, Air & oil cooled ← 1 cylinder ← 57.0 mm (2.24 in) 48.8
Four-stroke, DOHC, Air & oil cooled ← 1 cylinder ← 57.0 mm (2.24 in) 48.8
Four-stroke, DOHC, Air & oil cooled ← 1 cylinder ← 57.0 mm (2.24 in) 48.8

Four-stroke, DOHC, Air & oil cooled

1 cylinder

57.0

mm (2.24 in)

48.8

mm (1.92 in)

124.5 (7.6 in 3 )

Carburetor

Electric starter

Wet sump

Type

Number of cylinder

 

Bore

Stroke

 

Piston displacement

 

Fuel system

 

Starter system

Lubrication system

TRANSMISSION

ITEM

ITEM

Clutch

Wet multi-plate type

Transmission

5-speed constant mesh

Gearshift pattern

1-down, 4-up

Reduction ratio

3.500

 

1st

2.750

2nd

1.786

Gear ratio

3rd

1.368

4th

1.046

5th

0.913

← ← ← ← ←
← ← ← ← ←
← ← ← ← ←
← ← ← ← ←
← ← ← ← ←

Drive chain

428SO, 130 links

428H, 132 links

428H, 130 links

10

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GENERAL INFORMATION 1-9

CHASSIS

ITEM Front suspension Telescopic type ← ← Rear suspension Swingarm type ← ← Steering angle
ITEM
Front suspension
Telescopic type
Rear suspension
Swingarm type
Steering angle
47˚(right & left)
45˚(right & left)
Caster
25˚
27.5˚
27˚
Trail
84
mm (3.31 in)
94 mm (3.70 in)
88 mm (3.47 in)
Front brake
Disk brake
Rear brake
Drum brake
Disk brake
Front tire size
130/80 - 18M/C 66P
2.75 - 21 45P
110/70 - 17M/C 58H
Rear tire size
180/80 - 14M/C 78P
4.10 - 18M/C 59P
130/70 - 17M/C 62H
Front fork stroke
160 mm (6.3 in)
250 mm (9.8 in)
⊙⊙ ELECTRICAL
ITEM
Ignition type
“CDI”type
Ignition timing
6˚B.T.D.C. at 1,900 rpm
and 27˚B.T.D.C. at 4,250 rpm
Spark plug
CR8E
Battery
12
V 6 Ah (MF)
Fuse
15 A
HI
12
V - HS1 : 35 W ×1
12
V - H4 : 60 W ×1
Head lamp
LO
12
V - HS1 : 35 W ×1
12
V - H4 : 55 W ×1
Position
12
V - W5 W × 1
Turn signal lamp
12
V - RY10 W × 4
Brake / Tail lamp
12
V - P21/5 W × 1
License plate lamp
12
V - W5 W × 1
Illumination lamp
LED type
High beam indicator lamp
12
V - 1.7 W × 1
Turn signal indicator lamp(right & left)
12
V - 1.7 W × 2
Neutral indicator lamp
12
V - 1.7 W × 1
LED : Light Emitting Diode
⊙⊙ CAPACITIES
ITEM
Fuel tank
Oil change
Oil and filter change
9.0 ℓ
8.0 ℓ
850
Engine oil
950
Engine overhaul
Front fork oil capacity (One side)
1,200 ㎖
215 ±
2.5 cc
443 ±
2.5 cc

NOTE

The specifications are subject to change without notice.

11

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12

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PERIODIC MAINTENANCE

2

CONTENTS

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)

13

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2
2

2-3 PERIODIC MAINTENANCE

MAINTENANCE PROCEDURES

This section describes the servicing procedures for each item.

CYLINDER HEAD COVER BOLTS, CYLINDER HEAD & CYLINDER BASE NUTS, EXHAUST PIPE NUTS AND MUFFLER BOLTS

Inspect Interval

Tighten Initial at 1,000 km and Every 4,000 km thereafter.

CYLINDER HEAD COVER BOLT

Tighten the cylinder head cover bolts to the specified torque.

Cylinder head cover boltthe cylinder head cover bolts ① to the specified torque. : 12 ~ 16 N ·

: 12 ~ 16 N··m (1.2 ~ 1.6 kgf··m)

CYLINDER HEAD & CYLINDER BASE NUT

Tighten the cylinder head base buts and cylinder base nuts to the specified torque.

Cylinder head base nut② and cylinder base nuts ③ to the specified torque. : 7 ~ 11 N ·

: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)

Cylinder base nut

: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)

EXHAUST PIPE NUTS & MUFFLER BOLTS

Tighten the exhaust pipe nuts , muffler connecting bolt , and muffler mounting bolts , to the specified torque.

muffler mounting bolts ⑥ , ⑦ to the specified torque. Exhaust pipe nut : 18 ~

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)

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① ①
② ③
⑦ ⑤ ⑥

14

PERIODIC MAINTENANCE 2-5-1

AIR CLEANER

Inspect Interval

Clean Every 3,000 km, Replace Every 12,000 km.

If the air cleaner is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and an increase in fuel consumption.

Check and clean the air cleaner element in the following manner :

the air cleaner element in the following manner : ■ ■ ● Remove the seat and

Remove the seat and right side cover.

Remove the six screws and remove the air cleaner case cover.

Take off the air cleaner element .

Clean the air cleaner element for the follwing :

Fill a washing pan of a proper size with a non- flammable cleaning solvent . Immerse the air cleaner element in the cleaning solvent and wash it.

Gently squeeze the air cleaner element between the palms of both hands to remove the excess solvent : do not twist or wring the element or it will develop 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.

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①
②
cleaner element in the reverse order of removal. Downloaded from www.Manualslib.com manuals search engine ① ②

15

2-5-2 PERIODIC MAINTENANCE

CAUTION Inspect the air cleaner element for tears. A torn element must be replaced. If

CAUTION

Inspect the air cleaner element for tears. A torn element must be replaced. If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or with torn element. Make sure that the air cleaner element is in good condition at all times. Life of the engine depends largely on this component!

AIR CLEANER OIL DRAIN TUBE

Inspect the air cleaner oil drain tube and drain water and oil at the periodic interval. The air cleaner oil drain tube is located beneath the air cleaner case.

①
■■ & ② ● Remove the seat. ● The air cleaner is located under the
■■
&
● 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.
8
8

16

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PERIODIC MAINTENANCE 2-5-3

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.

CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions,

CAUTION

More frequent servicing may be performed on motorcycles that are used under severe conditions, also clean the air cleaner element when replacing the engine oil to prevent damage of the engine.

AIR CLEANER OIL DRAIN TUBE

Inspect the air cleaner oil drain tube and drain water and oil at the periodic interval. The air cleaner oil drain tube is located beneath the air cleaner case.

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8 8 ①
8
8

17

2-6-1 PERIODIC MAINTENANCE

VALVE CLEARANCE

Inspect Interval

Inspect Initial 1,000 km and Every 4,000 km thereafter.

Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification, if necessary.

Remove the seat and fuel tank.

Remove the spark plug.

Remove the cylinder head cover .

The valve clearance specification is different for both

intake and exhaust valves. Valve clearance adjustment must be checked and adjusted :

1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.

Remove the magneto cover plug and valve timing inspection plug .

NOTE

The piston must be at top dead center (TDC) on the compression stroke in order to check or adjust the valve clearance. The valve clearance should only be checked when the engine is cold.

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①
③ ②

18

PERIODIC MAINTENANCE 2-6-2

Rotate the magneto rotor clockwise or counter- clockwise with a socket wrench to set the piston at TDC on the compression stroke. (Rotate the magneto rotor until the “T” index mark on the magneto rotor is aligned with the triangle mark on the crankcase.)

To inspect the valve clearance, insert a thickness gauge between the tappet and the camshaft.

Valve clearance

Valve clearance
Valve clearance Standard (When cold) IN. 0.1 ∼ 0.2 mm (0.004 ~ 0.008 in) EX. 0.2

Standard (When cold)

IN. 0.1 ∼ 0.2 mm (0.004 ~ 0.008 in) EX. 0.2 ∼ 0.3 mm (0.008
IN. 0.1 ∼ 0.2 mm (0.004 ~ 0.008 in) EX. 0.2 ∼ 0.3 mm (0.008

IN.

0.1 0.2 mm (0.004 ~ 0.008 in)

EX.

0.2 0.3 mm (0.008 ~ 0.012 in)

~ 0.008 in) EX. 0.2 ∼ 0.3 mm (0.008 ~ 0.012 in) Thickness gauge : 09900-20806

Thickness gauge : 09900-20806

If the clearance is out of specification, first remove the 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 refer to the tappet shim selection chart. (Refer to page 90·91)

Adjust valve timing, install the camshaft housing and the cam chain tension adjuster. After the crankshaft rotate about 10 times, measure the valve clearance. If the clearance be not correct, adjust the standard clearance as the same manner above.

In case of valve adjustment which is not the tappet shim selection chart, please follow instructions of example in the below. For example, the intake clearance is 0.4 and the shim is 170 (1.70 mm), select 195 (1.95 mm) of the shim which 170 (1.70 mm) of the shim add up the excess clearance 0.25 mm when adjust with the standard 0.15 as the intake standard clearance 0.10.2 mm.

CAUTION If you don’t rotate the crankshaft about 10 times before measuring the valve clearance,

CAUTION

If you don’t rotate the crankshaft about 10 times before measuring the valve clearance, there is no meaning of valve clearance.

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clearance, there is no meaning of valve clearance. Downloaded from www.Manualslib.com manuals search engine ① 19
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19

2-7 PERIODIC MAINTENANCE

SPARK PLUG

Inspect Interval

Clean Initial 1,000 km and Every 4,000 km thereafter. Replace Every 8,000 km.

Disconnect the spark plug cap and remove the spark plug.

TYPE

Hot type

Standard type

Cold type

SPARK PLUG SPECIFICATION

CR7E

CR8E

CR9E

CARBON DEPOSITS

Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a wire or pin with a pointed end.

SPARK PLUG GAP

Measure the spark plug gap using a thickness gauge. If the spark plug gap is out of specification, adjust the gap.

Spark plug gap

0.7 0.8 mm (0.028 ~ 0.032 in)

gap. Spark plug gap 0.7 ∼ 0.8 mm (0.028 ~ 0.032 in) Thickness gauge : 09900-20806

Thickness gauge : 09900-20806

ELECTRODE

Check to see the worn or burnt condition of the elec- trodes. If it is extremly worn or burnt, replace the spark plug with a new one. And also replace the spark plug if it has a broken insulator, damaged thread, etc.

CAUTION To avoid damaging the cylinder head threads ; first, finger tighten the spark plug,

CAUTION

To avoid damaging the cylinder head threads ; first, finger tighten the spark plug, and then tighten it to the specified torque using the spark plug wrench.

20

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①
①
spark plug wrench. 20 Downloaded from www.Manualslib.com manuals search engine ① 0.7 ~ 0.8 mm (0.028
0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
0.7 ~ 0.8 mm (0.028 ~ 0.032 in)
0.7 ~ 0.8 mm (0.028 ~ 0.032 in)

0.7 ~ 0.8 mm (0.028 ~0.032 in)

PERIODIC MAINTENANCE 2-8

Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque.

Spark plug : 20 ~ 25 N· · m (2.0 ~ 2.5 kgf · · m) ··m (2.0 ~ 2.5 kgf··m)

ENGINE OIL

Inspect Interval

Replace Initial 1,000 km and Every 4,000 km thereafter.

Necessary amount of engine oil

Oil change

850

Oil and filter change

950

Engine overhaul

1,200

Engine oil type

SAE 10W/40 API Over SL

Engine oil should be changed while the engine is warm.

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 and drain plug .

Reinstall the drain plug gasket and engine oil

drain plug .

Tighten the drain plug to the specified torque, and pour fresh engine oil through the engine oil filler hole. Use an engine oil that meets the API service classification of Over SL and that has a viscosity rating of SAE 10W/40.

Engine oil drain plug : 25 ~ 30 N· m (2.5 ~ 3.0 kgf · m) ·m (2.5 ~ 3.0 kgf·m)

Install the engine oil filler plug .

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 the engine oil level lens.

If the level is below markF, add engine oil to

Flevel. If the level is above markF, drain

engine oil toFlevel. The motorcycle must be in

a level position for accurate measurement.

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②

2-9 PERIODIC MAINTENANCE

CAUTION Never operate the motorcycle if the engine oil level is below the “ Lower

CAUTION

Never operate the motorcycle if the engine oil level is below theLower line mark (L)in the engine oil level lens. Never fill the engine oil above the Upper line mark (F). Engine oil level being most suitable about 1 mm under theUpper line mark (F)of the engine oil level lens. In case of the engine oil pouring in excessively, the engine output being made insufficient. Be careful not to pour the engine oil excessively into the engine.

CAUTIONNecessarily, confirm and clean the oil strainer ① ① when replace the engine oil (specially,

Necessarily, confirm and clean the oil strainer when replace the engine oil (specially, when first replacement).

CAUTION More frequent servicing may be performed on mo- torcycles that are used under severe

CAUTION

More frequent servicing may be performed on mo- torcycles that are used under severe conditions.

ENGINE OIL FILTER

Inspect Interval

Replace Initial 1,000 km and Every 4,000 km thereafter.

Drain the engine oil as described in the engine oil replacement procedure.

Remove the oil filter cap by removing the three nuts.

Remove the oil filter .

Install the new O-ring .

Install the new oil filter.

Install the new O-ring and spring to the oil filter cap.

Install the oil filter cap .

CAUTION Before installing the oil filter cap, apply engine oil lightly to the new O-ring

CAUTION

Before installing the oil filter cap, apply engine oil lightly to the new O-ring .

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new O-ring ⑤ ⑤ . 22 Downloaded from www.Manualslib.com manuals search engine ① ② ② ③
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②
② ③ ⑤ ⑥

PERIODIC MAINTENANCE 2-10

OIL FILTER INSTALLATION

CAUTION When installing the oil filter, necessarily, “ HYOSUNG ” character and “ 16510H05240 ”

CAUTION

When installing the oil filter, necessarily, HYOSUNGcharacter and16510H05240parts NO. is installed toward the outside, otherwise can damage the engine.

WARNING

WARNING

Engine oil and exhaust pipes can be hot enough to burn you. Wait until the engine oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil.

Add new engine oil and check the engine oil level as described in the engine oil replacement procedure.

CAUTIONONLY USE A GENUINE HYOSUNG MOTORCYCLE ENGINE OIL FILTER. Other manufacturer’s engine oil filters may

ONLY USE A GENUINE HYOSUNG MOTORCYCLE ENGINE OIL FILTER. Other manufacturer’s engine oil filters may differ filtering performance and durability which may lead to engine damage or oil leaks.

CARBURETOR

Inspect Interval

Inspect Initial 1,000 km and Every 4,000 km thereafter.

IDLE SPEED

CAUTION Make this inspection when the engine is hot.

CAUTION

Make this inspection when the engine is hot.

Connect an engine tachometer to the high tension cord. Start up the engine and set its speed at anywhere of the specified value by turning throttle stop screw .

Engine idle speed 1,400 ∼ 1,600 rpm & Engine idle speed 1,400 ∼ 1,500 rpm
Engine idle speed
1,400 ∼ 1,600 rpm
&
Engine idle speed
1,400 ∼ 1,500 rpm
∼ 1,600 rpm & Engine idle speed 1,400 ∼ 1,500 rpm Engine tachometer : 09900- 26006

Engine tachometer : 09900-26006

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INSERTED

DIRECTION

16510H05240
16510H05240

HYOSUNG

LUSTER MATERIAL

OUTSIDE

manuals search engine ⇦ ⇦ INSERTED DIRECTION 16510H05240 HYOSUNG LUSTER MATERIAL OUTSIDE ①
①

2-19 PERIODIC MAINTENANCE

COMPRESSION PRESSURE CHECK

The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression reading for each maintenance service.

Compression pressure

Standard

Service limit

14 ~ 16 kgf/

12 kgf/

COMPRESSION TEST PROCEDURE

NOTE

Before testing the engine for compression pressure, make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing. Be sure that the battery used is in fully- charged condition.

Remove the related parts and test the compression pressure in the following manner :

Remove the spark plug.

WARNING

WARNING

The hot engine can burn you. Wait until the engine are cool enough to touch.

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 reading as the cylinder compression.

the maximum gauge reading as the cylinder compression. Compression gauge : 09915-64511 24 Downloaded from

Compression gauge : 09915-64511

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Low compression pressure can indicate some of the following 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

NOTE

When the compression pressure goes below specification, check the engine for conditions listed above.

head gasket NOTE When the compression pressure goes below specification, check the engine for conditions listed

PERIODIC MAINTENANCE 2-20

OIL PRESSURE CHECK

Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.

Oil pressure

Standard

0.4 ~ 0.6 kgf/(at 60 ℃·3,000 rpm)

Oil pressure Standard 0.4 ~ 0.6 kgf/ ㎠ (at 60 ℃· 3,000 rpm)

If the engine oil pressure is lower or higher than the specification, the following causes may be considered.

LOW OIL PRESSURE

Clogged oil filter

Oil leakage from the oil passage way

Damaged O-ring

Defective oil pump

Combination of the above items

HIGH OIL PRESSURE

Engine oil viscosity is too high

Clogged oil passage way

Combination of the above items

OIL PRESSURE TEST PROCEDURE

Check the engine oil pressure in the following manner :

Remove the oil check plug and install the oil pressure gauge and adapter into the oil check plug removed 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 speed to 3,000 rpm. (with the engine tachometer), and read the oil pressure gauge.

the engine tachometer), and read the oil pressure gauge. Engine tachometer : 09900- 26006 Oil pressure

Engine tachometer : 09900-26006 Oil pressure gauge : 09915-74511

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ENGINE

CONTENTS

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

29 (3-6) UPPER END COMPONENTS OF ENGINE INSPECTION AND SERVICING

AND SERVICING ……………………………………………………… 34 (3-11)

44(3-21)

UPPER END COMPONENTS OF ENGINE REASSEMBLY LEFT END COMPONENTS OF ENGINE DISASSEMBLY RIGHT END COMPONENTS OF ENGINE DISASSEMBLY LOWER END COMPONENTS OF ENGINE DISASSEMBLY LOWER END COMPONENTS OF ENGINE INSPECTION

54 (3-31)

57 (3-34)

60 (3-37)

AND SERVICING ……………………………………………………… 63 (3-40)

LOWER END COMPONENTS OF ENGINE REASSEMBLY 66 (3-43)

RIGHT END COMPONENTS OF ENGINE REASSEMBLY LEFT END COMPONENTS OF ENGINE REASSEMBLY

71 (3-48)

75 (3-52)ENGINE REASSEMBLY 66 (3-43) RIGHT END COMPONENTS OF ENGINE REASSEMBLY LEFT END COMPONENTS OF ENGINE REASSEMBLY

3
3
CAUTION Mark an identification of assembly location on each removed part so that each will

CAUTION

Mark an identification of assembly location on each removed part so that each will be restored to the original 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 bolts and check that the tightening margin is equal in each bolt.

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3-5 ENGINE

ENGINE REMOVAL AND REMOUNTING

ENGINE REMOUNTING

Remount 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 the specified torque.

Engine mounting bolt (M10) ① ①

: 48 ~ 72 N··m (4.8 ~ 7.2 kgf··m)

Engine mounting bolt (M8) ,, ,,

: 22 ~ 33 N··m (2.2 ~ 3.3 kgf··m)

Tighten the engine mounting bracket bolts and nuts to the specified torque.

Engine mounting bracket bolt (M8) ⑤ ⑤

: 22 ~ 33 N··m (2.2 ~ 3.3 kgf··m)

INSTALLING POSITION FOR CLUTCH RELEASE ARM

Align the clutch release arm slit surface with the notch mark on the clutch release camshaft.

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② ③
① ④
⑤
Notch Mark
Notch Mark

Slit

28

ENGINE 3-6

UPPER END COMPONENTS OF ENGINE DISASSEMBLY

NOTE

If only the upper end components of the engine is repaired, there is no necessary to remove the engine from the frame. Remove the seat and fuel tank so that the upper end components of the engine is disassemble.

Drain the engine oil by removing the drain plug located on the bottom of the engine.

Remove the magneto cover plug and the timing inspection plug .

Remove the cylinder head cover by removing the four wrench bolts.

Bring the piston at TDC (Top Dead Center).

CAUTION Align the “ “ T ” ” index mark on the magneto rotor with

CAUTION

Align theTindex mark on the magneto rotor with the triangle mark on the magneto cover as turn the crankshaft clockwise or counter- clockwise.

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①
③ ②
④
⑤

29

3-7 ENGINE

Remove the cam chain tension adjuster .

Remove the cam chain guide NO.2 .

Remove the camshaft housings .

Remove the dowel pins, intake camshaft and exhaust camshaft.

NOTE

Do not drop the dowel pins and cam chain into the crankcase.

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②
③ ③
pins and cam chain into the crankcase. Downloaded from www.Manualslib.com manuals search engine ① ② ③

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ENGINE 3-8

Remove the camshaft C-rings .

Loosen the three cylinder head bolts.

Loosen the three cylinder head base nuts.

Remove the cam chain guide NO.1.

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①
head base nuts. ● Remove the cam chain guide NO.1. Downloaded from www.Manualslib.com manuals search engine
head base nuts. ● Remove the cam chain guide NO.1. Downloaded from www.Manualslib.com manuals search engine
head base nuts. ● Remove the cam chain guide NO.1. Downloaded from www.Manualslib.com manuals search engine

31

3-9 ENGINE

Remove the tappet and the shim.

CAUTIONDraw out the tappet and shim with the strong magnet not to be scratched.

Draw out the tappet and shim with the strong magnet not to be scratched.

CAUTIONThe tappet and shim should be lined so that each will be restored to the

The tappet and shim should be lined so that each will be restored to the original position during reassembly.

Compress the valve spring by using the special tools.

● Compress the valve spring by using the special tools. Valve spring compressor : 09916-14510 Valve

Valve spring compressor : 09916-14510 Valve spring compressor attachment : 09916H35C00

Take out the valve cotter from the valve stem.

Remove the valve spring retainer .

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stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
stem. ● Remove the valve spring retainer ② . Downloaded from www.Manualslib.com manuals search engine ①
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32

ENGINE 3-10

Pull out the valve from the other side.

Remove the two cylinder base nuts and the cylinder.

CAUTION If tapping with the plastic hammer is necessary, pay attention to break the fins.

CAUTION

If tapping with the plastic hammer is necessary, pay attention to break the fins.

Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase. Remove the piston pin circlips with the long-nose pliers.

Remove the piston pin by using the special tool.

● Remove the piston pin by using the special tool. Piston pin puller : 09910-34510 33

Piston pin puller : 09910-34510

33

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①
using the special tool. Piston pin puller : 09910-34510 33 Downloaded from www.Manualslib.com manuals search engine
using the special tool. Piston pin puller : 09910-34510 33 Downloaded from www.Manualslib.com manuals search engine
using the special tool. Piston pin puller : 09910-34510 33 Downloaded from www.Manualslib.com manuals search engine

3-11 ENGINE

UPPER END COMPONENTS OF ENGINE INSPECTION AND SERVICING

CYLINDER HEAD DISTORTION

Decarbonize in combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance reading at several places as indicated. If any clearance reading exceeds the service limit, replace the cylinder head with a new one.

Cylinder head

Cylinder head

Service limit

distortion

distortion

0.05

mm (0.002 in)

limit distortion distortion 0.05 mm (0.002 in) Thickness gauge : 09900-20806 ⊙ ⊙ VALVE FACE WEAR

Thickness gauge : 09900-20806

VALVE FACE WEAR

Visually inspect each valve face for wear or damage. If any abnormal wear is found, replace the respective valve with a new one. The thickness of the valve face decreases as the face wears. Measure the valve head thickness . If the valve head thickness is not within the specified value, replace the valve with a new one.

Cylinder head

Valve head thickness

Service limit

distortion

(IN. & EX.)

0.5 mm (0.02 in)

Vernier calipers : 09900-20101limit distortion (IN. & EX.) 0.5 mm (0.02 in) ⊙ ⊙ VALVE STEM RUNOUT Check the

VALVE STEM RUNOUT

Check the valve stem for abnormal wear or bend. Support the valve using a V-blocks and measure the valve stem runout using the dial gauge, as shown. If the service limit is exceeded or abnormal condition exists, replace the valve with a new one.

Cylinder head

Valve stem runout

Service limit

distortion

(IN. & EX.)

0.05

mm (0.002 in)

distortion (IN. & EX.) 0.05 mm (0.002 in) Dial gauge : 09900-20606 Magnetic stand : 09900-20701

Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304

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Magnetic stand : 09900-20701 V-block : 09900-21304 34 Downloaded from www.Manualslib.com manuals search engine
Magnetic stand : 09900-20701 V-block : 09900-21304 34 Downloaded from www.Manualslib.com manuals search engine
Magnetic stand : 09900-20701 V-block : 09900-21304 34 Downloaded from www.Manualslib.com manuals search engine

ENGINE 3-12

CAMSHAFT RUNOUT

Support the camshaft using a V-blocks and measure the camshaft runout using the dial gauge. If the runout exceeds the service limit, replace the camshaft with a new one.

Camshaft runout

Service limit

(IN. & EX.)

0.10 mm (0.004 in)

Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304Service limit (IN. & EX.) 0.10 mm (0.004 in) ⊙ ⊙ CAMSHAFT The camshaft should be

CAMSHAFT

The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out-put power. Any of these abnormality could be caused by a worn camshaft.

CAMSHAFT WEAR

Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height , which is to be measured with a micrometer. Replace camshafts if found it worn down to the limit.

Cam height

Service limit

Cam height Service limit Intake cam 34.17 mm (1.345 in) Exhaust cam 34.12 mm (1.343 in)
Cam height Service limit Intake cam 34.17 mm (1.345 in) Exhaust cam 34.12 mm (1.343 in)

Intake cam

34.17

mm (1.345 in)

Exhaust cam

34.12

mm (1.343 in)

Micrometer(25~50 mm) : 09900-20202mm (1.345 in) Exhaust cam 34.12 mm (1.343 in) Downloaded from www.Manualslib.com manuals search engine

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Downloaded from www.Manualslib.com manuals search engine TDC (0。。) Intake open Exhaust close (B.T.D.C)
TDC (0。。) Intake open Exhaust close (B.T.D.C) (A.T.D.C) 17。 45。 270。 90。 48。 14。 Intake
TDC (0。。)
Intake open
Exhaust close
(B.T.D.C)
(A.T.D.C)
17。
45。
270。
90。
48。
14。
Intake close
Exhaust open
(A.B.D.C)
(B.B.D.C)

BDC (180)

VALVE TIMING DIAGRAM

90。 48。 14。 Intake close Exhaust open (A.B.D.C) (B.B.D.C) BDC (180 。 。 ) VALVE TIMING

35

3-13 ENGINE

TAPPET & SHIM WEAR

When measuring the valve clearance, the clearance should be within the standard range.

Valve clearance

Standard (When cold)

Intake valve

0.1 ~ 0.2 mm

(0.004 ~ 0.008 in)

(When cold) Intake valve 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) Exhaust valve 0.2 ~
(When cold) Intake valve 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) Exhaust valve 0.2 ~

Exhaust valve

0.2 ~ 0.3 mm

(0.008 ~ 0.012 in)

in) Exhaust valve 0.2 ~ 0.3 mm (0.008 ~ 0.012 in) Thickness gauge : 09900-20806 ●

Thickness gauge : 09900-20806

Inspect the tappet for wear and scratch. If modification or scratch is present, replace the tappet. When you checked the valve clearance, if the valve clearance is wide please replace the present shim into thick one, if the valve clearance is narrow please replace the present shim into thin shim. (Refer to page 90·91)

SHIM KIND

There are 41 kinds of shim which thickness is

increased by each 0.025 mm from 1.20 mm to 2.20

mm.

36

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is increased by each 0.025 mm from 1.20 mm to 2.20 mm. 36 Downloaded from www.Manualslib.com
is increased by each 0.025 mm from 1.20 mm to 2.20 mm. 36 Downloaded from www.Manualslib.com
is increased by each 0.025 mm from 1.20 mm to 2.20 mm. 36 Downloaded from www.Manualslib.com
is increased by each 0.025 mm from 1.20 mm to 2.20 mm. 36 Downloaded from www.Manualslib.com
is increased by each 0.025 mm from 1.20 mm to 2.20 mm. 36 Downloaded from www.Manualslib.com

ENGINE 3-14

VALVE HEAD RADIAL RUNOUT

Support the valve using a V-block and measure the valve head radial runout using the dial gauge, as shown. If the runout exceeds the service limit, replace the valve with a new one.

Cylinder head

Valve head radial

distortion

runout (IN. & EX.)

Service limit

0.03 mm (0.0012 in)

(IN. & EX.) Service limit 0.03 mm (0.0012 in) Dial gauge : 09900-20606 Magnetic stand :

Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304

VALVE STEM DEFLECTION

Lift the valve about 10 mm (0.39 in) from the valve seat. Measure the valve stem deflection in two directions, “X” and “Y”, perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, determine whether the valve or the guide should be replaced with a new one.

Valve stem deflection

Service limit

IN.

EX.

0.35 mm

(0.014 in)

0.35 mm

(0.014 in)

Dial gauge : 09900-20606 Magnetic stand : 09900-20701IN. EX. 0.35 mm (0.014 in) 0.35 mm (0.014 in) ⊙ ⊙ VALVE STEM DIAMETER Measure

VALVE STEM DIAMETER

Measure the valve stem outside diameter using the micrometer. If the diameter measured exceeds the standard, replace the valve.

Valve stem diameter IN. EX. Standard 4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in) 4.455

Valve stem diameter

IN.

EX.

Standard

4.475 ~ 4.490 mm

(0.1762 ~ 0.1768 in)

4.455 ~ 4.470 mm

(0.1754 ~ 0.1760 in)

~ 0.1768 in) 4.455 ~ 4.470 mm (0.1754 ~ 0.1760 in) Micrometer(0~25 mm) : 09900-20201 37

Micrometer(0~25 mm) : 09900-20201

37

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mm (0.1754 ~ 0.1760 in) Micrometer(0~25 mm) : 09900-20201 37 Downloaded from www.Manualslib.com manuals search engine
mm (0.1754 ~ 0.1760 in) Micrometer(0~25 mm) : 09900-20201 37 Downloaded from www.Manualslib.com manuals search engine
mm (0.1754 ~ 0.1760 in) Micrometer(0~25 mm) : 09900-20201 37 Downloaded from www.Manualslib.com manuals search engine
mm (0.1754 ~ 0.1760 in) Micrometer(0~25 mm) : 09900-20201 37 Downloaded from www.Manualslib.com manuals search engine

3-15 ENGINE

VALVE SPRING

The force of the coil spring keeps the valve seat tight. A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them. If the spring length is less than the service limit or if the force required to compress the valve spring is not within specification, replace the valve spring.

Cylinder head

Valve spring free

distortion

length (IN. & EX.)

Service limit

37.80 mm (1.488 in)

Vernier calipers : 09900-20101(IN. & EX.) Service limit 37.80 mm (1.488 in) Cylinder head distortion Valve spring tension (IN.

Cylinder head

distortion

Valve spring tension

(IN. & EX.)

Standard

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)

CYLINDER DISTORTION

Check the gasketed surface of the cylinder for distortion using a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder.

Service limit

Cylinder distortion

0.05 mm (0.002 in)

Thickness gauge : 09900-20806Service limit Cylinder distortion 0.05 mm (0.002 in) 38 Downloaded from www.Manualslib.com manuals search

38

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0.05 mm (0.002 in) Thickness gauge : 09900-20806 38 Downloaded from www.Manualslib.com manuals search engine
0.05 mm (0.002 in) Thickness gauge : 09900-20806 38 Downloaded from www.Manualslib.com manuals search engine
0.05 mm (0.002 in) Thickness gauge : 09900-20806 38 Downloaded from www.Manualslib.com manuals search engine

ENGINE 3-16

CYLINDER BORE

Measure the cylinder bore diameter at six place.

If any one of the measurements exceeds the limit,

overhaul the cylinder and replace the cylinder.

Cylinder bore Standard Service limit 57.000 ~ 57.015 mm (2.2441 ~ 2.2447 in) 57.080 mm

Cylinder bore

Standard

Service limit

57.000 ~ 57.015 mm (2.2441 ~ 2.2447 in)

57.080 mm

(2.2472 in)

Cylinder bore Standard Service limit 57.000 ~ 57.015 mm (2.2441 ~ 2.2447 in) 57.080 mm (2.2472

Cylinder gauge set : 09900-2050857.015 mm (2.2441 ~ 2.2447 in) 57.080 mm (2.2472 in) ⊙ ⊙ PISTON DIAMETER INSPECTION Measure

PISTON DIAMETER INSPECTION

Measure the outside diameter of the piston in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using

a micrometer.

If the measurement is found less than the service limit, replace the piston.

Service limit

Piston diameter

56.880 mm (2.2394 in)

Micrometer(50 ~ 75 mm) : 09900-20203Service limit Piston diameter 56.880 mm (2.2394 in) ⊙ ⊙ PISTON TO CYLINDER CLEARANCE To determine

PISTON TO CYLINDER CLEARANCE

To determine the piston to cylinder clearance, calculate the difference between the cylinder bore and outside diameter of the piston.

Piston to

cylinder

clearance

Standard Service limit 0.050 ~ 0.060 mm 0.120 mm (0.0020 ~ 0.0024 in) (0.0047 in)

Standard

Service limit

0.050 ~ 0.060 mm

0.120 mm

(0.0020 ~ 0.0024 in)

(0.0047 in)

39

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mm (0.0020 ~ 0.0024 in) (0.0047 in) 39 Downloaded from www.Manualslib.com manuals search engine 15 mm
15 mm (0.6 in)
15 mm (0.6 in)

15 mm (0.6 in)

mm (0.0020 ~ 0.0024 in) (0.0047 in) 39 Downloaded from www.Manualslib.com manuals search engine 15 mm

3-17 ENGINE

PISTON RING TO GROOVE CLEARANCE INSPECTION

Remove carbon deposit both from the piston ring and its 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.

Service limit

Piston ring-groove clearance

1st

2nd

Service limit Piston ring-groove clearance 1st 2nd 0.180 mm (0.007 in) 0.150 mm (0.006 in)
Service limit Piston ring-groove clearance 1st 2nd 0.180 mm (0.007 in) 0.150 mm (0.006 in)
Service limit Piston ring-groove clearance 1st 2nd 0.180 mm (0.007 in) 0.150 mm (0.006 in)
Service limit Piston ring-groove clearance 1st 2nd 0.180 mm (0.007 in) 0.150 mm (0.006 in)

0.180

mm (0.007 in)

0.150

mm (0.006 in)

Piston ring groove width

Standard

 

1.01

~ 1.03 mm

1st

(0.040 ~ 0.041 in)

 

1.01

~ 1.03 mm

2nd

(0.040 ~ 0.041 in)

 

2.01

~ 2.03 mm

Oil

(0.079 ~ 0.080 in)

Piston ring thickness Standard 1st 0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in) 2nd 0.970
Piston ring thickness Standard 1st 0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in) 2nd 0.970
Piston ring thickness Standard 1st 0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in) 2nd 0.970

Piston ring thickness

Standard

Piston ring thickness Standard 1st 0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in) 2nd 0.970 ~

1st

0.970 ~ 0.990 mm

(0.0382 ~ 0.0390 in)

2nd

0.970 ~ 0.990 mm

(0.0382 ~ 0.0390 in)

~ 0.0390 in) 2nd 0.970 ~ 0.990 mm (0.0382 ~ 0.0390 in) Micrometer(0~25 mm) : 09900-20201

Micrometer(0~25 mm) : 09900-20201 Thickness gauge : 09900-20806

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mm) : 09900-20201 Thickness gauge : 09900-20806 40 Downloaded from www.Manualslib.com manuals search engine
mm) : 09900-20201 Thickness gauge : 09900-20806 40 Downloaded from www.Manualslib.com manuals search engine

ENGINE 3-18

PISTON RING FREE END GAP INSPECTION

Before installing the piston rings, measure the free end gap of each ring using vernier calipers. If the gap is less than the service limit, replace the ring.

Piston ring free end gap

Service limit

1st

5.7

mm (0.224 in)

2nd

4.6

mm (0.181 in)

Vernier calipers : 09900-201011st 5.7 mm (0.224 in) 2nd 4.6 mm (0.181 in) ⊙ ⊙ PISTON RING END GAP

PISTON RING END GAP INSPECTION (Assembly condition)

Insert the piston ring squarely into the cylinder using the piston head. Measure the end gap with a thickness gauge. If the gap exceeds the service limit, replace the piston ring with a new one.

Pistonringendgap(Assemblycondition)

Standard

1st

2nd

0.20 ~ 0.32 mm

(0.008 ~ 0.013 in)

0.20 ~ 0.32 mm

(0.008 ~ 0.013 in)

Pistonringendgap(Assemblycondition)

Service limit

1st

0.50 mm (0.020 in)

Pistonringendgap(Assemblycondition) Service limit 1st 0.50 mm (0.020 in) 2nd 0.50 mm (0.020 in)
Pistonringendgap(Assemblycondition) Service limit 1st 0.50 mm (0.020 in) 2nd 0.50 mm (0.020 in)

2nd

0.50 mm (0.020 in)

Thickness gauge : 0990-208061st 0.50 mm (0.020 in) 2nd 0.50 mm (0.020 in) 41 Downloaded from www.Manualslib.com manuals search

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2nd 0.50 mm (0.020 in) Thickness gauge : 0990-20806 41 Downloaded from www.Manualslib.com manuals search engine
2nd 0.50 mm (0.020 in) Thickness gauge : 0990-20806 41 Downloaded from www.Manualslib.com manuals search engine

3-19 ENGINE

PISTON PIN HOLE BORE

Using a dial calipers, measure the piston pin hole bore both the vertical and horizontal directions. If the measurement exceeds the service limit, replace the piston with a new one.

 

Piston pin

Service limit

hole bore

15.030

mm (0.5917 in)

Dial calipers : 09900-20605Service limit hole bore 15.030 mm (0.5917 in) ⊙ ⊙ PISTON PIN DIAMETER INSPECTION Using a

PISTON PIN DIAMETER INSPECTION

Using a micrometer, measure the piston pin outside diameter at three position, both the ends and the center. If any of the measurements is founds less than the service limit, replace the pin with a new one.

Service limit

Piston pin diameter

14.980 mm (0.5898 in)

Micrometer(0~25 mm) : 09900-20201limit Piston pin diameter 14.980 mm (0.5898 in) ⊙ ⊙ CONROD SMALL END INSIDE DIAMETER INSPECTION

CONROD SMALL END INSIDE DIAMETER INSPECTION

Using a dial calipers, measure the conrod small end inside diameter both in vertical and horizontal directions. If any of the measurements exceeds the service limit, replace the conrod.

Conrod small

end I.D.

Standard

Service limit

 

15.006 ~ 15.014 mm (0.5908 ~ 0.5911 in)

15.040 mm

(0.5921 in)

15.014 mm (0.5908 ~ 0.5911 in) 15.040 mm (0.5921 in) Dial calipers : 09900-20605 42 Downloaded

Dial calipers : 09900-20605

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15.040 mm (0.5921 in) Dial calipers : 09900-20605 42 Downloaded from www.Manualslib.com manuals search engine
15.040 mm (0.5921 in) Dial calipers : 09900-20605 42 Downloaded from www.Manualslib.com manuals search engine
15.040 mm (0.5921 in) Dial calipers : 09900-20605 42 Downloaded from www.Manualslib.com manuals search engine

ENGINE 3-20

CONROD DEFLECTION INSPECTION

Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. Turn the conrod and see if it moves smoothly without play and noise. This method can also be used to check the extent of wear on the parts of the conrod’s big end.

Conrod deflection

Service limit

Conrod deflection Service limit 3.0 mm (0.12 in)
Conrod deflection Service limit 3.0 mm (0.12 in)
Conrod deflection Service limit 3.0 mm (0.12 in)

3.0 mm (0.12 in)

Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304end. Conrod deflection Service limit 3.0 mm (0.12 in) ⊙ ⊙ CONROD BIG END SIDE CLEARANCE

CONROD BIG END SIDE CLEARANCE INSPECTION

Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. If the clearance exceeds the service limit, replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts (conrod, big end bearing, crankshaft, crank pin, etc.) with new ones.

Conrod big

Standard

Service limit

Conrod big Standard Service limit end side clearance 0.10 ~ 0.45 mm 1.00 mm (0.004 ~
Conrod big Standard Service limit end side clearance 0.10 ~ 0.45 mm 1.00 mm (0.004 ~

end side

clearance

0.10 ~ 0.45 mm

1.00 mm

(0.004 ~ 0.018 in)

(0.040 in)

Thickness gauge : 09900-20806~ 0.45 mm 1.00 mm (0.004 ~ 0.018 in) (0.040 in) ⊙ ⊙ CRANKSHAFT RUNOUT INSPECTION

CRANKSHAFT RUNOUT INSPECTION

With the right and left crank journals supported using a V-block, turn the crankshaft slowly. At this time, measure the crankshaft end runout using a dial gauge. If the runout exceeds the service limit, replace the crankshaft with a new one.

Crankshaft runout

Service limit

Crankshaft runout Service limit 0.05 mm (0.002 in)
Crankshaft runout Service limit 0.05 mm (0.002 in)

0.05 mm (0.002 in)

Crankshaft runout Service limit 0.05 mm (0.002 in) Dial gauge : 09900-20606 Magnetic stand : 09900-20701

Dial gauge : 09900-20606 Magnetic stand : 09900-20701 V-block : 09900-21304

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Magnetic stand : 09900-20701 V-block : 09900-21304 Downloaded from www.Manualslib.com manuals search engine 43
Magnetic stand : 09900-20701 V-block : 09900-21304 Downloaded from www.Manualslib.com manuals search engine 43
Magnetic stand : 09900-20701 V-block : 09900-21304 Downloaded from www.Manualslib.com manuals search engine 43

43

3-21 ENGINE

UPPER END COMPONENTS OF ENGINE REASSEMBLY

PISTON RING

Install the oil ring first, the 2nd ring second, and the 1st ring last.

NOTE

The 1st and 2nd piston rings differ in shape. The 1st and 2nd piston rings should be installed with the mark facing up.

First, install a spacer into the oil ring groove, and then install the two side rails . The spacer and side rails do not have a designated top and bottom. They can be installed in any position.

CAUTION When installing the spacer, be careful not to allow its two ends to overlap

CAUTION

When installing the spacer, be careful not to allow its two ends to overlap in the groove.

Position the piston ring gaps as shown. Before inserting the piston into its cylinder, check that the gaps are properly positioned.

2nd ring and lower side rail Upper side rail 1st ring and spacer

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① ②

44 Downloaded from www.Manualslib.com manuals search engine ① ② CORRECT INCORRECT EX ⑤ ⑥ ⑦ IN
CORRECT
CORRECT

INCORRECT

EX ⑤ ⑥ ⑦ IN
EX
IN

ENGINE 3-22

PISTON AND CYLINDER

Apply MOLY PASTE on the piston pin and small end of the conrod.

MOLY PASTEMOLY PASTE on the piston pin and small end of the conrod. ● Place a clean

Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase, and then fit the piston pin circlip with the long-nose pliers.

CAUTIONUse a new piston pin circlip to prevent circlip failure with a bent one.

Use a new piston pin circlip to prevent circlip failure with a bent one.

NOTE

Install the piston with the punch mark on the piston head facing toward the exhaust side.

Apply the engine oil to the sliding surface of the piston and big end of the conrod.

Install the dowel pins and new gasket onto the crankcase.

CAUTIONUse a new gasket to prevent oil leakage.

Use a new gasket to prevent oil leakage.

Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder. Make sure that the piston rings are caught by the cylinder skirt.

NOTE

When mounting the cylinder, after attaching the cam chain, keep the cam chain taut. The cam chain must not be caught between the cam chain sprocket and crankcase when the crankshaft is rotated.

Tighten the cylinder base nut to the specified torque.

Cylinder base nut : 7 ~ 11 N · · m (0.7 ~ 1.1 kgf · · m) : 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)

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nut : 7 ~ 11 N · · m (0.7 ~ 1.1 kgf · · m)
①
②
③

3-23 ENGINE

VALVE AND SPRING

Apply MOLY PASTE to the valve as shown, and then insert them into the valve guides.

MOLY PASTEvalve as shown, and then insert them into the valve guides. CAUTION When inserting each valve

CAUTION When inserting each valve into the valve guides, make sure not to damage the

CAUTION

When inserting each valve into the valve guides, make sure not to damage the lip of the oil seal.

Install the valve spring with the smaller pitch facing the cylinder head.

Put on the valve spring retainer ①, and using the valve spring compressor, press down the spring, fit the cotter halves to the stem end, and release the valve spring compressor to allow the cotter to wedge in between retainer and stem. Be sure that the rounded lip of the cotter fits snugly into the groove in the stem end.

Valve spring compressor : 09916-14510 Valve spring compressor attachment : 09916H35C00cotter fits snugly into the groove ④ in the stem end. CAUTION After installing the valve

CAUTION After installing the valve cotter, tap the valve stem end by using the plastic

CAUTION

After installing the valve cotter, tap the valve stem end by using the plastic hammer at 2~3 times for assembly of the valve and cotter.

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and cotter. 46 Downloaded from www.Manualslib.com manuals search engine Cylinder head direction ③ ④ ① ②
and cotter. 46 Downloaded from www.Manualslib.com manuals search engine Cylinder head direction ③ ④ ① ②
Cylinder head direction

Cylinder head

direction

and cotter. 46 Downloaded from www.Manualslib.com manuals search engine Cylinder head direction ③ ④ ① ②
③ ④ ① ②

ENGINE 3-24

Install the dowel pins and new gasket.

CAUTION Use a new cylinder head gasket to prevent gas leakage.

CAUTION

Use a new cylinder head gasket to prevent gas leakage.

CYLINDER HEAD

Install the cylinder head .

With the cylinder head snugly seated on the cylinder, secure it by tightening the bolts in diagonal stages. Tighten the cylinder head bolts diagonally to the specified torque.

Cylinder head boltthe cylinder head bolts diagonally to the specified torque. : 21 ~ 25 N · ·

: 21 ~ 25 N··m (2.1 ~ 2.5 kgf··m)

NOTE

Apply engine oil to the threaded parts of the cylinder head bolts and its washers. Be sure to install the washer with rounded side facing up. Pay caution to prevent the cam chain from dropping into the crankcase.

After tightening the cylinder head bolts to the specification, tighten the cylinder head base nuts to the specified torque.

Cylinder head base nutthe cylinder head base nuts ③ to the specified torque. : 7 ~ 11 N ·

: 7 ~ 11 N··m (0.7 ~ 1.1 kgf··m)

Install the tappet and shim.

CAUTION With the tappet fitted, it should be replaced if it doesn ’ t turn

CAUTION

With the tappet fitted, it should be replaced if it doesnt turn smoothly by the hand.

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①
if it doesn ’ t turn smoothly by the hand. 47 Downloaded from www.Manualslib.com manuals search
②
③
if it doesn ’ t turn smoothly by the hand. 47 Downloaded from www.Manualslib.com manuals search

3-25 ENGINE

CAUTION The tappet and shim should be installed at the original position when removed. If

CAUTION

The tappet and shim should be installed at the original position when removed. If otherwise, it is difficult to adjust the valve clear- ance.

With pulling up the cam chain, align theTindex mark of the magneto rotor into the triangle mark of the magneto cover to turn the crankshaft.

CAUTION If turn the crankshaft without pulling up the cam chain, the cam chain may

CAUTION

If turn the crankshaft without pulling up the cam chain, the cam chain may be fallen off between the crankcase and cam chain drive sprocket.

Fit the cam chain guide NO.1.

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Tappet Shim
Tappet
Shim
①
● Fit the cam chain guide NO.1. 48 Downloaded from www.Manualslib.com manuals search engine Tappet Shim

ENGINE 3-26

CAMSHAFT ASSEMBLY

Distinguish theEXmark for the exhaust camshaft, theINmark for the intake camshaft.

Install the camshaft C-rings .

When installing the camshaft and camshaft sprocket, apply a small quantity of the THREAD LOCK “1324” to the thread portion of the camshaft sprocket bolts.

THREAD LOCK “1324”to the thread portion of the camshaft sprocket bolts. ● Tighten the camshaft sprocket bolts to

Tighten the camshaft sprocket bolts to the specified torque.

Camshaft sprocket bot : 10 ~ 12 N· · m (1.0 ~ 1.2 kgf · · m) ··m (1.0 ~ 1.2 kgf··m)

Apply the engine oil to the camshaft bearings.

Install the exhaust camshaft first, following the intake camshaft.

CAUTION Do not rotate the magneto rotor while doing this operate.

CAUTION

Do not rotate the magneto rotor while doing this operate.

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IN
IN
EX
EX
①
the magneto rotor while doing this operate. 49 Downloaded from www.Manualslib.com manuals search engine IN EX
the magneto rotor while doing this operate. 49 Downloaded from www.Manualslib.com manuals search engine IN EX

3-27 ENGINE

With the “T” index mark on the magneto rotor is aligned with the triangle mark on the magneto cover, hold the camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft sprocket. The exhaust camshaft sprocket has an arrow marked “1” . Turn the exhaust camshaft so that the arrow marked “1” is aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust camshaft sprocket.

The other arrow marked “2” should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked “2” , count out 16 roller pins (from the exhaust camshaft side going towards the intake camshaft side). Engage the 16th roller pin on the cam chain with the arrow marked “3” on the intake sprocket. Refer to the following photograph and illustrations.

② ③ ① 2↑ 3↑ 1 ← Exhaust Intake
① 2↑
3↑
1
Exhaust
Intake
16 Pins ③ ② 3↑ 2↑ 1 ① ←
16 Pins
3↑
2↑
1
① ←

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ENGINE 3-28

NOTE The cam chain should now be on all three sprockets. Be careful not to
NOTE
The 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.
16 Pins ② ③ ① Notch mark EXHAUST INTAKE
16 Pins
Notch mark
EXHAUST
INTAKE

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3-29 ENGINE

Each camshaft housing is punched withA”“B” “C”“D. Put on the housingAto theAof head surface, the housingBto theB, the housing Cto theCand the housingDto theDas thatA”“B”“C”“Dis punched also to the cylinder head upper surface.

Fix the four camshaft housing and cam chain guide 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 the same torque.

CAUTION If get damaged the cylinder head or surface of camshaft housing thrust, produce an

CAUTION

If get damaged the cylinder head or surface of camshaft housing thrust, produce an result that the camshaft housing not was tightened.

Tighten the camshaft housing bolt with the specified torque.

CAUTION The camshaft housing bolt is made of the special material. This bolt is superior

CAUTION

The camshaft housing bolt is made of the special material. This bolt is superior at the degree of hardness more than the different high tension bolt. Pay special caution that the different type of bolt should not be used. This bolt head is punched the9mark.

Camshaft housing bolt : 8 ~ 12 N· m (0.8 ~ 1.2 kgf · m) ·m (0.8 ~ 1.2 kgf·m)

If turn the lock shaft handle of the cam chain tension adjuster in clockwise ( ) direction, the pushrod is inserted in. Turn the mechanical spring continually until the handle is turned to the end.

spring continually until the handle is turned to the end. ● Fix the cam chain tension

Fix the cam chain tension adjuster into the cylinder block.

Tighten the cam chain tension adjuster mounting bolt with the specified torque.

Cam chain tension adjuster mounting bolt : 8 ~ 12 N· m (0.8 ~ 1.2 kgf · m) ·m (0.8 ~ 1.2 kgf·m)

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