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Documente Cultură
SERVICE MANUAL
SERVICE MANUAL
99000-91310
FOREWORD GROUP INDEX
COMPONENT PARTS
Apply BOND“1215”.
GENERAL INFORMATION
1
CONTENTS
SPECIFICATIONS 1-6
1-1 GENERAL INFORMATION
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions cleaner.
Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a
particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
WARNING
● Proper service and repair procedures are important for the safety of the service machanic and the safety
and reliability of the vehicle.
● When 2 or more persons work together, pay attention to the safety of each other.
● When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
● When working with toxic or flammable materials, make sure that the area you work in is wellventilated
and that you follow all off the material manufacturer’s instructions.
● Never use gasoline as a cleaning solvent.
● To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
● After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for
leaks.
GENERAL INFORMATION 1-2
CAUTION
● If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
● When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
● Be sure to use special tools when instructed.
● Make sure that all parts used in reassembly are clean, and also lubricated when specified.
● When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
● When removing the battery, disconnect the negative cable first and then positive cable. When reconnect-
ing the battery, connect the positive cable first and then negative cable, and replace the terminal cover on the
positive terminal.
● When performing service to electrical parts, if the service procedures do not require use of bat-
tery power, diconnect the negative cable at the battery.
● Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
● 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. Also, before installing these new
parts, be sure to remove any left over material from the mating surfaces.
● Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seat-
ed in its groove and securely fitted.
● Do not use self-locking nuts a few times over.
● Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil
if a thread is smeared with them.
● After reassembly, check parts for tightness and operation.
● To protect environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires.
● To protect Earth’s natural resouces, properly dispose of used vehicles and parts.
1-3 GENERAL INFORMATION
TRANSMISSION OIL
Make sure that the transmission oil you use comes under API
classification of SH, SG or SF and that its viscosity rating
is SAE 10W/30 or 10W/40. If an SAE 10W/30 or 10W/40 motor
oil is not available, select an alternate according to the right chart.
GENERAL INFORMATION 1-4
ENGINE OIL
Specification and classification: APOLLOIL BIKE-K, HYPOL HS
BRAKE FLUID
Specification and classification: DOT4
WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not
use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the sys-
tem, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts to“BREAK-IN”before subjecting the engine to maximum
stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its
early life. The general rules are as follows:
● Keep to these break-in engine speed limits:
Up to 1,000km(600miles): Less than 1/2 throttle.
● Upon reaching an odometer reading of 1,000 km you can subject the motorcycle to full throttle operation.
● Do not maintain constant engine speed for an extended period during any portion of the break-in. Try to vary the
throttle position.
1-5 GENERAL INFORMATION
EXTERIOR ILLUSTRATION
350
635
320
1,110
990
740
125
1,270
1,825
135
710
600
535
GENERAL INFORMATION 1-6
SPECIFICATIONS
ENGINE
Type Two-stroke, forced air cooled
Number of cylinder 1
Bore 41 mm (1.6 in)
Stroke 37.4 mm (1.5 in)
Piston displacement 49 ㎤ (3.0 cu.in)
Carburetor SIDE DRAFT VARIABLE VENTURI (PISTON)
Air cleaner Wet filter type
Starter system Kick/self starter
Corrected compression ratio 7.4 : 1
Intake system Reed valve
TRANSMISSION
Clutch Dry shoe, automatic, centrifugal type
Reduction ratio 2.997~0.813
Drive system V-belt drive
CHASSIS
Front suspension Telescopic type
Rear suspension Coil spring type
Caster 25。
Trail 75mm (2.95in)
Steering angle 45。(right & left)
Front tire size 110/70-12 47J
Rear tire size 120/70-12 51J
Front brake Disc
Rear brake Drum
1-7 GENERAL INFORMATION
ELECTRICAL
Ignition type “CDI”type
Ignition timing 20。B.T.D.C. at 1,000 rpm
Spark plug BR8HSA
Battery 12V 3Ah/10HR
Generator Magneto
Fuse 10A
Headlamp 15W×2
Turn signal lamp 10W×4
Tail/Brake lamp 5/10W
Speedometer lamp 1.7W×2
Oil level indicator lamp 1.7W
Turn signal indicator lamp 1.7W
CAPACITIES
Fuel tank 4.8ℓ
Engine oil tank 1.0ℓ
Transmission oil 110cc (Replace)
130cc (Overhaul)
NOTE:
The specifications are subject to change without notice.
PERIODIC MAINTENANCE
CONTENTS
BATTERY 2- 3
SPARK PLUG 2- 4
FUEL LINE 2- 5
OIL PUMP 2- 7
TRANSMISSION OIL 2- 8
BRAKES 2- 8
TIRES 2-10
STEERING 2-11
NOTE:
More frequent servicing should be performed on motorcycles that are used under severe conditions.
CHASSIS
Interval
Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Brakes Inspect Inspect - 2-9
Inspect Inspect -
Brake hose 2-9
Replace every 4 years
Inspect Inspect -
Brake fluid 2-9
Replace every 2 years
Tires Inspect Inspect - 2-10
Steering Inspect Inspect - 2-11
Front suspension Inspect - Inspect 2-11
Rear suspension Inspect - Inspect 2-12
Chassis bolts and nuts Inspect Inspect - 2-12
PERIODIC MAINTENANCE 2-2
LUBRICATION CHART
The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is
calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.
Interval
Initial and Every 4,000 km Every 8,000 km
Item
Throttle cable Motor oil -
Throttle grip - Grease
Brake cable Motor oil -
Speedometer cable - Grease
Speedometer gear box - Grease
Brake cam - Grease
Steering stem bearing Grease every 2 years or 20,000 km
WARNING
Be careful not to apply too much grease into the brake cam. If grease is on the linings, brake slippage will
result.
Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has
been operated under wet or rainy conditions.
Before lubricating each part, clean off rusty sports and wipe off grease, oil, dirt or grime.
2-3 MAINTENANCE PROCEDURE
MAINTENANCE PROCEDURE
This section describes the service procedures for
each section of the periodic maintenance.
BATTERY
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
● Remove the pillion seat for measure of battery voltage.
● Remove the battery � lead and then � lead at the
battery terminls and remove the battery.
● Using pocket tester, measure the battery voltage.
If the tester reading is less than 12.0V, recharge
the battery with a battery charger. (Refer to page 5-13)
Pocket tester : 09900-25002
Recharge
Standard charge 0.4A×5~10 Hours
Fast charge 4A×30 Minutes
CAUTION
∙W h e n r e c h a r g i n g t h e b a t t e r y r e m o v e
the battery from motorcycle.
Otherwise, regulator/rectifier unit
should be an obstacle.
∙W h e n r e c h a r g i n g t h e b a t t e r y , d o n o t
remove the caps.
∙When recharging the battery, above the
charge electric current and time should
be kept as 12V.
MAINTENANCE PROCEDURE 2-4
SPARK PLUG
NOTE:
Inspect Initial 1,000km and Every 4,000km,
Replace every 8,000km.
Neglecting the spark pulg maintenance eventually leads to
difficult starting and poor performance. If the spark plug is
used for a long period, the electrode gradually burns away
and carbon builds up along the inside part. In accordance
with the Periodic Inspection Chart, the plug should be
removed for inspection, cleaning and to reset the gap.
● Carbon deposits on the spark plug will prevent good
sparking and cause misfiring. Clean the deposits off
periodically.
2-5 MAINTENANCE PROCEDURE
CAUTION
FUEL LINE
NOTE:
Inspect Initial 1,000 km and Every 4,000 km,
Replace every four years.
NOTE:
Clean Every 3,000km and Replace Every 12,000km.
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
CAUTION
OIL PUMP
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
The engine oil is fed by the oil pump to the engine. The
amount of oil fed to it is regulated by engine speed and
oil pump control lever which is controlled by amount of
throttle opening.
Check the oil pump in the following manner to confirm
correct operation for throttle valve full closing position.
● Fix the throttle grip. (The early idling condition)
● Check whether the mark ② on the oil pump control
lever is aligned with the index mark ③ when the
throttle grip is fixed as above.
● If the marks are not aligned, loosen lock nuts ④ and ②
turn the adjuster ⑤ in or out to align the marks. ③
● After aligning the marks, tighten the lock nuts ④.
CAUTION
⑤ ④
MAINTENANCE PROCEDURE 2-8
TRANSMISSION OIL
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
BRAKES
NOTE:
Inspect Initial 1,000 km and Every 4,000 km. Middle line
Replace the hose Every four years.
Replace the brake fluid Every two years.
BRAKE PADS
Wearing condition of brake pads can be checked by
observing the limit line ① marked on the pad. When the
wear exceeds the limit mark, replace the pads with new
ones.
①
BLEEDING AIR FROM THE BRAKE FLUID CIRCUIT
Air trapped in the fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full brak-
ing performance of the brake caliper. The presence of
air is indicated by“sponginess”of the brake lever and
also by lack of braking force. Considering the danger to
which such trapped air exposes the machine and rider,
it is essential that, after remounting the brake and
restoring the brake system to the normal condition, the
brake fluid circuit be purged of air in the following man-
ner:
● Fill up the master cylinder reservoir to the upper end
of the inspection window. Replace the reservoir cap
to prevent entry of dirt.
● Attach a pipe to the caliper bleeder valve, and insert
the free end of the pipe into a receptacle.
Bleeder valve : 6~9 N∙m (0.6~0.9 kg∙m)
CAUTION
WARNING
15~25 mm
Handle the brake fluid with care: the fluid reacts
�
chemically with paint, plastics, rubber materials, etc.
REAR BRAKE
Adjust by turning the adjusting nut ① so that the play � 사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
Range
사용범위
사용범위
사용범위
사용범위
사용범위
사용범위
is 15~25 mm as shown in the illustration. 핀
핀
핀
P
핀
핀
핀in
여유가
여유가
여유가
여유가
여유가
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had
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많아진다
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조정너트
조정너트
Adjuster
조정너트
조정너트
조정너트
조정너트
조정너트 nut ①
TIRES
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
TIRE PRESSURE
If the tire pressure is too high, the motorcycle will tend to
ride stiffly and have poor traction. Conversely, if the tire
pressure is too low, stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
roadability and to prolong tire life.
2-11 MAINTENANCE PROCEDURE
CAUTION
STEERING
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
FRONT SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
REAR SUSPENSION
NOTE:
Inspect Initial 1,000 km and Every 8,000 km.
Inspect the rear shock absorber for oil leak and the
mounting rubbers including engine mountings for wear
and damage. Replace the defective part if necessary.
NOTE:
Inspect Initial 1,000 km and Every 4,000 km.
These bolts and nuts listed below are important safety parts. They must be loosened first and retightened, to the specified
torque with a torque wrench.
①
2-13 MAINTENANCE PROCEDURE
⑩
③
⑪
⑥
⑤
⑧
⑫
⑬
⑨
ENGINE
CONTENTS
ENGINE REMOVAL
②
Before taking the engine out of the frame, thoroughly
clean the engine with a suitable cleaner. The procedure
of engine removal is sequentially explained as follows.
● Remove the low leg shield.
● Remove the air cleaner by removing the mounting
bolts ① and clamp screw ②. ①
�
�
④ ②
③
ENGINE REMOUNTING
The engine can be mounted in the reverse order of
removal.
Front side
● Install the damper to the crankcase bracket as shown “UP”mark ①
in the illustration.
● With“UP”mark faced upward, install the crankcase 10mm
②
③ ①
④
ENGINE 3-4
�
�
ENGINE DISASSEMBLY
MUFFLER
● Remove the muffler by removing the nuts.
MAGNETO
● Remove the cooling fan.
● Remove the magneto rotor nut ① with the special
tool. ①
Rotor holder : 09930-40113
3-5 ENGINE
REED VALVE
● Remove the intake pipe ② with reed valve ①.
OIL PUMP
● Remove the oil pump ③.
● Remove the oil pump driven gear ④.
CYLINDER
● Remove the cylinder cowling.
● Remove the cylinder head ⑤ and cylinder ⑥.
⑥
ENGINE 3-6
PISTON
● Place a cloth beneath the piston and remove the pis-
ton circlip ① with a long nose pliers.
● Remove the piston pin ② and piston ③.
● Remove the piston pin bearing ④. ③
②
①
KICK STARTER
● Remove the kick starter lever ⑤.
● Remove the clutch cover ⑥.
⑧ ⑦
⑨
⑩
3-7 ENGINE
② ①
⑥
ENGINE 3-8
;;
;;;;
②
;;
;;
;; ;;
;;;;
①
③
②
CAUTION
⑥
3-9 ENGINE
CAUTION
�
�
CAUTION
TRANSMISSION
● Drain transmission oil.
● Remove the gear box cover ①.
● Remove the driveshaft ②. ①
②
ENGINE 3-10
● Remove the oil seal ① from the gear box cover with
the special tool.
Oil seal remover : 09913-50121
CAUTION ①
CAUTION ②
WHEEL, BRAKE
● Remove the rear axle nut ① and washer ②.
● Remove the rear wheel ③.
①
③
CENTER STAND
● Remove the return spring ②.
CRANKCASE
● Remove the crankcase securing screws.
CAUTION
Bushing
Bushing
Crankcase Crankcase
ENGINE COMPONENTS
INSPECTION AND SERVICING
BEARINGS
Wash the bearing with cleaning solvent and lubricate
with motor oil before inspecting.
Turn the inner ring and check to see that the inner ring
turns smoothly. If it does not turn lightly, quietly and
smoothly, or if noise is heard, the bearing is defective
and must be replaced with a new one.
OIL SEAL
Damage to the lip of the oil seal may result in leakage of
the fuel-air mixture or oil. Inspect for damage and be
sure to replace the damaged seal if found.
3-15 ENGINE
CRANKSHAFT
CRANKSHAFT RUNOUT
Support crankshaft by“V”blocks, with the dial gauge
rigged to read the runout as shown.
Crankshaft runout Service limit 0.08 mm
1. CLUTCH-IN INSPECTION
Warm up the motorcycle to normal operating tempera-
ture.
Remove the right frame side cover.
Connect an engine tachometer to the engine.
Seated on the motorcycle with the motorcycle on level
ground, increase the engine RPMs slowly and note the
RPM at which the motorcycle begins to move forward.
Engine tachometer : 09900-26006
CAUTION
DRIVE V-BELT
Remove the drive V-belt and check for cracks, wear and
separation. Measure the drive V-belt width with a vernier
calipers. Replace it if the drive V-belt width is less than
the service limit or any defect has been found.
Drive V-belt width Service limit 15.3 mm
CAUTION
DRIVE FACE
Inspect the V-belt contact surface of the drive faces for
wear, scratches or any abnormality. If there is some-
thing unusual, replace the drive face with a new one.
CYLINDER HEAD
Decarbon the combustion chamber.
Check the gasketed surface of the cylinder head for dis-
tortion with a straightedge and thickness gauge, taking a
clearance reading at several places.
Thickness gauge : 09900-20806
CYLINDER
Decarbon exhaust port and upper part of the cylinder,
taking care not to damage the cylinder wall surface.
PISTON
CYLINDER TO PISTON CLEARANCE
Cylinder-to-piston clearance is the difference between
piston diameter and cylinder bore diameter. Be sure to
take the maked diameter at right angles to the piston
pin. The value of elevation � is prescribed to be 15 mm
from the skirt end.
Micrometer(25~50 mm) : 09900-20202
DE-CARBONING
De-carbon the piston and piston ring grooves, as illus-
trated. After cleaning the grooves, fit the rings and rotate
them in their respective grooves to be sure that they
move smoothly.
Carbon in groove is liable to cause the piston ring to get
stuck in the groove, and this condition will lead to
reduced engine power output.
A piston whose sliding surface is badly grooved or
scuffed due to overheating must be replaced. Shallow
grooves or minor scuff can be removed by grinding with
emery paper of about # 400.
PISTON RINGS
Check each ring for end gap, reading the gap with a
thickness gauge shown in the illustration. If the end gap
is found to exceed the limit, indicated below, replace it
with a new one.
The end gap of each ring is to be measured with the
ring fitted squarely into the cylinder bore and held at the
least worn part near the cylinder bottom, as shown in
the illustration.
Thickness gauge : 09900-20806
Fix the piston ring in the piston ring groove, measure the
ring side clearance with the thickness gauge while
matching the sliding surfaces of piston and ring.
Piston ring-ring groove clearance Standard
1st 0.02~0.06 mm
2nd 0.02~0.06 mm
ENGINE 3-22
REED VALVE
When reinstalling the reed valve and stopper plate to
the body, align the both cut on the reed valve and stop-
per plate.
Apply THREAD LOCK“ 1324 ”to the stopper plate
securing screws.
Thread Lock“1324”
ENGINE REASSEMBLY
Reassembly is generally performed in the reverse order
of disassembly, but there are a number of reassembling
steps that demand or deserve detailed explanation or
emphasis. These steps will be taken up for respective
parts and components.
ell
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A valnia
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M ulti-
OIL SEALS
Fit the oil seals to the crankcase following the procedure
below.
Replace removed oil seals with new ones.
● Coat SUPER GREASE“A”to the lip of the oil seals.
Super Grease“A”
● Be sure to apply THREAD LOCK“1324”to outer
surfaces of right and left crankshaft oil seals to pre-
vent them from moving.
Thread Lock“1324”
NOTE:
Align the oil seal with edge � of the crankcase as
shown in the illustration.
3-23 ENGINE
BEARINGS
Install new bearings with the special tool.
Bearing installer : 09913-75810
Bearing installer : 09913-76010
BUSHINGS ②
Using two steel tubes of appropriate size and a vise,
press the mounting bushings ① and ② into the
crankcase holes as shown in the illustration.
NOTE:
Knurled end � should face inside. Protrusion � and �
should be in the same dimension.
ENGINE 3-24
Bushing ②
Bushing ①
Crankcase
Crankcase
CRANKSHAFT
① Crank shaft
② Crankcase RH
③ Oil seal
④ Oil seal
⑤ Oil pump drive gear
⑥ Oil pump driven gear
⑦ Oil seal
② ⑥
⑤
⑦ ④
CRANKCASE
● Wipe the crankcase mating surfaces(both
surfaces)with cleaning solvent.
● Apply BOND“1215”uniformly to the mating surface
of the left half of the crankcase, and install the dowel
pins.
BOND“1215”
● Install the two dowel pins.
● Tighten the crankcase screws securely.
● Check if the crankshaft rotates smoothly.
NOTE:
Align the oil seal with edge � of the crankcase as
shown in the illustration.
Bearing installer : 09913-85210
�
ENGINE 3-26
CENTER STAND
● Install the center stand ①. ④
● Install the shaft ②, washer ③ and cotter pin ④. ③
①
⑤
3-27 ENGINE
�
ENGINE 3-28
Slit
CAUTION
TRANSMISSION
④
③ ①
Center
Thrust
� Circlip
⑥
Rounded coner
ENGINE 3-30
①
②
⑥
3-31 ENGINE
②
ENGINE 3-32
;;
;;;;
;; ;;
;;;;
3-33 ENGINE
CAUTION ②
Take care that hit inner race of the bearing.
(Fall to ring in the bearing a case.)
CAUTION
Thrust
�
Rounded coner
Pin
④
Spacer
⑦
⑥
3-35 ENGINE
②
ENGINE 3-36
MOVABLE DRIVE
④
⑥
3-37 ENGINE
③ ④
� � �
ENGINE 3-38
�
�
�
�
KICK STARTER
3-39 ENGINE
Super Grease“A”
● Position the kick starter shaft return spring and hook
the spring end on the crankcase cover boss ①.
PISTON
Locating pin
CORRECT INCORRECT
3-41 ENGINE
● Apply engine oil on the piston pin and install the pis-
ton to the conrod.
CAUTION
②
3-43 ENGINE
④
②
③
MAGNETO
①
ENGINE 3-44
MUFFLER
● Tighten the exhaust pipe bolts and muffler mounting
bolts to the specified torque.
Exhaust pipe bolt : 8~12 N∙m (0.8~1.2 kg∙m)
Muffler mounting bolt : 18~28 N∙m (1.8~2.8 kg∙m)
FUEL SYSTEM
CONTENTS
CARBURETOR 4- 1
REMOVAL 4- 1
DISASSEMBLY 4- 2
INSPECTION 4- 4
4- 5
REASSEMBLY AND REMOUNTING
4
FUEL TANK 4- 7
REMOVAL 4- 7
CLEANING 4- 8
REMOUNTING 4- 8
OIL PUMP 4- 8
FUEL PUMP 4- 9
4-1 FUEL SYSTEM
CARBURETOR
REMOVAL
● Open the seat, and separate the helmet box by
removing the four lock nuts.
③ ④
⑤
DISASSEMBLY
● Remove the thermoelement assembly.
4-3 FUEL SYSTEM
CAUTION
③
②
⑤
FUEL SYSTEM 4-4
CAUTION
②
When removing the pilot air
screw, record the revolu-
tions until tighten completly.
① ②
③,④
③
INSPECTION
Check following items for any damage or clogging. Inspect the valve surface for worn
● Pilot jet
● Main jet
● Pilot air screw
● Needle jet air bleeding hole Foreign matter
● Float
● Gasket
● Pilot outlet and bypass holes
③ ④ ① ②
⑤ ⑥
● Install the air vent hose ①, oil hose ② and fuel hose ③.
③
②
FUEL TANK
①
REMOVAL
● Remove the low leg shield ①.
CLEANING
Dust from the fuel tank tends to bulid up in the fuel filter
①
which, when the fuel filter has been neglected for a long
period, inhibits the flow of fuel.
Remove the dust from, the fuel filter ① using com-
pressed air.
REMOUNTING
Remount the fuel tank in the reverse of removal.
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OIL PUMP
AIR BLEEDING
Whenever evidence is noted of some air having leaked ①
into the oil pipe from the oil tank in a machine brought in
for servicing, or if the oil pump has to be removed for
servicing, be sure to carry out an air bleeding operating
with the oil pump in place before returning the machine
to the user.
To bleed air, hold the machine in standstill condition.
Loosen the air bleeding screw ① to let out air and after
making sure that the trapped air has all been bled, tight-
en the air bleeding screw completely.
4-9 FUEL SYSTEM
CAUTION
FUEL PUMP
REPLACE
● Remove the rear shock absorber, and support the
center stand by a 70 mm wooden block.
● Open the seat, and remove the trunk by loosing the
four nuts.
● Remove the one lock nut of fuel pump.
① Disconnect the inlet hose.
CAUTION
CONTENTS
ELECTRICAL PARTS 5- 1
IGNITION/CHARGING SYSTEM 5- 2
IGNITION COIL 5- 2 5
STATOR COILS 5- 3
REGULATOR/RECTIFIER 5- 4
STARTER SYSTEM 5- 4
THERMOELEMENT 5- 9
BATTERY 5-11
5-1 ELECTRICAL SYSTEM
ELECTRICAL PARTS
① Ignition coil ①
② Thermolement assembly
③ Fuel level gauge
④ Oil level gauge
Speedometer
cable
Brake
hose
④
ELECTRICAL SYSTEM 5-2
IGNITION/CHARGING SYSTEM
Stator Regulator/Rectifier
lgnition CDI
coil unit
Spark Lighting Battery
plug switch 12V 3AH
H/L T/L M/L (MF)
Engine stop
switch
IGNITION COIL
● Check the ignition coil with electro tester.
● Test the ignition coil for sparking performance. Test
connection is as indicated. Make sure that the three-
needle sparking distance is at least 8mm. Test it at
least for 5 minutes.
Electro tester : 09900-28106
Yellow Red(+)
Spark
Black
Black(-)
5-3 ELECTRICAL SYSTEM
C.D.I. UNIT
● Using the pocket tester (R 1 range), measure the Ground
resistance between the lead wire in the following table. Plug cap
Pocket tester : 09900-25002
Unit : ㏀
� Probe of tester to :
B/Y W/BL B/R B/W W Br
B/Y ∞ ∞ ∞ ∞ ∞
� Probe of tester to :
REGULATOR/RECTIFIER
● Disconnect the coupler.
● Using the pocket tester(×1㏀ Range), measure the
resistance between the terminals as shown in the fol-
lowing table. If the resistance checked is incorrect,
replace the regulator/rectifier.
1 1 502~ 260 ∞3 ∞ 4
2 50 ~ 230 ∞ ∞
3 ∞ ∞ ∞
4 ∞ ∞ 10 ~ 100
STARTER SYSTEM
The starter system is shown in the diagram below: namely, the starting motor, starter relay, starter switch and battery.
Depressing the starter switch (on the right handlebar switch box) while squeezing the front or rear brake lever energizes
the relay, causing the contact points to close which connects the starting motor to the battery.
Starter relay
R R/W
Fuse
Y/G
IG switch Starter switch
Point
Starter
motor
Brake switch
W/B
Battery
5-5 ELECTRICAL SYSTEM
COMMUTATOR
If the commutator surface is dirty, starting performance
will decrease. Polish the commutator with #400 or simi-
lar fine emery paper when it is dirty. After polishing wipe Segment
①
the commutator with a clean dry cloth.
Measure the commutator under cut ①.
Commutator under cut Service limit 4 mm
ELECTRICAL SYSTEM 5-6
ARMATURE COIL
Using the pocket tester, check the coil for open and
ground by placing probe pins on each commutator seg-
ment and rotor core (to test for ground)and on any two
segments at various places (to test for open), with the
brushes lifted off the commutator surface.
If the coil is found to be open-circuited or grounded,
replace the armature. Continuous use of a defective
armature will cause the starting motor to suddenly fail.
O B/W
Y/B
Fuel tank
IG switch
Battery
5-9 ELECTRICAL SYSTEM
THERMOELEMENT
R
B/R
Y/W R/W
� �
Battary Regurator/Rectifier Magneto
PTC
ELECTRICAL SYSTEM 5-10
INSPECTION
● Disconnect the thermoelement coupler ①.
● Connect the thermoelement coupler ① to a 12V bat- ①
tery and touch the thermoelement ② to check the
temperature being raised. ②
The thermoelement ② should become heated to a
temperature more than that of human body within
five minutes. If not, replace with new one.
CAUTION
SWITCHES INSPECTION
STARTER SWITCH
Inspect each switch for continuity with the pocket tester W/B Y/G
referring to the chart. If it is found any abnormality,
ON ○ ○
replace the respective switch assembly with new one.
OFF
Pocket tester : 09900-25002
OFF
ON ○ ○
C ○ ○ ○ ○ ○
5-11 ELECTRICAL SYSTEM
BATTERY
BATTERY
Type YT4L-BS Filter
Cap Safety valve
Capacity 12V, 3AH/10HR
Standard electrolyte S.G. 1.32(at 20℃)
INITIAL CHARGING
FILLING ELECTROLYTE
● Remove the aluminum tape ① sealing the battery
electrolyte filler holes ②.
CAUTION
NOTE:
If no air bubbles are coming up from a filler port, tap the
bottom of the two or three times.
Never remove the container from the battery.
CAUTION
NOTE:
Initial charging for a new battery is recommended if two
years have elapsed since the date of manufacture.
(Minutes)
Time
RECHARGING OPERATION
● Using the pocket tester, check the battery voltage. If
the voltage reading is less than 12.0V(DC), recharge
the battery with a battery charger.
● When recharging the battery, remove the battery
from the motorcycle.
● Do the battery by standard charging usually.
CONTENTS
FRONT WHEEL 6- 1
FRONT BRAKE 6- 7
STEERING 6-18
6
6-1 CHASSIS
FRONT WHEEL
③
6-3 CHASSIS
Drive out the both bearing with the special tool in the fol-
lowing procedures.
● Insert the adapter into the bearing.
● After inserting the wedge bar from the opposit side,
lock the wedge bar in the slit of the adapter.
● Drive out the bearing by knocking the wedge bar.
CAUTION
INSPECTION
WHEEL RIM
Make sure that the wheel rim runout does not exceed
the service limit when checked as shown.
An excessive runout is usually due to worn or loose
wheel bearings and can be reduced by replacing the
bearings. If bearing replacement fails to reduce the
runout, replace the wheel.
TIRE
Inspect the tires for wear and damage, and check the
tire tread depth as shown. Replace a badly worn or dam-
aged tire. A tire with its tread worn down to the limit(in
terms of tread depth)must be replaced.
CHASSIS 6-4
WHEEL BEARING
● Apply SUPER GREASE“A”to the bearings before ell
S h
installing. A valnia
3
Super Grease“A”
ase
CAUTION
Clearance
Bearing(L) Bearing(L)
6-5 CHASSIS
OIL SEAL
● Install the oil seal ① with the special tool.
DISC PLATE
● Install the disc plate and tighten them to the specified
torque.
Front brake disc bolt : 18 ~ 28 N∙m(1.8 ~ 2.8 kg∙m)
�
CHASSIS 6-6
CAUTION
FRONT WHEEL
● Tighten the front axle nut to the specified torque.
FRONT BRAKE
CAUTION
Never re-use the brake fluid left over from the last ②
servicing and stored long periods. ③
CALIPER INSPECTION
Inspect the caliper cylinder bore wall for nicks, scratches
or other damage.
Inspect piston for damage and wear.
CALIPER REASSEMBLY
Reassemble and remount the caliper in the reverse
order of removal and disassembly, and also carry out the
following steps.
{
CAUTION
{
fluid before reassembly. Never use cleaning sol-
vent or gasoline to wash them. Apply brake fluid
to the caliper bore and piston to be inserted into
the bore.
Silicone Grease
SPECIFIED TORQUE
Item N∙m kg∙m ①
① 18 ~ 28 1.8 ~ 2.8
② 20 ~ 25 2.0 ~ 2.5 ②
WARNING
CAUTION
⑦ ⑤
6-13 CHASSIS
Wash the master cylinder components with fresh spring Piston Circlip
brake fluid before reassembly. Never use clean- Primary cap Second cap
ing solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all the
internals to be inserted into the bore.
CAUTION Upside
Handlebar
Clearance
CHASSIS 6-14
FRONT FORK
● Loosen the front fork bolt, then draw out the fork
spring.
● Loosen the front fork lower clamp bolts.
①
CHASSIS 6-16
①
②
CAUTION
INSPECTION
● Inspect pipe seat for wear and damage.
FORK SPRING
● Measure the fork spring free length.
FORK OIL
● For the fork oil, be sure to use a front fork oil whose
viscosity rating meets specification below.
Up side
Fork oil type TELLUS # 37
Capacity 50 cc(One side)
CUSHION SPRING
● When installing the front fork spring, the close end
should position upside.
CHASSIS 6-18
STEERING
REMOVAL AND DISASSEMBLY
● Remove the handlebar cover.
● Remove the handlebar by removing the clamp bolt ①
and set bolt ②.
①
②
⑦
6-19 CHASSIS
INSPECTION
Inspect the removed parts for the following abnormali-
ties.
● Bearing race wear and brinelling.
● Worn and damaged steel balls.
● Distortion of steering stem or handlebar.
INNER RACE
● Press in the upper and lower inner races with the spe-
cial tool.
Steering race installer : 09941-34513
STEEL BALL
● Apply SUPER GREASE“ A ”when installing the
upper and lower steel balls.
Super Grease“A”
INSPECTION
REAR BRAKE DRUM
Measure the brake drum I.D. to determine the extent of
wear and, if the limit is exceeded by the wear noted,
replace the drum. The value of this limit is indicated
inside the drum.
Rear brake drum I.D Service limit 100.7 mm
BRAKE SHOE
Using a vernier calipers, measure the brake shoe out-
side diameter at the place as shown in the photo. If the
measurement is less than the limit, replace the brake
shoe.
Brake shoe lining for thickness Service limit 96 mm
CAUTION
WHEEL
Refer to page 6-3.
TIRE
Refer to page 6-4.
CONTENTS
TROUBLESHOOTING 7- 1
SPECIAL TOOLS 7- 6
7
7-1 SERVICING INFORMATION
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Dirty or heavy 1. Too much engine oil to the engine. Check oil pump.
exhaust smoke. 2. Use of incorrect engine oil. Change.
CARBURETOR
Complaint Symptom and possible causes Remedy
Trouble with 1. Starter jet is clogged. Clean.
starting. 2. Air leaking from a joint between starter body and carburetor. Check starter body and carburetor
for tightness, and replace gasket.
3. Air leaking from carburetor’s joint or vacuum hose joint. Check and replace.
4. Starter plunger is not operating properly. Check and replace.
Idling or low-speed 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
trouble. 2. Air leaking from carburetor’s joint, vacuum pipe joint, or starter. Clean and replace.
3. Pilot outlet is clogged. Check and clean.
4. Starter plunger is not fully closed. Check and replace.
Medium or high- 1. Main jet or main air jet is clogged. Check and clean.
speed trouble. 2. Needle jet is clogged. Check and clean.
3. Fuel level is improperly set. Check and replace.
4. Throttle valve is not operating properly. Check throttle valve for operation.
5. Fuel filter is clogged. Check and clean.
ELECTRICAL
Complaint Symptom and possible causes Remedy
Spark plug 1. Spark plug too hot. Replace by hot type plug.
electrodes overheat 2. The engine overheats. Turn up.
or burn. 3. Spark plug loose. Retighten.
4. Mixture too lean. Adjust carburetor.
5. Not enough engine oil. Check oil pump.
Magneto does not 1. Open or short in lead wires, or loose lead connections. Repair, replace or retighten.
charge. 2. Shorted, grounded or open magneto coil. Replace.
3. Shorted or open regulator/rectifier. Replace.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or Repair, or retighten.
but charging rate is loosely connected at terminal.
below the specific- 2. Grounded or open-circuited stator coils of magneto. Replace.
ations. 3. Defective regulator/rectifier. Replace.
4. Defective cell plates in the batttery. Replace the battery.
Ustable charging. 1. Lead wire insulation frayed due to vibration, Repair or replace.
resulting in intermittent shorting.
2. Magneto coil internally shorted. Replace.
3. Defective regulator/rectifier. Replace.
BATTERY
Complaint Symptom and possible causes Remedy
Battery runs down 1. The charging method is not correct. Check the magneto and regulator/rec-
quickly. tifier circuit connections, and make
necessary adjustments to obtain spe-
cified charging operation.
2. Cell plates have lost much of their active material as a result Replace the battery, and correct
of over-charging. the charging system.
3. A short-circuit condition exists within the battery due to Replace the battery.
excessive accumulation of sediments caused by the incorrect
electrolyte.
4. Battery is too old. Replace the battery.
Reversed battery 1. The battery has been connected the wrong way round in the Replace the battery and be sure to
polarity. system, so that it is being charged in the reverse direction. connect the battery properly.
CHASSIS
Complaint Symptom and possible causes Remedy
Handling feels 1. Steering stem nut overtightened. Adjust.
too heavy. 2. Broken bearing/race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust.
Wobbly handle. 1. Loss of balance between right and left front suspension. Replace.
2. Distorted front axle or crooked tire. Replace.
BRAKES
Complaint Symptom and possible causes Remedy
Insufficient brake 1. Leakage of brake fluid from hydraulic system. Repair or replace.
power. 2. Worn pad. Replace.
3. Oil adhesion on engaging surface of pad. Clean disc and pads.
4. Worn disc. Replace.
5. Air entered into hydraulic system. Bleed air.
6. Worn shoe. Replace.
7. Friction surfaces of shoes are dirty with oil. Replace.
8. Excessively worn drum. Replace.
9. Too much brake lever play. Adjust.
Brake squeaking. 1. Carbon adhesion on pad surface. Repair surface with sandpaper.
2. Tilted pad. Modify and fitting.
3. Damaged wheel bearing. Replace.
4. Worn pad. Replace.
5. Foreign substance entered into brake fluid. Replace brake fluid.
6. Clogged return ports of master cylinder. Disassemble and clean master cylinder.
7. Brake shoe surface glazed. Repair surface with sandpaper.
8. Loose front-wheel axle or rear-wheel axle nut. Tighten to specified torque.
9. Worn shoe. Replace.
7-5 SERVICING INFORMATION
SPECIAL TOOLS
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09900-00401 09900-20205
Micrometer
“L”type hexagon wrench set (1/100mm, 0-25mm)
09900-00410 09900-20508
Cylinder gauge set
Hexagon wrench set (1/100mm, 40-80mm)
09900-05108 09900-20602
Dial gauge
Snap ring pliers (1/100mm, 1mm)
09900-06105 09900-20605
Dial calipers
Snap ring pliers (1/100mm, 10-34mm)
09900-06107 09900-20606
Dial gauge
Snap ring pliers (1/100mm, 10mm)
09900-09003 09900-20701
Impact driver set Magnetic stand
09900-20102 09900-20806
Vernier calipers Thickness gauge
09900-20202 09900-21304
Micrometer
(1/100mm, 25-50mm) V-block set
09900-20203 09900-21602
Micrometer
(1/100mm, 50-75mm) CCI Oil gauge
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09900-22301 09913-60710
Plastic gauge Bearing remover
Measure clearance of crankshaft thrust Remove bearing with the rotor remove sliding shaft
09900-22401 09913-75520
Small bore gauge
(10-18mm) Bearing installer
09900-25002 09913-75821
Pocket tester Bearing installer
09900-26006 09913-75830
Tachometer Bearing installer
Measure rotational frequency of engine Install rear axle shaft oil seal
09900-28107 09913-76010
Electro tester Bearing installer
09910-20115 09915-63310
Conrod holder Compression gauge adapter
09910-32812 09915-64510
Crankshaft installer Compression gauge
09913-14541 09916-84511
Fuel level gauge set Tweezers
09913-50121 09920-13120
Oil seal remover Crankcase separater
Special tools Part Number∙Part Name∙Description Special tools Part Number∙Part Name∙Description
09921-20200 09930-30163
Bearing remover (10mm) Rotor remover
Remove oil seal or bearing Attached to the top of sliding shaft when removing rotor
09921-20210 09930-32420
Bearing remover (12mm) Rotor holder
09922-55131 09930-40113
Bearing installer Rotor holder
Used to drive bearing in Widely used to lock rotary parts such as a flywheel magneto
09923-73210 09940-10122
Bearing remover (17mm) Clamp wrench
Remove bearing with the rotor remove sliding shaft A hook wrench to adjust the steering head of motorcycle
09923-74510 09940-34520
Bearing remover (20~35mm) T-handle
Remove bearing with the rotor remove sliding shaft Remove and remounting front fork oil cylinder
09924-84521 09940-34561
Bearing installer Front fork assembling tool attachment“D”
09925-98221 09940-50113
Bearing installer Front fork oil seal installer
09930-10121 09941-34513
Spark plug socket wrench set Bearing installer
09930-30102 09941-50110
Rotor remove sliding shfat Wheel bearing remover
09943-74111
Front fork oil level gauge
09943-88211
Bearing remover
09951-76010
Bearing installer
TIGHTENING TORQUE
ENGINE
ITEM N∙m kg∙m
Magneto rotor nut 35 ~ 45 3.5 ~ 4.5
Muffler mounting bolt 18 ~ 28 1.8 ~ 2.8
Exhaust pipe nut 8 ~ 12 0.8 ~ 1.2
Spark plug 25 ~ 30 2.5 ~ 3.0
Cylinder head nut 8 ~ 12 0.8 ~ 1.2
Engine mounting bolt 40 ~ 60 4.0 ~ 6.0
Engine mounting bracket bolt 48 ~ 72 4.8 ~ 7.2
Oil drain plug 9 ~ 15 0.9 ~ 1.5
Oil level bolt 9 ~ 15 0.9 ~ 1.5
Oil pump bolt 3~5 0.3 ~ 0.5
Clutch shoe nut 40 ~ 60 4.0 ~ 6.0
Clutch housing nut 40 ~ 60 4.0 ~ 6.0
Kick starter driven nut 40 ~ 60 4.0 ~ 6.0
Kick starter lever bolt 8 ~ 12 0.8 ~ 1.2
7-11 SERVICING INFORMATION
CHASSIS
ITEM N∙m kg∙m
Rear brake cam lever bolt 6~9 0.6 ~ 0.9
Rear shock absorber bolt 22 ~ 35 2.2 ~ 3.5
Rear axle nut 60 ~ 90 6.0 ~ 9.0
Steering stem lock nut 60 ~ 100 6.0 ~ 10.0
Front brake disc bolt 18 ~ 28 1.8 ~ 2.8
Front brake master cylinder bolt 8 ~ 12 0.8 ~ 1.2
Front brake air bleeder valve 6~9 0.6 ~ 0.9
Front brake caliper mounting bolt 18 ~ 28 1.8 ~ 2.8
Front brake hose union bolt 20 ~ 25 2.0 ~ 2.5
Front axle nut 33 ~ 52 3.3 ~ 5.2
Front fork bolt 35 ~ 55 3.5 ~ 5.5
Handlebar set bolt 22 ~ 28 2.2 ~ 2.8
Handlebar clamp nut 48 ~ 52 4.8 ~ 5.2
SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit : mm
ITEM STANDARD LIMIT
ITEM STANDARD
CLUTCH Unit : mm
TRANSMISSION Unit : mm
CARBURETOR Unit : mm
ITEM SPECIFICATION
Carburetor type VM14
Main bore size ф 14
ELECTRICAL Unit : mm
ITEM SPECIFICATION NOTE
Ignition timing 20�at 1,000 rpm
Type BR8HSA
Spark plug
Gap 0.6 ~ 0.7
WATTAGE Unit : W
ITEM SPECIFICATION
Head lamp bulb 15W × 2
Tail/Brake lamp bulb 5 / 10W
Turn signal lamp bulb 10W × 4
Turn signal / Oil level check light pilot lamp 1.7W / 17W
Speedometer lamp bulb 1.7W × 2
CAUTION
BRAKE+WHEEL Unit : mm
ITEM STANDARD LIMIT
Front 5 ~ 20
Brake lever play
Rear 15 ~ 25
Brake drum I.D Rear 100 100.7
Brake lining thickness Rear 99.2 96
Brake disc plate thickness Front 4.0 ± 0.2 3.5
Brake disc plate runout Front 0.30
Master cylinder bore I.D. Front 11.000 ~ 11.043 11.055
Master cylinder piston diam. Front 10.957 ~ 10.984 10.945
Brake caliper I.D. Front 30.230 ~ 30.306 30.315
Brake caliper piston diam. Front 30.150 ~ 30.200 30.140
Axial 3.0
Wheel rim runout
Radial 3.0
Axle shaft runout Front 0.25
Front 110/70-12 47J
Tire size
Rear 120/70-12 51J
Front 1.6
Tire tread depth
Rear 1.6
7-17 SERVICING INFORMATION
SUSPENSION Unit: mm
ITEM STANDARD LIMIT
Front fork stroke 75
Front fork spring length(Free condition) 290.9
Front fork oil specification TELLUS # 37
Front fork oil capacity(One side) 50 cc
Rear wheel travel 66
TIRE PRESSURE
COLD INFLATION SOLO RIDING DUAL RIDING
TIRE PRESSURE kPa kg/㎠ kPa kg/㎠
FRONT 123 1.25 172 1.75
REAR 196 2.00 221 2.25
FUEL + OIL
ITEM SPECIFICATION NOTE
Gasoline used should be graded 85 ~ 95 octane or higher.
Fuel type An unleaded gasoline is recommended.
Fuel tank capacity 4.8 ℓ
REAR BRAKE
Rear turnsignal L
Battery cover
Rear turnsignal
R/L
Switch thermo
Starter relay
Fuse case
09407-22402 09407-22402
Rear turnsignal R Starter motor
Lamp assy, Tail & Stop 09407-22402
Rear turnsignal R/L magneto
Clamp
Engine earth
Ignition coil
Rear brake
cable
Brake cable
CABLE
Front
Fender, Front upper
Switch thermo
D
Ignition coil
B
Shield leg lower rear
Rear turnsignal RH/LH Heater carburetor Clamp Clamp
Harness
Fuel tank
Starter motor
REAR TURNSIGNAL LAMP Regulator
Engine earth Front turnsignal RH/LH
Starter motor Throttle cable
magneto Head lamp
Front Rear brake
Frame
cable
Harness
Throttle cable
Frame earth
Speedometer
Rear brake cable
cable Harness Brake
hose
VIEW B
VIEW D
VIEW C
Speedometer Handle switch RH
Starter Lighting Oil gauge Carburetor, Heater
Regulator
Front brake switch Fuel gauge Thermo switch
Horn Turnsignal relay P.T.C
Frame earth
WIRING DIAGRAM
Front turnsignal RH
Rear turnsignal RH
Head lamp
Rear turnsignal LH
Front turnsignal LH
Turnsignal
Rear brake Magneto C.D.I unit
Spark plug
Handle switch LH Ignition switch switch
Rear turnsignal 10
Front turnsignal 10
WIRE COLOR
Oil pilot lamp 1.7
turnsignal pilot lamp 1.7 B : Black Lg : Light green Y : Yellow RB : Red with Black tracer
Illumination 1.7×2
Br : Brown O : Orange BG : Black with Green tracer RW : Red with White tracer
Tail 5
Rear combination G : Green R : Red BW : Black with White tracer WB : White with Black tracer
Stop 10
Head lmap 15×2 Gr : Gray Sb : Light blue BR : Black with Red tracer WR : White with Red tracer
Lamp DEST L : Blue W : White LW : Blue with White tracer YB : Yellow with Black tracer
SERVICING INFORMATION 7-20
Prepared by