Set the handlebars to match its punched mark to themating face of the holder. Ifthe voltage reading is less than the 12. Install each bolt diagonally by using the wrench pulling the shaft down. Valve clearance adjustment must be checked and adj usted, 1 at the ti me of peri odi c i nspecti on, 2 when t he val ve mechani sm i s ser vi ced, and 3 when the camshaft i s di sturbed by removi ng i t for servicing. I unit, side stand switch, gear position switch, starter switch, engine stop switch, ignition switch and battery.
Color classificationPainted redPainted yellowOversize oil ring0. After reassembly, check parts for tightness and operation. When the motorcycle is not used for a long period,check the battery every 1 month to prevent the bat-tery discharge. Never fill the engine oil above theUpper line mark F. Refer to page 2-16 Inspection after reassembly : Refer to page 2-14Front brake caliper mounting bolts:18~28 Nm 1. When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
Remove all the spark plug. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips,and certain other parts as specified, be sure to replace them with new ones. Do not use any brake fluid taken from old or used or unsealed containers. Change t he el ect rol yt e byconsulting the battery maker'sdirections. Refer to page 4-1 Drain the engine oil.
Measure the end gap with a thickness gauge. Thickness gauge : 09900-20806Spark plug gap0. Follow the procedures in this manual carefully and completely. Remove the fuel pump mounting bolts. .
Use only genuine Hyoung replacement parts or their equivalent. Makesure that there is always some fluid visible inthe reservoir. Micrometer 0~25 mm : 09900-20201Vernier calipers : 09900-20101Piston ring end gap Assembly condition Standard0. Carefully examine the air cleaner element for tears duringcleaning. Close the air bleeder valve, and disconnect the hose. The classification is Ffor the front andRforthe rear.
Be distinguished always each camshaft what has notch at the rightside end and leftside end of it. Disconnect the fuel hoses , and vacuum hose. If the gap exceeds the service limit, replace the piston ring. For example, the intake clearance is 0. If not emited spark or the spark bring out the orangecolor, replace the ignition coil. If the diameter measured exceeds the standard, replace the valve.
Wait until the oil drain plug and exhaust pipes arecool enough to touch with bare hands before drain-ing oil. Pay attention to the following points : Reassembly the starter motor as shown in the illustration. If excessive resistance is felt while turn-ing the st ar t er dr i ven gear , i nspect t he st ar t erclutch. Float is not working properly. Align the hole of the diaphragm with passage way on the carburetor body. Air trapped in brake fluid circuit. Inspect IntervalReplace Initial 1,000 km and Every 4,000 km.
Warm up the engine as follows :Summer : 10 min. Crankcase bolt : 8~12 Nm 0. To store brake fluid, make sure to seal the container and keep it in a safe place to be out of reach ofchildren. Worn or distorted pressure plate. Refer to page 2-9 Connect each electric part and its couplers. The presence of air is indicated by sponginessof the brake lever and also by lack of braking force. Worn swing arm bushing or bearing.
All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head. Replace the brake hoses Every 4 years,Replace the brake fluid Every 2 years. Internal short-circuit in the battery. Install the clutch release arm as following:Turn the clutch release shaft toward This time, mark on the shaft align outside contact line the stopper screw the right. Check the fuel flow when starting the engine for few seconds by pressing the starter switch.