D01 - Service Manual - ENG - Vers 2015 01 - Klein

REPAIR MANUAL
D01 - TRIGGER 50 Vers. 2015_01

2
INTRODUCTION
It is important that you read this repair manual carefully before the start of work.
Only use GENERIC/ KSR spare parts.
KSR Motot Motorcycles is a registered brand by KSR Group GmbH.
This vehicle can only fulfil the demands placed on it if the service work is made by qualified experts and in accordance
with the service schedule.
The repair manual was written to correspond to the current state of this model.
We reserve the right to make changes in this manuals in the interest of technical advancements and improvements
without a notice.
It is recommended that repair work will be done by a fully educated mechanic.
We will not provide descriptions of general workshop methods, safety rules that necessary in a workshop.
All specifications refers to the current state and are nonbinding. KSR Group GmbH specifically reserves the right to
modify the information in this manual without notice and without specifying reasons.
KSR Group GmbH accepts no liability deviations from illustrations and descriptions or misprints and other errors.
The models in this manual partly contain special equipment that does not belong to the regular scope of delivery fur-
ther the illustrations and pictures are symbolic images, and may differ from the actual components.
© 2012 by KSR Group GmbH, Krems Austria

All rights reserved
Reproduction of this manual is permitted only with the express written permission of the copyright owner.
Within the meaning of the international quality management standard ISO 9001, KSR Group GmbH uses quality as-
surance processes that lead to the maximum possible quality of the products.
KSR Group GmbH

A-3500 Krems, Austria
3
INDEX
IMPORTANT NOTES 6 REAR BRAKE HOSE REPLACEMENT 37
FRONT BRAKE LEVER ADJUSTMENT 38
LOCATION OF SERIAL NUMBERS REAR BRAKE LEVER ADJUSTMENT 38
VIN (VEHICLE IDENTIFICATION NUMBER)
AND FRAME PLATE 7 DRIVE CHAIN
ANTI TEMPERING LABEL 7 DRIVE CHAIN SLACK INSPECTION 39
ENGINE NUMBER 7 DRIVE CHAIN SLACK ADJUSTMENT 39
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7 DRIVE CHAIN LUBRICATION 39
DRIVE CHAIN WEAR INSPECTION 40
GENERAL SPECIFICATIONS
VEHICLE SPECIFICATION 8 SUSPENSION
SPECIFIC TIGHTENING TORQUE 10 FRONT FORK OPERATION INSPECTION 40
GENERAL TIGHTENING TORQUE 11 FRONT FORK OIL LEAK INSPECTION 40
REAR SHOCK OPERATION INSPECTION 41
SPECIAL TOOLS REAR SHOCK OIL LEAK INSPECTION 41
SPECIAL TOOLS 12
STEERING
1. PERIODIC MAINTENANCE STEERING PLAY INSPECTION 41
STEERING BEARING LUBRICATION 42
PERIODIC MAINTENANCE CHART
CHECKLIST OF CONSTANT MAINTENANCE 15 ELECTRICAL SYSTEM
BATTERY INSPECTION/ CHARGING 43
IMPORTANT PREPARATION REFERENCES FUSES 44
IMPORTANT PREPARATION REFERENCES 18 LIGHT AND SWITCHES OPERATION INSPECTION 44
HEADLIGHT AIMING INSPECTION 45
FUEL SYSTEM
AIR CLEANER 21 2. REPAIR AND DIAGNOSTIC
CHANGING INTERVALS 21
THROTTLE WIRE INSPECTION/ ADJUSTMENT 21 CHASSIS
IDLE ADJUSTMENT 22 EXPLODED VIEW / PART LOCATION - FRAME 47
CARBURETTOR ADJUSTMENT 22 EXPLODED VIEW / PART LOCATION - REAR
FUEL HOSE INSPECTION 22 SWING ARM 48
FUEL FILTERS CLEANING 23 EXPLODED VIEW / PART LOCATION - SEAT 48
ENGINE FUEL SYSTEM

ENGINE OIL LEVEL INSPECTION 23 EXPLODED VIEW / PART LOCATION - FUEL SYSTEM 50
ENGINE OIL LEVEL SENSOR INSPECTION 24 SPECIFICATION 51
OIL PUMP INSPECTION 24
OIL PUMP ADJUSTMENT 26 CARBURETTOR
TRANSMISSION OIL LEVEL INSPECTION 27 EXPLODED VIEW / PART LOCATION - CARBURETTOR 52
SPARK PLUG INSPECTION 27 CARBURETTOR REMOVAL 53
SPARKPLUG IMAGES AND ANALYSIS 28 CHOKE/ CABLE REMOVAL 53
SPARK PLUG REPLACEMENT 28 CARBURETTOR UPPER COVER REMOVAL 54
CYLINDER PRESSURE INSPECTION 28 CARBURETTOR ADJUSTMENT 54
CLUTCH FUEL SUPPLY

CLUTCH CABLE FREE PLAY ADJUSTMENT 29 FUEL SUPPLY INSPECTION 54
ADJUSTING THE CLUTCH CABLE FREE PLAY FUEL TANK REMOVAL 55
ON THE ENGINE SIDE 29 FUEL COCK 56
CLUTCH ADJUSTMENT 30
ENGINE
WHEELS EXPLODED VIEW / PART LOCATION - CYLINDER/
AIR PRESSURE INSPECTION 30 CYLINDER COVER 57
WHEEL BEARING AND WHEEL AXLE EXPLODED VIEW / PART LOCATION - CRANK
DAMAGE INSPECTION 31 ASSEMBLY 58
EXPLODED VIEW / PART LOCATION - CRANKCASE 59
BRAKES SPECIFICATION 60
BRAKE FLUID LEAK INSPECTION FRONT 31 TROUBLESHOOTING 61
BRAKE FLUID LEAK INSPECTION REAR 31 ENGINE OVERHAUL/ REMOVAL 62
BREAK OPERATION INSPECTION FRONT 31 ENGINE PREPARATION 62
BREAK OPERATION INSPECTION REAR 32 ENGINE REMOVAL 62
BRAKE FLUID LEVEL INSPECTION FRONT 32
BRAKE FLUID LEVEL INSPECTION REAR 32 ENGINE TOP END
FRONT BRAKE PADS INSPECTION 33 CYLINDER COVER REMOVAL 63
REAR BRAKE PADS INSPECTION 33 CYLINDER REMOVAL 63
FRONT BRAKE DISC INSPECTION 34 PISTON REMOVAL 63
REAR BRAKE DISC INSPECTION 35 OIL PUMP REMOVAL 64
FRONT BRAKE LEVER/ MASTER BRAKE WATER PUMP REMOVAL 64
CYLINDER REPLACEMENT 35 CRANKCASE (RIGHT) REMOVAL 64
FOOT BRAKE LEVER/ MASTER BRAKE CLUTCH REMOVAL 65
CYLINDER REPLACEMENT 36 CRANKSHAFT GEAR AND MAIN SHAFT GEAR REMOVAL 66
FRONT BRAKE CALLIPER REPLACEMENT 36 MEMBRANE 66
REAR BRAKE CALLIPER REPLACEMENT 36 SPROCKET REMOVAL 66
FRONT BRAKE HOSE REPLACEMENT 37 CRANKCASE COVER (LEFT) REMOVAL 67
4
INDEX
STARTER REMOVAL 67 STEERING
STARTER GEAR REMOVAL 67 EXPLODED VIEW - PART LOCATION / STERRING 107
STATOR REMOVAL 67 HANDLEBAR REPLACEMENT 108
CRANKCASE SEPARATION 68 CLUTCH LEVER REPLACEMENT 109
CRANKSHAFT REMOVAL 68 BRAKE LEVER REPLACEMENT 110
TRANSMISSION DISASSEMBLY 69
INPECTION OF TRANSMISSION AND GEAR SHIFT EXHAUST
MECHANISM 70 EXHAUST REPLACEMENT 110
EXPLODED VIEW / PART LOCATION - PRIMARY
SHAFT ASSY/ SECONDARY SHAFT ASSY 71 SECONDARY AIR SYSTEM
EXPLODED VIEW / PART LOCATION - SHIFT SECONDARY AIR SYSTEM INSPECTION 112
MECHANISM 72
EXPLODED VIEW / PART LOCATION - REDUCTION ELECTRICAL SYSTEM
GEAR 73 WIRING DIAGRAM 114
INSPECTION OF TRANSMISSION AND SHIFT LOCATION - ELECTRICAL SYSTEM 115
MECHANISM 74 LOCATION - LIGHTS / INSTRUMENTS SWITCHES 116
TRANSMISSION ASSEMBLING 75 SPECIFICATION 117
CRANKSHAFT INSPECTION 76
TOP END PARTS INSPECTION 78 FUSES
PISTON INSTALLATION 80 FUSE REPLACEMENT 118
CYLINDER INSTALLATION 81 SPECIFICATION 118
CYLINDER COVER INSTALLATION 81 TROUBLESHOOTING 118
LEFT CRANKCASE ASSEMBLING 82
SPROCKET INSTALLATION 83 BATTERY
MEMBRANE INSPECTION 83 BATTERY GENERAL INFORMATION 118
MEMBRANE INSTALLATION BATTERY REMOVAL 119
RIGHT CRANKECASE ASSEMBLING 83 BATTERY AND CHARGING SYSTEM 119
CLUTCH INSPECTION 84
EXPLODED VIEW / PART LOCATION CLUTCH 85 CHARGING SYSTEM
CLUTCH ASSEMBLING 86 CHARGING SCHEME 120
OUTWARD RELEASE LEVER ADJUSTMENT 87 CHARGING PERFORMANCE TEST 120
ACTUATING LEVER INSPECTION 87 REGULATOR - RECTIFIER INSPECTION 121
ACTUATING LEER ASSEMBLING 87 GENERATOR CHARGING COIL 121
RIGHT CRANKCASE ASSEMBLING 87
ACTUATING LEVER ADJUSTMENT 88 IGNITION SYSTEM
EXPLODED VIEW / PART LOCATION - OIL PUMP 89 IGNITION SYSTEM 122
INSPECTION OF THE OIL PUMP 89 PREPARATORY DATA 122
OIL PUMP ASSEMBLING 89 SPECIFICATION 123
LUBRICATION SCHEME 90 FAULT DIAGNOSIS 123
COOLING SYSTEM SCHEME 91 IGNITION SYSTEM INSPECTION 124
WATER PUMP INSPECTION 91 PRIMARY VOLTAGE OF IGNITION COIL 124
WATER PUMP ASSEMBLING 91 TRIGGER (PICK UP) 124
TRIGGER INSPECTION 125
WHEELS AND TIRES CDI ASSEMBLY 125
EXPLODED VIEW / PART LOCATION - FRONT WHEEL 92 IGNITION COIL REMOVAL 125
EXPLODED VIEW / PART LOCATION - REAR WHEEL 93 PRIMARY COIL INSPECTION 125
WHEELS (RIMS) 94 SECONDARY COIL INSPECTION 126
TIRES 94
WHEEL BEARING REPLACEMENT FRONT WHEEL 94 STARTING SYSTEM
WHEEL BEARING REPLACEMENT REAR WHEEL 95 STARTING DIAGRAM 126
WHEEL BEARING INSPECTION 95 FAULT DIAGNOSIS 127
WHEEL AXLE INSPECTION 95 STARTING MOTOR 127
RIM INSPECTION 95 STARTING MOTOR INSPECTION 127
STARTING RELAY 127
BRAKES STARTING RELAY ACTUATION INSPECTION 127
EXPLODED VIEW / PARTLOCATION - FRONT BRAKE 96 STARTING RELAY VOLTAGE INSPECTION 128
EXPLODED VIEW / PART LOCATION - REAR BRAKE 97
BRAKE LEVERS / FRONT BRAKE LEVER 98 LIGHTNING SYSTEM
BRAKE LEVERS / REAR BRAKE PEDAL 98 BULBS REPLACEMENT GENERAL INFORMATION 129
BRAKE FLUID 99 HEADLAMP BULB REPLACEMENT 129
BRAKE HOSE 99 POSITION LIGHT BULB REPLACEMENT 130
REAR BRAKE PAD WEAR INSPECTION 99 WHOLE HEADLIGHT REPLACEMENT 130
BRAKE PEDAL REPLACEMENT 100 REAR WINKER REPLACEMENT 131
FRONT WINKER REPLACEMENT 131
SUSPENSION BULB WINKER REPLACEMENT 132
EXPLODED VIEW / PART LOCATION - FRONT BULB TAILLIGHT REPLACEMENT 132
SUSPENSION 101 TAILLIGHT REPLACEMENT 133
EXPLODED VIEW / PART LOCATION - ADJUSTABLE LICENSE PLATE BULB REPLACEMENT 133
REAR-SUSPENSION 103
FRONT SUSPENSION REPLACEMENT 104 SPEEDOMETER
FRONT SUSPENSION WHOLE FORK REPLACEMENT 105 SPEEDOMETER DESCRIPTION 134
REAR SUSPENSION REPLACEMENT 105 SPEEDOMETER REPLACEMENT 134
REAR SWING ARM REPLACEMENT 106
5
INDEX
SWITCHES AND SENSORS
IGNITION SWITCH INSPECTION 134
IGNITION SWITCH REPLACEMENT 134
STEERING LOCK 134
ELECTRIC HORN INSPECTION 135
ELECTRIC HORN REPLACEMENT 135
LEFT HANDLE SWITCH 135
RIGHT HANDLE SWITCH 135
LEFT HANDLE SWITCH INSPECTION 136
LEFT HANDLE SWITCH REPLACEMENT 136
RIGHT HANDLE SWITCH INSPECTION 136
RIGHT HANDLE SWITCH REPLACEMENT 137
FRONT BRAKE LIGHT SWITCH
INSPECTION / REPLACEMENT 137
REAR BRAKE LIGHT SWITCH INSPECTION 138
REAR BRAKE LIGHT SWITCH REPLACEMENT 138
NEUTRAL SENSOR INSPECTION 139
NEUTRAL SENSOR REPLACEMENT 139
SPEED SENSOR INSPECTION 140
SPEED SENSOR REPLACEMENT 140
FAULT DIAGNOSIS 142
CHASSIS
SEAT REMOVAL 143
LEFT / RIGHT SIDE COVER REMOVAL 143
LEFT / RIGHT LOWER SIDE COVER REMOVAL 143
LEFT / RIGHT TANK SIDE COVER REMOVAL 144
REAR BODY PANEL REMOVAL 144
REAR SIDE COVER REMOVAL 145
REAR FENDER REMOVAL 145
FRONT FENDER REMOVAL 146
HEADLIGHT COVER REMOVAL 146
COVER FRONT SHOCK ABSORBER LEFT REMOVAL 147
COVER FRONT SHOCK ABSORBER RIGHT REMOVAL 148
MIRROW
BACK VIEW MIRROWS 149
BACK VIEW MIRROWS REMOVAL 149
SECOND SPEEDOMETER
SECOND SPEEDOMETER 150
SWITCH BUTTON FUNCTION LIST 150
REMOVAL OF POWER LIMITATION

REMOVAL OF POWER LIMITATION 151
LEVEL 1 151
LEVEL 2 151
6
IMPORTANT NOTES
WARRANTY
The work prescribed in the service schedule must be carried out in an authorized workshop and confirmed in the cus-
tomer‘s service card, otherwise no warranty claims will be recognized. No warranty claims can be considered for dam-
age resulting from manipulations and/or alterations to the vehicle.
NOTES AND WARNINGS

Pay attention to the notes/warnings in this manual.
! WARNING
• Identifies dangers that will lead to environmental damage if the measures are not taken.
• Identifies dangers that is likely to lead to fatal or serious injury if the measures are not taken.
• Identifies dangers that will lead to considerable machine and material damage if the measures are not taken.
• Identifies dangers that will immediately lead to fatal or serious permanent injury if the appropriate measures are not
taken.
REPAIR MANUAL
It is important that you read this manual completely before the start of work. It contains useful information how to
repair and maintain the vehicle.
FUEL AND LUBRICANTS

Use only the fuels, oils and lubricants according to specifications as listed in this manual.
Please consider that KSR Group GmbH give no approval for Bio- Ethanol (E 10 or higher) fuel.
SPARE PARTS AND ACCESSORIES

Only use spare parts and accessory that have been approved or recommended by KSR Group GmbH.
PRACTICE
Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and
maintenance of the vehicle. Special tools mentioned inside of this manual.
When thread locker is used on connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or
worn parts.
IMPORTANT
• After each repair or maintenance work security check and a test drive must be done.
• Before you delivery the vehicle to the customer a road safety test must be done.
7
LOCATION OF SERIAL NUMBERS
VIN (CHASSIS NUMBER) AND FRAME PLATE

2 1
The vehicle identification number (VIN) (1) is punched into the
right side of the steering tube. The frame plate (2) is located
on the right side in front of the frame.
ANTI TEMPERING LABEL

3
The anti tempering label (3) is fixed on the inner side of the
seat bench.
ENGINE NUMBER
The engine number (4) is stamped into the left side of the
engine case.
4
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER
EXAMPLE: VA4D0115XDB775449
VA4 - WORLD MANUFACTURER INDEX (NAME OF MANUFACTURER)

D01 - MODEL TYPE
1 - VARIANT OF MODEL
5 - VERSION OF MODEL
X - RANDOM NUMBER
D - YEAR OF PRODUCTION (CB = 2012/ DB = 2013,.........)
B - ASSEMBLING PLANT (LOCATION OF FACTORY)
775449 SERIAL NUMBER
8
GENERAL SPECIFICATION
ENGINE Version 0
Engine type: Liquid cooled 2 - stroke
Cylinder arrangement: Horizontal (+60°) single cylinder
Displacement: 49.6 cm³
Compression ratio: 7.0:1
Max. output (kw/rpm): 2.2 kW/ 6500 rpm
Max. torque (Nm/rpm): 3.6 Nm/ 5500 rpm
Starting system: Electric starter and Kick starter
Lubrication system: Fresh oil lubrication
ENGINE OIL QUANTITIY

Capacity: 1 L
Recommended type: CASTROL Power 1-Racing 2T Fully Synthetic

TRANSMISSION OIL
Quantity 0.5 L for disassemble/ 0.4 for replacement
Recommended type: CASTROL Power 1-Racing 4T 10W-40

AIR FILTER ELEMENT
Foam filter
FUEL
Recommended fuel: Unleaded gasoline only ≥ 95 Oct
Do not use Bio-Ethanol fuel - E10 is not permitted
Fuel tank capacity: 10 L ± 0.2 L
CARBURETTOR
Type/ Manufacturer: PZ19JB JB-4/ LEADER or QJ
Main jet: 95
Idle jet: 22.5 Version 1
SPARK PLUG
Manufacturer/ model: NGK/BR8ES

CLUTCH
Clutch type: Multi-disc in oil bath
TRANSMISSION TYPE
Manual, 5 speed
CHASSIS
Frame type: Steel tube
TIRES (Version 0 = Trigger X)

Front tire
Type: Tubeless/ Pressure on cold tire: 2.25 bar
Size: Rim: 1.6*21
Tire: 3.00-21
Rear tire
Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar
Size: Rim: 1.85*18
Tire: 4.10-18
TIRES (Version 1 = Trigger SM)

Front tire
Type: Tubeless/ Pressure on cold tire: 2.25 bar
Size: Rim: 2.5*17
Tire: 100/80-17
Rear tire
Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar
Size: Rim: 3.00*17
Tire: 130/80-17
9
GENERAL SPECIFICATION
BRAKES
Front brake
Type: Single Hydraulic disc brake (280 mm)/ Right hand operation
Brake fluid: DOT4
Recommended brake fluid: (CASTROL SUPER DISK BRAKE
FLUID DOT 4.)
Rear brake
Type: Hydraulic disc brake (220 mm)/ Right foot operation
Brake fluid: DOT4
Recommended brake fluid: (CASTROL SUPER DISK BRAKE
FLUID DOT 4.)
FRONT SUSPENSION
Type: Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
REAR SUSPENSION
Type: Unit swing
Spring/shock absorber type: Coil spring/oil damper
ELECTRICAL SYSTEM
Ignition system: CDI
Charging system: Magneto
BATTERY
Model: YT4L-BS/ 12V, 3 Ah
LIGHT AND BULBS

Headlight : 12 V , 35.0 W
Tail/brake light: 12 V , 21.0 W / 5.0W
Position light 12 V, 35.0 W
Front turn signal light: 12 V, 10.0 W
Rear turn signal light: 12 V, 10.0 W
License plate light: 12 V, 5.0 W
High beam indicator light: 12 V, 2 W

Turn signal indicator lights: 12 V, 3 W
N signal indicator light: 12V, 3 W
Instrument lights (2x): 12V, 3 W
MAIN FUSES
10.0 A
10
SPECIFIC TIGHTENING TORQUES
MODULE PART TORQUE / Nm

Starting motor clutch cover bolt 12
Starting motor clutch locknut 95
Electrical System Rectifier bolt 5
Fixing bolt of ignition coil 9
Fixing bolt of flywheel 35-40
Front wheel spindle 55 - 62
Wheel Axles
Rear wheel spindle nut 85 - 98
Fixing bolt for fuel tank 5-9
Fuel tank
Cushion mounting bolt 9-10
Fixing bolt of brake disc 22-29
Front brake system Mounting bolt of brake caliper 22-29
Fixing bolt of hand brake lever braket 5-9
Fixing bolt of brake disc 22-29
Rear brake system Mounting bolt of brake caliper 22-29
Fixing bolt of hand brake lever braket 5-9
Top nut of rear shock absorber 37-44
Rear shock absorber
Bottom nut of rear shock absorber 37-44
Front fork Front shock absorber mounting bolt 37-44
Handlebar Upper bracket assembly mounting bolt 40-60
Mounting bolt for muffler 5-9
Muffler
Combined screw for muffler protecting plate 5-9
Cylinder cover nut 18-22
Fixing nut in the power gear of clutch 50-60
Stud bolt of air cylinder 18-22
Clutch locknut 50-60
Spark plug 10-15
Limiting screw of the feet starter lever 35-40
Shift positioned bolt 10-16
Mould assembling bolt 10-12
Engine Bolts on the right and left crankcase cover 10-12
Loop bolt 10-12
Motor fixing bolt 10-12
Seperating disk bolt of clutch 10-16
Fixing bolt of inlet valve 10-12
Setscrew of shift display 4-7
Setscrew of constant temperature set 4-7
Setscrew of electric wire clamp 4-7
Fixing bolt of water pump 10-12
Frame Rear swing arm shaft nut 70-83
11
GENERAL TIGHTENING TORQUES
If no specific torque is given for a bolted assembling use the table below to tighten the screws. If you release a bolted
and glued assembling it must be glued in assembling again. For the bonding of screws use Loctite ® 243 ™, follow
the instructions for use from the manufacturer.
MAXIMUM TORQUE IN NM REFERRING ISO 898/1 FOR METRIC

FASTENERS/ COEFFICIENT OF FRICTION 0.12
Size *Strength (R) 3.6 *Strength (R) 8.8 *Strength (R) 12.9
M1.6 0.047 Nm 0.169 Nm 0.285 Nm
M2 0.10 Nm 0.35 Nm 0.60 Nm
M 2.5 0.21 Nm 0.73 Nm 0.12 Nm
M3 0.36 Nm 0.12 Nm 0.21 Nm
M4 0.82 Nm 3.0 Nm 5.1 Nm
M5 1.6 Nm 5.9 Nm 10.0 Nm
M6 2.8 Nm 10.1 Nm 17.4 Nm
M8 6.8 Nm 24.6 Nm 42.2 Nm
M 10 13.7 Nm 48 Nm 83 Nm
M 12 23 Nm 84 Nm 144 Nm
M 14 37 Nm 133 Nm 229 Nm
M 16 57 Nm 206 Nm 354 Nm
M 18 80 Nm 295 Nm 492 Nm
M 20 112 Nm 415 Nm 692 Nm
*The value R (strength) indicates the material property. The lower the value of R is the lower the torque of the bolts.
12
SPECIAL TOOLS
Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and
maintenance of the vehicle. After disassembly, clean the parts that are to be reused and check them for damage and
wear. Replace damaged or worn parts.
NAME REMARKS
Flywheel extractor Figure 1
Spacer gauge Figure 2
Dismounting tools for bearing Figure 3
Assembling tools for bearing Figure 4
Oil-seal dismounting tool Figure 5
Handle of dismounting tools Figure 6
Piston pin exhaustion apparatus Figure 7
Piston ring opening pincer Figure 8
Spark plug circular wrench Figure 9
Dial dictator (subito) - Measure inner bore Figure 10
Cylinder diameter tester Figure 11
Inner hexagon wrench Figure 12
Rest wrench Figure 13
Micrometer Figure 14
Circular wrench Figure 15
Dial indicator Figure 16
Magnetic stand, V-shape block Figure 17
Square caliper Figure 18
Whack-type screw drive Figure 19
Front fork oil seal dismounting tools Figure 20
Front part seal element driving-in tools Figure 21
Steering nut wrench Figure 22
Universal meter Figure 23
Spring clip-ring clipper Figure 24
Ignition tester Figure 25
Clutch holder Figure 26
Valve guide remover Figure 27
Valve guide installer Figure 28
Valve clearance adjuster Figure 29
Valve spring remover Figure 30
Valve guide reamer Figure 31
Crankcase remover Figure 32
Dial gauge, V-block Figure 33
Brake bleeder device no picture
Fig. 1 Fig. 2
13
SPECIAL TOOLS
Fig. 3 Fig. 4
Fig. 5 Fig. 6
Fig. 7 Fig. 8
Fig. 9 Fig. 10
Fig. 11 Fig. 12
Fig. 13 Fig. 14
14
SPECIAL TOOLS
1. Bush-head 2.Shake-handle
3.Ratchet type wrench 4.Connecting-rod
Fig. 15 Fig. 16
Fig. 17 Fig. 18
Fig. 19 Fig. 20
Fig. 21a Fig. 21b
Fig. 22a Fig. 22b
Fig. 23a Fig. 23b

15
SPECIAL TOOLS
Fig. 24 Fig. 25
Fig. 26 Fig. 27
Fig. 28 Fig. 29
Fig. 30 Fig. 31
Fig. 32 Fig. 33
Following special tools are not used for 2-stroke engines:
-> Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig.32, Fig. 33
1. PERIODIC MAINTENANCE
17
PERIODIC MAINTENANCE CHART
Important maintenance work have to be carried out by an authorized workshop.
CHECKLIST OF CONSTANT MAINTENANCE
The inspection intervals are required, otherwise, no guaran- 1000 km or 4.000 km or 7.000 km or 10.000 km or 13.000 km or
tee can be granted. 1. month 6. month 12. month 18. month 24. month
PART TO DO
Air filter Clean / exchange √ √ exchange √ √
Wheels, rims Control √ √ √ √ √
Tires Control / tire pressure √ √ √ √
Wheel bearing Control / exchange √ √ √ √
Steering bearing Control / clean / lubricate √ √ √ lubricate √
Screws Coverparts Control / tighten √ √ √ √
Brake system Control / clean / exchange √ √ √ √
Main stand Control / clean / lubricate √ √ √ √
Front fork Control √ √ √ √
Rear suspension Control √ √ √ √
Oil filter Clean √ √ √
Engine oil Control / exchange exchange √ exchange √ exchange
Valves (Engine) Control / adjust √ √ √ √ √
Transmission oil* Exchange exchange exchange exchange
Variomatic belt* Control / exchange √ exchange √
Fly wheels* Control / exchange √ exchange √
Driven chain / sprokets* Control / clean / exchange √ √ √ √ √
Clutch Control √ √ √ √ √
Cable / bowden Control / clean / lubricate √ √ √ √ √
Throttle Control / adjust / lubricate √ √ √ √
Lights / switches Control / adjust √ √ √ √ √
Fuel line / fuel filter Control / exchange √ exchange √ √
Idle speed Control / adjust √ √ √ √ √
Exhaust system Control / tighten √ √ √ √
Coolant* Control √ √ √ √ √
CAUTION: Variomatic belt, fly wheels respectively drive chain/sproket, spark pluge, fuel filter and air filter element
have to be exchanged every 7000km. Only use duration coolant. Brake lines have to be exchanged at least every
4 years. From 13.000km or 24th month the inspection should be made every 7000km. The vehicle is constantly
checked for rust. The owner is responsible for rust prevention.
* Model specific deviations are possible

18
IMPORTANT PREPARATION REFERENCES
ENGINE
Oil/ Oil pump
Item Standard Service Limit

Transmission oil Oil for replacement 0.4+/- 0.1 L --
capacitiy Oil for disassemble 0.5+/- 0.1 L --
Engine oil capacity Engine oil 1L
Oil pump Outer diameter of the piston -- 2.45 mm
Cylinder/ Piston
Item Standard value [mm] Allowable limit [mm]

Bore diameter 40.27 - 40.28 40.3
Bend --- 0.05
Air cylinder
Cylindricity --- 0.05
Roundness --- 0.05
Clearance between the piston Top ring 0.015 - 0.05 0.09
ring and the pinston ring groove Second ring 0.015 - 0.05 0.09
Interface clearance Top ring 0.1 - 0.25 0.5
Second ring 0.1 - 0.25 0.5
Piston and Outer diameter of piston 40.22 - 40.23 40.2
piston ring Clearance of piston and air cylinder 0.04 - 0.06 0.1
Bore diameter of piston pin hole 12.002 - 12.008 12.04
Outer diameter of piston pin 11.994 - 12 11.96
Clearance of piston pin hole and piston 0.002 - 0.014 0.08
Bore diameter of connectin rod small end 14.995 - 15.006 15.06
Carburettor
Item Standard value

Throat diameter 17.5
Main nozzle B03
Carburettor Main jet 95
Idle jet 22.5
Needle valve B05-Z
Fuel tank
Item Standard Tolerance

Fuel tank capacity 10 L +/- 0.2 L
19
TRANSMISSION
Item Standard value [mm] Allowable limit [mm]

Clearance of connecting rod big end in right 0.1 - 0.35 0.55
and left direction
Crankshaft Axial clearance of connecting rod big end in
0 - 0.008 0.005
vertical angle
Vibration --- 0.1
Thickness of wearing plate 2.9 - 3 2.6
Clutch
Length of pressure spring 29.4 - 30.6 29.0
Bore diameter of shift fork 7.825 - 7.845 7.91
Thickness of shift fork 3.95 - 4.05 3.9
Shift mechanism
Outer diameter of shift drum 41.8 - 42 41.75
Locked groove width of shift drum 6.05 - 6.15 6.3
ELECTRICAL SYSTEM
Item Specification
Capacity 12 V / 3 AH
Voltage Fully recharged 13.1 V
(20°C) Must be recharged 12.3 V
Battery Standard 0.4 A
Charging current
Quick 1.5 A
Standard 5-10 h
Charging period
Quick 1h
Max. capacity 80W / 1500 rpm
Magneto
Coil impedance value (20°C) Between white and black 3.3 - 3.5 Ω
single-phase semi wave SCR charge,
Type
Voltage regulator SCR semi wave short circuit mode
Battery recharging voltage 14-15 V / 5000 rpm
IGNITION
Item Standard value

Spark plug NGK/BR8ES
Spark plug gap 0.6 - 0.7 mm
Primary coil 0.4 Ω±10% (bl/w-bl)
With spark plug cover 8-11 KΩ
Ignition coil impedance value (20°C)
Secundary coil Without spark plug
4.5-5.5 KΩ
cover
Resistance value of trigger (20°C) 100-200 Ω (bl/w-gr/w)
Trigger voltage Above 1.7 V
20
STARTER MOTOR
Item Standard value Allowable limit

Brush length of startup motor 12.5 mm 8.5 mm
Liner of startup idler shaft 8.3 mm
Outer diameter of startup idler shaft 7.94 mm
WHEELS
Item Specification Tire pressure (bar)

Front wheel of inside 3.00-21 2.25
Rear wheel of inside 4.10-18 2.25
Tire pressure unit
Front wheel 100/80-17 2.25
Rear wheel 130/80-17 2.25
Measuring position Item Standard value (mm) Service limit (mm)

Front wheel shaft Curvature 0.2
Wheel Longitudinal 2.0
Front wheel shimmy Transversal Within 1.0 2.0
21
FUEL SYSTEM
AIR CLEANER
Replacement of the air filter element.
1. Remove the seat and the covers on the left side (1).
2. Remove the five mounting bolts (2) and the cover (3) to
remove the air cleaner element (4).
3. Assembling in reversed order.
2
Check to see if the filter element is polluted or damaged. If it is
polluted or damaged, please replace with a new one.
3
CHANGING INTERVALS
If the motorcycle is frequently driven on bad road or in rain, it

should be replaced early. Under normal condition replace it refer-
ring the maintenance chart.
NOTE
Please note that it is a paper element. Do not use any air filter oil
or other to protect or clean the element. Use only appropriate air 4
pressure to clean the element.
THROTTLE WIRE INSPECTION/ ADJUSTMENT
Check the smoothness of accelerator pull wire.

Free displacement: 5-10 mm
NOTE
The main adjusting position is on the throttle grip.

2
1
1. To adjust the free play of the throttle grip loosen the fixing nut
(2) and adjust by turning adjusting nut (1).
2. After the adjustment is done tighten the nut (2).
The second adjusting position is on the carburettor.

3
1. To adjust the free play of the gas wire loosen the fixing nut (4)
and adjust by turning adjusting nut (3).
2. After the adjustment is done tighten the nut (4).
NOTE
4
When the gas wire work sluggishly check if it is damaged or rusty.
Replace it if worn or grease it with silicone spray if it is rusty.
22
FUEL SYSTEM
IDLE ADJUSTMENT
Start and warm up the engine for about 3 minutes, so that the 2
engine will operate in normal running temperature. Adjust the idle
adjustment screw (1) and set the idle speed to 1800 U/min.
Create a round and stabile engine speed, using the air/ fuel con-
trol screw (2).
1
Reset the idle adjustment screw (1) and set the engine speed
down to 1200-1500 ± 100 U/min.
Pull the throttle for several times for acceleration and inspect
whether the idle speed is steady.
CARBURETTOR ADJUSTMENT
Attention: When the vehicle is ready for sell, the idle adjusting
bolts have already been adjusted, so they generally require no
adjustment. When dismantling the carburettor, the number of
turning of the bolts should be recorded because this is very help-
ful during the installation.
Switch on and warm up the machine for about 3 minutes, so that
the engine will operate in normal running temperature;
Adjust the idle adjustment bolts and set engine speed to be 1800
U/min.
Screw the mixture adjustment bolt to the end with proper force.
At this point the engine will stall, if not inspect whether air es-
capes at the interface of air filter, whether the bolt is tightened and
whether the intake of the air filter is blocked;
Withdraw the mixture adjustment bolt for 1 1/2 circle anti-clock-
wise;
Slowly adjust the mixture adjustment bolts anti-clockwise, till the
engine speed reaches its utmost mixture.
Reset the idle adjustment screw and set the engine speed down
to 1200-1500±100 U/min.
Pull the throttle for several times for acceleration and inspect
whether the idle speed is steady.
Test the outlet and compare it with the specified standards.
FUEL HOSE INSPECTION
When working on the carburettor, engine and during each main-

tenance work, check the fuel lines (3). Please note that this may 3
not be brittle or leaking. Leaking fuel can ignite and cause serious
injury and damage.
! WARNING
If the fuel line is brittle or leaking it must be replaced immediately.

23
FUEL SYSTEM/ ENGINE
FUEL FILTERS CLEANING

2
The fuel filter must be changed concerning the maintenance chart 3
or when it is blocked.
Always check the fuel filter during each work on the fuel system.
The fuel filters are placed in the tank.
Cleaning: 1
1. Switch of the ignition.
2. Switch the fuel cock (1) to the “OFF” position.
3. Disconnect the fuel line (2) from the Carburetor
4. Leave out the fuel (switch the fuel cock to the “ON” position).
5. Remove the fuel tank.
6. Remove the fuel cock (3).
7. Clean the two fuel filters (4).
8. Reassemble in reverse order.
4 4
ENGINE OIL LEVEL INSPECTION
When it is necessary to refill engine oil please only use the

recommended type.
Recommended engine oil

Quantity 1 L
Castrol Power 1-Racing 2T Fully Synthetic
Under regular conditions the engine oil consumption is approxi-

mately 1L/ 700 km.
The engine oil must be checked by the end user during each fuel
refilling. 2
The engine oil tank (1) is located on the left handle side in the 4
front.
Engine oil level inspection 1

2. Remove the engine oil tank cap (2).
3. Check the oil level.
4. Refill the recommended engine oil type till overflow hose (3)
shown on the next page.
NOTE
• Check the engine oil level when the engine is warmed up.
• Check the oil level just one minute after stopping the engine.
If the engine oil level become too low the red indicator light will
come on.
If the engine oil level will be not indicated correct please check
the oil level sensor (5).
If the oil level sensor do not work correct you must replace it
against a new one.
24
ENGINE
ENGINE OIL LEVEL SENSOR INSPECTION
1. Remove the front left side cover (4). 3

2. Remove the oil level sensor (5).
3. Switch on the ignition
4. Remove the oil level sensor, move the floater up and down
and check if the indicator light (6) in the dashboard comes on
5
or not. If the indicator light do not come one replace the oil
level sensor.
OIL PUMP INSPECTION
The lubricating system supplies oil to the wear surfaces to reduce

part wear and friction, to cool parts, and to carry away impurities.
The throttle cable is connected with the carburettor and the oil
pump. The oil pump supplies oil from the oil tank to the carburet-
tor. From the carburettor the fuel-oil mixture is injected in the
cylinder head.
The oil pump cable must open the pump earlier (1° on the throt-
tle grip) than the carburetter cable opens the throttle, to secure
enough lubrication in the mixture. When you pull the throttle grip,
you must feel a easy resistance from the oil pump. When you
keep pulling, you must feel a stronger resistance from the car-
burettor. The cables can be adjusted on the oil pump and on the
carburettor. The right adjustment is very important to prevent any
engine damage.
1
To inspect the oil pump you must remove first the oil pump cover
(1).
Disconnet the oil pump cable (2).

Release the screws (3) to remove the oil pump.
2
3
25
ENGINE
When you inspect the oil pump you can check several points.
1. Is the oil pump leaking (1)?

2. Does the oil pump work properly?
1. Does the oil pump leak (1)?

1
Check the gaskets on the oil pump shaft. If the gaskets are dam-
aged or worn replace the oil pump.
2. Does the oil pump work properly ?
To test the proper function of the oil pump, the oil pump must be
mounted.
1. Remove the oil line (2) from the carburettor.

2. Start the vehicle and open the throttle ~ 80%.
3. After ~ 5 sec. a drop of oil must emerge.
4. Average flow is ~ 1 drop of oil/ 5 - 10 sec. in idle speed. 2
Let the engine work max. 30 sec. without lubrication.
A) When oil appear wipe away the first drop of oil and repeat the
process to make sure that the pump works proper.
B) If there no oil appear please check below points.
Bleed the oil pump ?
NOTE
To bleed the oil pump it is not necessary to start the engine. The
oil flows automatically due to gravity. 3
1. Open the bleed screw (3) until only oil flows from the pump.
There must be no air present.
2. Next, check whether the oil pump works proper. If not we
recommend to bleed the oil system as described in the next
step.
Bleed the oil system ?
1. Remove the oil tube also from the oil tank and refill the sys-
tem from the top with fresh oil.
2. For this use a one way syringe or similar. The system must be
refilled in the direction from the oil tank.
3. When the system is refilled correct connect the oil tube to the
oil tank and do the above test once again.
4. If everything is fine you can reassemble all parts.
26
ENGINE
OIL PUMP ADJUSTMENT
! WARNING
Before you start to adjust the oil pump make sure that the oil cir-
cuit is vented correct. If you are start to adjust before the system
is vented correct you risk an engine failure during the adjustment.
NOTE
It doesn’t matter which variant is installed because both need to

become adjusted in the same way.
Adjustment preparation
1. Remove the oil pump cover (1).

2. Check if all components installed correct. (Check oil pump
inspection)
3. Check the default settings of the oil pump.
a) The oil pump start working as soon the throttle grip is turned.
b) The oil pump start work to late. It could be possible that the 1
engine runs without oil. The settings need to be readjusted.
Adjustment
There are 3 positions which have to be considered for a correct

adjustment.
1. Oil pump: Open the fixation nut (2) and turn the adjustment
nut (3) to get the recommended setting.
2. After the settings correct tighten the fixation nut. If it is not
possible to get the recommended setting you also have to 3 2
readjust the settings of the throttle wire (3).
3. Throttle grip: Open the fixation nut (4) and turn the adjust-
ment nut (5) to get the recommended setting. After the set-
tings correct tighten the fixation nut.
4. Final you have to check if the oil pump and the throttle valve
of the carburettor work synchronized. If not readjust the car-
burettor in the same way.
4 5
5. If the throttle valve in the carburettor and the oil pump do not
work synchronized you must readjust the throttle valve set-
tings on the carburettor. Open the fixation nut (6) and turn the 7
adjustment nut (7) to get the recommended setting.
6
27
ENGINE
TRANSMISSION OIL LEVEL INSPECTION

2. Place the vehicle on a flat ground. 1
3. Open the level screw (1).
NOTE
Oil can flow out.
4. If no oil flow out of the level screw, open the oil cap (2) and fill
oil in, till oil flow out of the level screw. 2
NOTE
• Check the engine oil level when the engine is warmed up.
• Check the oil level just one minute after stopping the engine.
RECOMMENDED TRANSMISSION OIL

Quantity 0.5 L for disassemble/ 0.4 for replacement
Recommended type: CASTROL Power 1 - Racing 4T 10W-40
SPARK PLUG INSPECTION

1
1. Remove the spark plug cap (1).
NOTE
Before removing the spark plug, blow away any dirt accumulated
in the spark plug well with compressed air to prevent it from fall-
ing into the cylinder.
2. Remove the spark plug (2).

3. Check the spark plug and replace it if it is damaged.
2
4. Check the spark plug gap and adjust it if it is not correct.
PART NO. TORQUE

2 10-15 Nm
Allowable limit A: Clearance: 0.6-0.7 mm
! WARNING
When you need to replace the spark plug always control the
installed type in before the replacement. It could be possible that
based on technical innovations the type which is described will
change. A
28
ENGINE
SPARK PLUG IMAGES AND ANALYSIS 1 2
Colour: 1. Gray/ 2. Light brown

Analysis: Engine management ok
Colour: 3. Matt black/ 4. Velvety coating 3 4

Analysis: Fuel/ air mixture wrong. Too much fuel!
Solution: Fuel/ air mixture need to adjust.
How to adjust see page 21.
Colour: 5. Oily soot/ 6. Oil coal 5 6

Analysis: Too much oil.
Solution: Check lubrication system.
Check piston rings.
SPARK PLUG REPLACEMENT
1. Follow the instructions on page 27.

RECOMMENDED SPARK PLUG TYPES:

NGK/BR8ES
CYLINDER PRESSURE INSPECTION
NOTE
The pressure inspection should be made when the engine is

warm.
1. Warm up the engine for several minutes. 2
2. Stop the engine, remove the spark plug and insert a
pressure gauge (1).
3. Turn choke valve to its full open position.
4. Set throttle handle to its full open position and start the
engine.
5. Start the engine till reading of pressure gauge.
Standard value: 6-8 bar

Allowable limit: 5.5 bar
NOTE
1. Check the following items if the compression pressure is too

low.
• If the cylinder head gasket is damaged
• The wear or damage of piston ring
• The wear of piston and cylinder
29
ENGINE/ CLUTCH
2. Check the following items if the compression pressure is too

high.
• Carbon deposition in combustion chamber or on the top
of the piston.
TROUBLESHOOTING
FAILURE CAUSE TO DO
Cylinder pressure below the allowable Worn piston ring or cylinder Check the carburettor
limit Defect gasket Clean or replace the fuel filter
Cylinder pressure higher than the allow- Carbon deposition in combustion chamber Remove the deposition or replace the
able limit or piston affected parts
CLUTCH CABLE FREE PLAY ADJUSTMENT
The clutch system is operated by a steel cable. By adjusting the

steel cable, the clutch can be set. Check clearance of clutch ca-
ble.
1. Operate the clutch lever until pressure builds.

The free play (A) between the 0 position and the pressure
point must be 10 to 15 mm. When free play is higher or lower
the clutch cable need to be adjusted.
2. To adjust the cable loosen the locknut (1) turn the adjustment 2 1
nut (2) in or out till the free play of the lever is ok.
3. Tighten the locknut.
Allowable limit: A= 10 - 15 mm
NOTE
If the clutch cable free play cannot be obtained on the handlebar

side of the clutch cable, use the adjusting nut on the engine side.
ADJUSTING THE CLUTCH CABLE FREE PLAY ON THE

ENGINE SIDE
1. To adjust the cable loosen the locknuts (1).

2. Turn the adjustment nut (2) in or out till the free play of the
lever is ok.
3. Tighten the locknuts.
2 1
30
CLUTCH/ WHEELS
CLUTCH ADJUSTMENT
1
NOTE
When the clutch lever free play is correct and the clutch do not
work sufficient check the clutch settings. Before you start to dis-
mantle the engine, check the oil level first. You don’t have to re-
move the engine from frame while checking the clutch.
1. Warm up the engine for several minutes.

2. Place a container under the engine.
3. Drain the oil.
NOTE
The mark on the push lever should flee with the mark on the left
1
engine cover as shwon in picture (1).
4. Remove the right engine cover.

5. Lock the clutch push rod (1) with a screwdriver. 2
6. Loose the locknut (2) counterclockwise.
7. Turn the clutch push rod until you feel resistance.
8. Then turn the clutch push rod out a 1/4 - 1/2 turn.
9. Tighten the locknut.
TROUBLESHOOTING
FAILURE CAUSE TO DO
Improperly adjusted clutch cable Adjust the clutch cable
Improperly adjusted push lever position Adjust the position
Shifting difficult
Improper engagement of clutch push rod Adjust the clutch push rod
Clutch plates defect (bent, worn or broken) Replace the clutch plates
Oil level wrong or viscosity wrong Oil consumed or polluted Replace or refill the engine oil
AIR PRESSURE INSPECTION
! WARNING
Low tire air pressure leads to abnormal wear and overheating of

the tire. The tire pressure should be measured under cold condi-
tion.
Use a conventional pressure gauge (1) to test the tire pressure. 1
Correct tire air pressure ensures optimal riding comfort and maxi-
mum tire service life.
SPECIFICATION PRESSURE/ BAR

Front tire 100/80-17
2.25
Front rim 2.50*17
Rear tire 130/80-17
2.25 - 2.5
Rear rim 3.00*17
31
WHEELS/ BRAKES
WHEEL BEARING AND WHEEL AXLE DAMAGE INSPECTION

FRONT
The wheels rotate with difficulties, sounds strange or have too

much free play, the wheel-axle bearings (1) or the gear seats (2)
are in failure. To locate the error, the wheel should be removed.
1 2 1
BRAKE FLUID LEAK INSPECTION FRONT
If the brake fluid level falls below the inspection glass (1) mark,
this indicates a leakage in the brake system or worn-out brake 1
linings.
1. Move the brake fluid reservoir mounted on the handlebar to

a horizontal position.
2. Check the brake fluid level.
3. Check the brake system and do not continue riding if the sys-
tem is leaking.
BRAKE FLUID LEAK INSPECTION REAR
If the brake fluid level falls below the MIN (1) mark, this indicates
a leakage in the brake system or worn-out brake linings. 1
1. Move the brake fluid reservoir mounted on rear frame to a

horizontal position.
3. Check the brake system and do not continue riding if the sys-
tem is leaking.
BRAKE OPERATION INSPECTION FRONT 1
1. Operate the hand brake lever (1) until the brake pads lie on
the brake disc and check if there is a pressure point. If there
is no pressure point check the brake system.
2. While operate the front brake lever push forward and back-
ward hard (picture 1) on the handlebar to check if the front
system is working. If the brake do not work correct check the
brake system.
3. Final make a driving test with low speed and check if the
brake system is working. If the brake do not work correct
check the brake system. 1
32
BRAKES
BRAKE OPERATION INSPECTION REAR 2
1. Operate the foot brake lever (2) until the brake pads lie on the
brake disc and check if there is a pressure point. If there is no
pressure point check the brake system.
2. While operate the foot brake lever push the vehicle forward
and backward (picture (1) on page 31) on the handlebar to
check if the brake system is working. If the brake do not work
correct check the brake system.
3. Final make a driving test with low speed and check if the
brake system is working. If the brake do not work correct
check the brake system.
BRAKE FLUID LEVEL INSPECTION FRONT

2
After a certain time the brake pads start to wear out and the brake
fluid level falls down. If the brake fluid level falls below the MIN 1
(1) mark, check the brake pads or and the brake system for any
leakage. Never add brake fluid only without checking the system.
1. Move the brake fluid reservoir mounted on the handlebar to

a horizontal position.
3. Add brake fluid if necessary.
4. Remove the cover (2) with the membrane.
5. Add brake fluid to the MAX level.
6. Mount the cover (2) with the membrane.
BRAKE FLUID LEVEL INSPECTION REAR

4
After a certain time the brake pads start to wear out and the brake
fluid level falls down. If the brake fluid level falls below the MIN 5
(1) mark, check the brake pads and the brake system for any
leakage. Never add brake fluid only without checking the system. 1
3
1. Remove the brake fluid reservoir (1). 2
2. Hold the brake fluid reservoir on a horizontal position.
4. Add brake fluid if necessary.
5. Remove the cover (2).
6. Remove the plastic part (3) and the rubber part (4).
7. Add brake fluid to the MAX (5) level.
8. Mount the cover (2).
Brake fluid type CASTROL SUPER DISK BRAKE FLUID DOT 4

Brake fluid boiling temperature > 170°C
Brake fluid water content < 3%
33
BRAKES
FRONT BRAKE PADS INSPECTION
Reduced braking efficiency caused by worn brake pads.

Change worn brake pads immediately. Always replace the brake
pads in pair.
1
1. Loose the mounting bolts (1) of the braking calliper bracket.
2. If the minimum thickness is less than the indicators (2),

2
damage or cracking is visible change the front brake pads.
3. Loosen the two mounting bolts (3).

4. Change the brake pads (4) in pair.
REAR BRAKE PADS INSPECTION

pads in pair.
1. Loose the mounting bolts (1) of the braking calliper bracket.
2. If the minimum thickness is less than the indicators (2),

damage or cracking is visible change the rear brake pads.
2
34
BRAKES
3. Remove the circlip (3).
4. Remove the bolt (4).

5. Change the rear brake pads in pair.
4
FRONT BRAKE DISC INSPECTION
1. Check the thickness of the front disk at several places on the

disk to see if it conforms to measurement.
Allowable limit A: 3 mm
A
If the brake disk thickness is less than the specified value
change the brake disk. Check the front disk for damage,
cracking and deformation. If the brake disk exhibits damage,
cracking or deformation change the brake disc.
2. Place an appropriate supporting stand under the vehicle in
order to raise the front wheel up.
3. Loosen the two screws (1).
4. Remove the front axle (2) in order to remove the front wheel.
5. Remove the six screws (3) to remove the front brake disc (4)
and mount a new one if the old one is worn.
NOTE 2
5
Take care to the position of the new brake disc (Arrow).
6. Reassemble in reverse order. 1
PART. NO. TORQUE

3 22-29 Nm
NOTE
Take special care that the axle spacer and the speedometer
gear (5) installed correct. 3
4
! WARNING
Always keep the brake discs free of oil and grease, and clean
them with brake cleaner when necessary. Please consider that a
dirty brake disc influence the brake performance.
35
BRAKES
REAR BRAKE DISC INSPECTION
1. Check the thickness of the rear disk at several places on the

disk to see if it conforms to measurement.
If the brake disk thickness is less than the specified value A

change the brake disk. Check the front disk for damage,
cracking and deformation. If the brake disk exhibits damage,
cracking or deformation change the brake disc.
order to raise the rear wheel up.
1
3. Disconnect the chain (1).
4. Remove the rear axle-nut (2) to remove the axle (3) in order
to remove the rear wheel.
5. Remove the six screws (4) to remove the rear brake disc (5)
and mount a new one if the old one is worn.
3
NOTE
Take care to the position of the new brake disc (Arrow). 2

PART. NO. TORQUE
3 85-98 Nm
4 22-29 Nm
NOTE 4
5
Take special care that the axle spacer are installed correct.
! WARNING
Always keep the brake discs free of oil and grease, and clean
them with brake cleaner when necessary. Please consider that a
dirty brake disc influence the brake performance.
FRONT BRAKE LEVER/ MASTER BRAKE CYLINDER RE-

PLACEMENT 4
When the performance of the front brake is poor it could be

possible that the plunger module gaskets are defect.
1. Drain the brake fluid from the hydraulic brake system. 1 2

2. Remove the brake line (1) from the master cylinder (2).
3. Remove the two bolts attaching the brake master cylinder (3). 3
4. Remove the brake master cylinder.
5. Remove the brake lever bolt (4) and the brake lever.
6. Replace defect parts and assemble in reversed order.
7. Refill the brake system.
NOTE
The plunger module is not available separately.

36
BRAKES
FOOT BRAKE LEVER/ MASTER BRAKE CYLINDER

REPLACEMENT
2
When the performance of the rear brake is poor it could be
possible that the plunger module gaskets are defect.
1
1. Drain the brake fluid from the hydraulic brake system.
2. Remove the two bolts (1) of the master cylinder cover (2).
3. Remove the two brake plugs (3) from the master cylinder (4).
4. Remove the nut (5). 3
5. Remove the two brake lines (6). 5 4
6. Remove the foot brake lever bolts (7) and the foot brake
lever.
7. Replace defect parts and assemble in reversed order.
6
! WARNING
7
When you need to replace the foot brake lever, always control the
spiral spring is positioned correct.
NOTE
The plunger module is not available separately.
FRONT BRAKE CALLIPER REPLACEMENT
When the performance of the front brake is poor it could be possi-

ble that the gaskets of the front brake calliper defect or the brake
pads are worn. 1
2
2. Remove the banjo bolt (1) from the master brake cylinder.
3. Remove the two bolts (2) attaching the brake calliper.
4. Replace the brake calliper.
NOTE
Always renew the washer of the banjo bolt.
REAR BRAKE CALLIPER REPLACEMENT
When the performance of the rear brake is poor it could be pos-

sible that the gaskets of the rear brake calliper defect or the brake
1
pads are worn.
The following steps are the same as described in

“FRONT BRAKE CALLIPER REPLACEMENT”.
2
37
BRAKES
FRONT BRAKE HOSE REPLACEMENT 5

2
When the front brake hose is leaking, cracked or worn you had
to replace it.
1
Please consider that there is no need to remove the brake calliper
when you need to replace the brake hose.
! WARNING
Brake fluid can cause skin irritation on contact.

Avoid contact with skin and eyes, and keep out of the reach of
children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and
contact a doctor immediately. 3
Brake fluid can damage paint, rubber and plastic parts. When
brake fluid dripping on such parts wipe it away immediately.
1. Place a container under the brake calliper. 4

2. Remove the banjo bolt (1) and empty the brake hose (2).
4. Replace the brake hose. Take care that the brake hose is
installed correct and is connected to all brackets. Use new
gaskets when you connect the brake hose.
5. Remove the cover (4) with the membrane.
6. Add the recommended brake fluid to the MAX level.
7. Open the bleed valve (5) and add a brake bleeding tool on
the valve. Start to aspirate the brake fluid as long as air is in
the system. Take care that the brake fluid level in the master
brake cylinder will not fall lower than the MIN level otherwise
you suck air in the system once again.
1. Suck continuously the air out of the system and add brake
fluid continuously until the system has been bleeded.
9. Close the vent valve and refill the brake fluid level to the MAX
level.
10. Reassemble all other parts in reverse order.
REAR BRAKE HOSE REPLACEMENT
When the rear brake hose is leaking, cracked or worn you must
replace it.
Please consider that there is no need to remove the brake calliper

when you need to replace the brake hose.
! WARNING
Brake fluid can cause skin irritation on contact.

1
Avoid contact with skin and eyes, and keep out of the reach of 5
children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and 2
contact a doctor immediately.
Brake fluid can damage paint, rubber and plastic parts. When
brake fluid dripping on such parts wipe it away immediately.
1. Place a container under the brake calliper.

2. Remove the banjo bolt (1) and empty the brake hose (2).
38
BRAKES
3. Remove the master brake cylinder cover.

4. Remove the two plugs (3).
6. Replace the brake hose. Take care that the brake hose is
installed correct and is connected to all brackets. Use new 3
gaskets when you connect the brake hose.
7. Remove the brake fluid reservoir. 4
8. Add the recommended brake fluid to the MAX level.
9. Open the bleed valve (5) and add a brake bleeding tool on
the valve. Start to aspirate the brake fluid as long as air is in
the system. Take care that the brake fluid level in the master
brake cylinder will not fall lower than the MIN level otherwise
you suck air in the system once again.
1. Suck continuously the air out of the system and add brake
fluid continuously until the system has been bleeded.
9. Close the vent valve and refill the brake fluid reservoir to the
MAX level.
10. Reassemble all other parts in reverse order.
FRONT BRAKE LEVER ADJUSTMENT
1. Loosen the nut (1).

2. To Adjust the front brake lever, screw the bolt (2) in or out.
3. If the position of the lever is adjust, thighten the nut (1). 2 1
If you can not adjust the free play correct check the brake pads
for wear.
REAR BRAKE LEVER ADJUSTMENT
1. Operate the right foot brake lever un-

til the brake pads lie down on the brake drum.
The free play (A) between the 0 position and the pressure
point must be 10 to 20 mm. When free play is higher or lower
the steel rod need to be adjusted.
1. Remove the master brake cylinder cover.
2. Loosen the nut (1).
A
3. To adjust the foot brake lever, screw the bolt (2) in or out.
4. Thighten the nut (1).
If you can not adjust the free play correct check the brake pads
of wear.
2
1
39
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION
NOTE
The drive chain slack must be checked at the tightest point on

the chain.
! WARNING
A drive chain that is too tight can overload the engine and other
parts. One that is too loose can skip and damage the swingarm
or cause an accident.
Keep the drive chain slack within the specified limits.
1. Place the motorcycle on a level surface.

NOTE
Both wheels should be on the ground without a rider on the
motorcycle.
2. Move the rear wheel several times and look for the tightest
position of drive chain.
3. Check the drive chain slack (A).
Allowable range A: 10 - 20 mm
NOTE
A
If the chain tension is not on the specified range, adjust it.
DRIVE CHAIN SLACK ADJUSTMENT
1. Loosen the fixing nut (1) of the rear axle.

2. Loosen the fixing lock (2). Adjust the chain with the
adjustment bolts (3) on both sides until the specified drive
chain slack is obtained.
3. Move the rear wheel several times and check the chain slack
again.
1
4. Thighten the the lock nut (2) and thighten the fixing nut (1) of 2
the rear axle.
3
PART. NO. TORQUE
1 85 - 98 Nm
NOTE
When it is necessary to replace a worn drive chain, do not install

a new drive chain onto worn sprockets or install a worn drive
chains on new sprockets.
Keep both sprocket and drive chain in good conditions, or newly
replaced chain or sprocket will be worn soon.
DRIVE CHAIN LUBRICATION

NOTE
If the drive chain is not maintained properly, it will wear out quick-
ly. Therefore, the drive chain should be serviced continuously,
especially when the motorcycle is used in dusty areas.
Steam cleaning, high-pressure washing, certain solvents, and
the use of a coarse brush can damage the chain. Use only suit-
able detergent to clean and lubricate the drive chain.
RECOMMENDED CHAIN LUBRICANT:

Chain Spray: Castrol chain spray O-R
40
DRIVE CHAIN/ SUSPENSION
DRIVE CHAIN WEAR INSPECTION
1. Measure length of 10 chain links. If they cannot meet the

specified value, replace the drive chain.
NOTE
A
Stretch the chain by hands and then measure it. The measuring
range is from chain link roller to inner side of roller.
When any damage is visible on the chain replace it.
DRIVE CHAIN REPLACEMENT

1
1. Relax the rear wheel.
2
2. Open the chain lock (1) of the defect chain.
3. Install the new chain in reversed order.
4. Fix the rear wheel in reversed order. Take care about the cor-
rect installation and correct chain slack.
NOTE
The open side of the chain lock (2) must be installed into
backward rotation direction (arrow).
FRONT FORK OPERATION INSPECTION
NOTE
At every inspection the fork should be controlled.
1. Apply the front brake and compress the front shock absorber
up and down (arrows) to check for correct operation.
2. When the fork stick, feel spongy or the free play between the
fork tubes is too big replace the defect fork leg.
3. Check if each screw is tightened.
FRONT FORK OIL LEAK INSPECTION
NOTE
At every inspection check also if the fork is tight.
1. Check the dust/ oil seal between the fork legs and the top end
(arrows). When oil is leaking replace the affected fork leg.
41
SUPENSION/ STEERING
REAR SHOCK OPERATION INSPECTION
NOTE
At every inspection the rear shock absorbers should be

controlled.
1. Compress the rear shock absorber up and down to check for

correct function (arrows).
2. Check whether a part of the rear shock absorber is damaged
or loosened.
3. Put the vehicle on the main stand and move the rear wheel
up down and left right to check whether any bush or bearing
is loosened or has abnormal free play.
4. When the absorbers stick, feel spongy or there is any other
abnormity replace it.
5. Check if each screw is tightened.
The rear shock absorber is spring loaded. The spring preload can
be adjusted with the locknuts (arrows) continuously. Choose the
preferred setting by your self. The factory setting refers to a rider
weight of approximately 75 kg.
REAR SHOCK OIL LEAK INSPECTION
NOTE
At every inspection the rear shock absorbers should be

controlled.
1. Check the dust/ oil seal and check if the spring are in correct
condition. When oil is leaking, a spring is cracked or worn
replace the shock absorber (arrow).
STEERING PLAY INSPECTION
Worn or loose steering bearings may cause danger. Therefore,

the operation of the steering must be checked as follows at the
intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the vehicle to raise the front wheel off
the ground.
2. Hold the lower ends of the front fork legs and try to move
them forward and backward (arrows). Check the steering
head for looseness or binding by turning the front fork all the
way in both directions.
3. If any free play or binding can be felt, replace the steering
bearing.
42
STEERING
STEERING BEARING LUBRICATION
1. Place the vehicle on a level surface.

2. Remove the head light, speedometer, handlebar and upper
triple tree.
3. Remove the fixation nut (1) and the dust cap (2).
4. Lift the vehicle or lower the front fork.
1
5. Now grease lower bearing (3). Please use only high quality
grease to keep water away.
6. After the bearings are greased assemble the parts in re- 3
verse order.
43
ELECTRICAL SYSTEM/ BATTERY
BATTERY INSPECTION/ CHARGING
The battery (1) is located on the right side of the vehicle. It is 2

recommended to extend the battery whenever it needs
servicing. Disconnect the battery poles (2) to extend the battery.
1. This is a conventional battery. You can remove the seal- 1

ing caps to maintain the balancing between the cells. The
manual for the battery first fill you will receive together with
the battery. Only fill with distilled water.
2. Before you install the battery first time please charge it for
at least 8 hours.
3. Charge the battery with a maximum of 10% of the capacity
specified on battery housing.
4. Do not connect the battery with the wire harness of the ve-
hicle when the vehicle is parked in the show room for more
than one month.
5. Please maintain/ charge the battery every 2 weeks when
the vehicle is not in use.
6. The voltage range of the battery is -12.3 Volt (DC) to - 13.1
Volt (DC).
7. To measure the Voltage of the battery use a conventional
volt meter (3). Measure between the battery terminals.
8. When you charge the battery installed in the vehicle discon-
nect the negative cable of the wire harness. 3
9. When you remove the battery from the vehicle disconnect
the negative pole first.
10. When you install the battery to the vehicle connect the plus
pole first. Add battery pole grease between the battery poles
and the cables.
11. The recharging voltage of the vehicle regulator rectifier is
approximately 14 Volt/ 5000 rpm.
! WARNING
Battery acid and battery gases cause serious cauterization.

Keep batteries out of the reach of children. Wear suitable pro-
tective clothing and goggles. Avoid contact with battery acid and
battery gases. Keep the battery away from sparks or open fire.
Charge only in well ventilated rooms. In the event of skin con-
tact, rinse with large amounts of water. If battery acid gets in
the eyes, rinse with water for at least 15 minutes and contact a
doctor.
44
ELECTRICAL SYSTEM/ FUSES/ SWITCHES
FUSES
The main fuses (1) are located next the battery. In the fuse socket 1
strap a replacement fuse (2) is added.
NOTE
To avoid a short circuit, always set the main switch to “OFF” when
checking or replacing a fuse.
1. Insult a new fuse of the correct amperage rating.

FUSE AMPERE RATING
Main Fuses 10 Ampere
Replacement 10 Ampere
2. Set on the switches to verify if the electrical circuit is opera-

tional.
3. If the fuse immediately blows again, check the electrical cir-
cuit.
2
! WARNING
Never use a fuse with an amperage rating other than that speci-
fied. Improvising or using a fuse with the wrong amperage rating
may cause extensive damage to the electrical system, cause the
lighting and ignition systems to malfunction and could possibly
cause a fire.
LIGHT AND SWITCHES OPERATION INSPECTION

1. Place the vehicle on the stand and start the engine.
NOTE
Some functions do not work as long the engine is not running.
2. Now you can test one by one the functions of all switches, the 1
function of the rear and front light and the brake light.
Switches/ Functions - left side
1. High/ Low beam switch/ Flasher

2. Indicator switch
3. Horn switch
2
3
Switches/ Functions - right side
4. Starter Button
4
45
ELECTRICAL SYSTEM
HEADLIGHT AIMING INSPECTION
1. Place the vehicle at a distance of 5 meters in front of a wall.

The vehicle must be placed horizontally.
5 cm
2. Measure the distance from the ground to the middle of the
headlight bulb (X).
3. Transfer this value to the wall and mark it with an X.
X
4. Then make a second X, 5 centimetre below the first X.
5m
5. Turn the screw (1), placed on the front side of the headlight,
in or out to adjust the height of the low beam.
1
46
2. REPAIR AND DIAGNOSTICS

47
CHASSIS
EXPLODED VIEW/ PARTS LOCATION - FRAME 45

44
32 8 41 45
33 44 43
30 29
31 42 41
23 17 16 7 1
43
28 2
11 5 41 3
25 10
4
17
24 26 6
20 25 41 6
27
25
19 9
34 40
5
18
7 8
35 6
2
39
16 37 9
10
22 2 6 11
21 38 12
36
12
2 38
20
13
19
14
16
18
17
2 15
PART LIST - FRAME
1. Frame 16. Screw M10x1,25 31. Nut M8

2. Screw M15×12 17. Splint 32. Washer
3. Washer M8 18. Footrest 33. Screw M8x50
4. Rubber pad 19. Spring 34. Rubber pad
5. Rubber pad 20. Pin 35. Direction sign
6. Screw M8x25 21. Exhaust bracket 36. Screw M8x120
7. Bracket passenger footrest 22. Screw M6x8 37. Screw M8x100
8. Passenger footrest 23. Foot brake lever 38. Nut M8
9. Nut M10 24. Screw M6x30 39. Screw M6x20
10. Snap ring M10 25. Nut M6 40. Bracket
11. Screw M10x45 26. Screw M6 41. Screw M6x12
12. Spring- Side stand 27. Pull handle 42. Lock mechanism seat
13. Locking plate 28. Pull rod 43. Rubber pad
14. Side stand 320mm 29. Washer 44. Spacer sleeve
15. Nut M10x1,25 30. Spring 45. Screw M8x16
48
CHASSIS
EXPLODED VIEW / PARTS LOCATION - REAR SWING ARM PART LIST - REAR SWING ARM
REAR SWING ARM 1. Mounting shaft

1
2. Anti dust ring
2 3. O-Ring
18 3 4. Bush
5. Sleeve
19 4
17 6. Chain guid
5 7. Rear swing arm
20
8. Nut M14x1.5
21 6 9. Chain adjuster right
16
10. Chain adjuster left
15 11. Nut M6
14 22 7
12. Chain guid
13
12 4 13. Spacer sleeve
14. Screw M6x16
3
15. Bracket chain case
11 2 16. Chain case
17. Screw Mx16
8 18. Screw M8x50
10
19. Washer M8
20. Spacer sleeve
21. Chain roller
9 22. Nut M8
EXPLODED VIEW / PART LOCATION - SEAT

PART LIST - SEAT
5
1. Seat
2. Rubber pad
3. Catch snap lock
4 4. Nut M5
3 5. Rubber pad
1
49
CHASSIS
TIGHTENING TORQUE OF FASTENING PARTS ON CHASSIS
FASTENING POSITION AND PART NAME TORQUE

Front wheel spindle 55-62 Nm
Fixing bolt of steering lever 5-9 Nm
Rear wheel spindle nut 85-98 Nm
Topping nut of the rear shock absorber 37-44 Nm
Bottom nut of the rear shock absorber 37-44 Nm
Fixing bolt of brake disc rear 22-29 Nm
Mounting bolt of brake caliper rear 22-29 Nm
Fixing bolt of brake disc front 22-29 Nm
Mounting bolt of brake caliper front 22-29 Nm
50
FUEL SYSTEM/ FUEL TANK
EXPLODED VIEW / PART LOCATION - FUEL SYSTEM
16
18
15 19
17 14
2
5
6
7
8
8 9
7
6
5
11
9
13 10
12 11
PART LIST FUEL SYSTEM
1. Screw M8x40 11. Hose clamp

2. Washer M8 12. Fuel hose
3. Sleeve 13. Tank closure
4. Rubber pad 14. Fuel tank cap gasket
5. Sleeve 15. Tank closure
6. Bush 16. Breather hose
7. Washer 17. Disposable breather hose
8. Screw M6x55 18. Screw M4×20
9. Screw M6x12 19. Bracket
10. Petcock
51
FUEL SYSTEM/ FUEL TANK
SPECIFICATION
FUEL
Recommended fuel: Unleaded gasoline only ≥ 95 Oct (SP 95 - SP 98)

Do not use any Bio-Ethanol fuel.
Fuel tank capacity: 10.0 L ± 0.2 L
NOTE
Fuel switch shall be set at “OFF” position while removing fuel tank.
SPECIAL TOOLS
See page 12 - 15
TROUBLESHOOTING
FAILURE CAUSE TO DO
Idle speed is not set correctly Adjust the idle speed
Engine turns but does not start No gasoline in the fuel tank Refill gasoline
or dies off Water in the carburettor or the jet is blocked Check the carburettor
Fuel filter blocked Clean or replace the fuel filter
Idling jet blocked Check the carburettor
Adjusting screw on carburettor distorted Adjust the idle speed
Engine have no idle Carburettor running over because float needle
Check the carburettor
is worn or blocked
Loose carburettor jet Check the carburettor
Fuel filter contaminated Clean the filter
Failure in fuel system Check the fuel system
Engine power is poor
Error at fuel cock Check the system
Fuel tank cap is blocked Check or replace it
52
FUEL SYSTEM/ CARBURETTOR
EXPLODED VIEW / PART LOCATION - CARBURETTOR

1
2 3
6 7
10
11
12 13
PART LIST - CARBURETTOR

8. Floater
1. Carburettor assy MJ95/ NJ22.5 9. Floater pin
2. Spring 10. Needle valve
3. Idle adjustment screw 11. Float chamber
4. Float chamber gasket 12. Drain screw
5. Main bubble tube 13. Screw M4x12
6. Idle Jet 22.5
7. Main jet 95
NOTE
Use a cloth to block the intake manifold after dis-

mounting carburettor to avoid other article entry.
For the detailed specification see page 8 and 18.

53
CARBURETTOR REMOVAL
1. Switch the fuel cock to “OFF” (1).

2. Empty the carburettor by opening the drain screw (2). 3
3
1
3. Loosen the two hose clamps (3).
4. Pull the carburetto backwards to disconnect the carburettor
from the membrane (4).
5. Turn the carburettor right and loosen the four screws (5) of
the gas wire bracket and the choke wire bracket. 9
6. Disconnect the carburettor from fuel line (6), gas wire (7), 2
choke wire (8) and the oil pump line (9).
NOTE
Take care about the fuel residues.

7
7. Pull out the carburettor.
8. Assembling in reversed order. 5
8
6 5
NOTE
4
Look to the grove on the membrane and the pin on the
5
carburettor.
5
! WARNING
Fuel is poisonous and a health hazard.

Avoid contact between fuel and skin, eyes and clothing. Do not
inhale fuel vapours. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas imme-
diately with soap and water. If fuel is swallowed, contact a doc-
tor immediately. Change clothing that has come into contact with
fuel. Store fuel in a suitable canister according to regulations and
keep it out of the reach of children.
CHOKE/ CABLE REMOVAL
1. Switch the fuel cock to “OFF” (1).

2. Loosen the two hose clamps (3).
3. Turn the carburettor right.
5. Loosen the screw (11).
6. Slide the left handle switch (12) to the right.
7. Slide the choke cable (13) to the right. 10
8. Feed out the cable (14). 10
12
11
14 13
54
CARBURETTOR UPPER COVER REMOVAL
1. Loosen the bolts (1) and dismantle the upper cover (2). 2
2. Take out the spring (3), valve piston (4) and the needle (5).
3. Examine the attrition condition of the parts.
1
4. If one the parts is worn down, it should be replaced.
5. Examine the attrition condition of the needle (5).
6. If the needle is worn down, it should be replaced. 5 4 3
7. Loosen screws (6) and take off the float chamber (7).
8. Dismantle the floater pin (8), floater (9) and valves (10).
NOTE
To enrich or reduce the fuel mixture position the clip to another

groove. When you install the clip and lift the needle the mixture is
enriched and vice versa. Do the settings gradually. 9
9. Examine if the needle valve core, needle valve and the float
components are damaged or worn. 10
10. If the needle valve core is damaged or worn down, it should
replaced.
6
11. If the needle valve seat is worn down, then the carburettor
body should be replaced. 8 7
12. If the floater tongue piece is worn down, it should be replaced.
13. Examine the idle metering hole, the main metering hole and
the main nozzle to see if they are damaged, worn down or
stained. If so, they should be replaced.
14. Examine the plunger to see if it is worn down. If so, it should
be replaced.
15. Examine the carburettor body and the oil-fired pipe. If they
are stained, clean every part with gasoline and blow them dry
with pressure air.
16. Always replace the needle valve and valve seat as a set.
CARBURETTOR ADJUSTMENT
Idle speed and air control adjustment see page 18.
PART DEFAULT SETTINGS

Needle (5) 2. groove from above
Floater chamber level 4 - 5 mm
FUEL SUPPLY INSPECTION
1. Start to check one by one the whole fuel supply system for
leaks and wear. If a part is defect please replace it immedi-
ately.
PARTS WHICH MUST BE CHECKED
1. Fuel tank
2. Fuel cock
3. Fuel tubes
4. Hose clamps
5. Vacuum tubes
6. Fuel filters
7. Gaskets and seals
8. Carburettor
55
FUEL SYSTEM/ FUEL SUPPLY
FUEL TANK REMOVAL

2. Switch the fuel cock (1) to the “OFF” position.
3. Remove the seat bench and the side covers (2).
1 2
4. Disconnect the fuel line (3) from the fuel cock.
NOTE
The fuel line is filled with fuel. Block it immediately after removal
from the fuel cock. It´s recommended to drain the fuel from the
tank before removal.
3
5. Remove the bolt (4) on the left and right side of the tank.
NOTE
Only one side (left side) is shown.

4
6. Remove the bolt (5) on the top of the tank.
5
7. Slide the fuel tank backwards to remove it.
NOTE
Check the correct position before tightening the bolts.

56
FUEL SYSTEM/ FUEL SUPPLY
FUEL COCK REMOVAL
NOTE
It´s recommended to drain the fuel from the tank before removal.
1. Switch off the ignition.

2. Switch the fuel cock to the “OFF” position.
3. Disconnect the fuel line from the Carburettor
1
4. Leave out the fuel (switch the fuel cock to the “ON” position).
5. Remove the fuel tank.
6. Lossen the two screws (1).
7. Remove the fuel cock.
8. Assembling in reverse order.
NOTE
Keep the fuel cock switch in correct position when tighten the
nut.
TORQUE LIST
PART. NO. TORQUE
1 Tighten that no fuel is leaking
For screws that are not listed use standard values(page 11).
57
ENGINE
EXPLODED VIEW / PART LOCATION - CYLINDER/ CYLINDER COVER
2
3
1
5
13 4
12 6
9
11
10
PART LIST - TOP ENGINE
1. Spark plug 8. Outer cylinder head gasket

2. Nut 9. Cylinder
3. Washer 10. Cylinder gasket
4. Temperature sensor 11. Cylinder cover
5. Thermostat 12. Seal ring
6. Screw M4x10 13. Thermo switch
7. Cylinder head gasket
TORQUE LIST
NOTE
PART. NO. TORQUE
In order to guarantee the sealing between cylinder and cylinder cover the
1 10-15 Nm
cylinder cover undertakes a very big Torque.
All parts should clean and blow dry by compressed air before inspecting 2 18-22 Nm
and measuring.
58
ENGINE
EXPLODED VIEW / PART LOCATION - CRANK ASSEMBLY
2 3
1
2
14
13 7
12
11
10
PART LIST - CRANK ASSEMBLY
1. Piston ring 8. Nut

2. Piston pin clip 9. Woodruff key
3. Needle bearing 10. Woodruff key
4. Piston 11. O-Ring 15.5x1.5
5. Piston pin 12. Bush
6. Connectin rod 13. Washer
7. Crankshaft 14. Nut
PART. NO. NOTE

14 Stick in
59
ENGINE
EXPLODED VIEW / PART LOCATION - CRANKCASE

1
26 27 2
25
3
4
3
5
6 8
7 9
10
24 21
23
11
22
21 12
13
14
20
19
16 15
18
17
PART LIST - CRANKCASE
1. Nut 10. Breather hose 19. Seal ring

2. Seal ring 11. Nut M6x55 20. Nut M8x12
3. Bearing 6203 12. Simmering 20x35x7 21. Main bearing
4. Needle bearing 13. Seal ring 22. Nut M6x12
5. Bearing 6202 14. Neutral switch gear 23. Locking plate
6. Bearing 15. Simmering 12x22x7 24. Crankcase right
7. Simmering 13.7x24x5 16. Tapping screw 25. Simmering 24x35x7
8. Hose clamp 17. Simmering 17x35x7 26. Stud
9. Engine breather connection 18. Crankcase left
SPECIAL TOOLS
See page 12-15
TORQUE LIST
PART. NO. TORQUE
11 8 - 12 Nm
60
ENGINE
SPECIFICATION
ENGINE TYPE 2 STROKE LIQUID COOLED

Unleaded gasoline
Fuel type ≥ 95 Oct (SP 95 - SP 98)
Do not use any Bio - Ethanol fuel
Number of cylinder 1 + 60° horizontal - liquid cooled
Bore and stroke 40.25×39
Displacement 49.6 ccm
Start system Electric starter
Lubrication Fresh oil lubrication
Air cleaner Paper element
Carburettor Main jet: 95/ Idle jet: 22.5
Idling speed - rpm 1800 ± 100 rpm/min
Maximum torque 3.60 Nm/ 5500 rpm/min
Maximum power 2.20 kW/ 6500 rpm/min
Compression ratio 7.0:1
SPECIAL TOOLS
See page 12-15

61
ENGINE
TROUBLESHOOTING
FAILURE CAUSE TO DO
Charge the battery
Battery discharged Check the charging of the battery
Check if the generator is working correctly

Engine does not start when the
electric starter button is pushed Check or replace
Fuse is blown
Starter relay defective Check the starter relay
Starter motor defective Check the starter motor
Check or replace
A fuse is blown
Idle speed is not set correctly Adjust the idle speed
Spark plug is contaminated Check or replace
Wire harness is worn Check the wiring harness

Engine turns but does not start or
dies off Check the plugs of the wiring harness
Contact problem in a plug
No gasoline in the tank Refill gasoline
Water in carburetor, jet blocked or failure in the pressurized Check the carburetor and pressurized system
system
Problem with the fuel filter Check or replace
Idling jet blocked Check the carburetor system
Engine has no idle Spark plug defective Check or replace
Adjusting screw on carburetor distorted Adjust the idle speed
Check the carburetor system

Carburetor running over because float needle dirty or worn
Loose carburetor jets Check the carburetor system
Air filter contaminated Clean the filter

Engine does not speed up
Fuel filter contaminated Clean the filter
Failure in fuel system Check the fuel system
Problem with the carburretor Check the carburretor
Exhaust system leaky or deformed Check exaust system
Blue smoke emission To much oil support Check the oil pump
Black smoke emission Fuel/ Air ratio wrong - too much fuel Check the carburretor
Low compression Piston, piston rings, gaskets, crankcase or cylinder worn or Check all parts and replace if necessary
damaged, inlet or exhaust valve do not seal of.
High compression Combustion chamber and the carbon deposition on the top Check all parts and replace if necessary
of the piston.
Piston noice Piston, piston rings, piston pin, cylinder, conrod or bearing Check all parts and replace if necessary
are worn or damaged
Heavy smoke Oil back flow valve defect Replace the oil back flow valve
62
ENGINE/ DISASSEMBLING
ENGINE OVERHAUL/ REMOVAL
NOTE
It’s not necessary to remove the engine in order to remove the

following components:
• Cylinder cover
• Cylinder
• Piston and piston ring
• Clutch
• Drive gear
• Gear shift shaft
• Magneto rotor
• Stator
• Oil pump
• Water pump
For a better understanding, the following steps are described with

replaced engine.
ENGINE PREPARATION
1
To reach the top end of the engine proceed as follow.
1. Switch of the fuel cock. 3

2. Remove the seat bench and the side covers.
3. Empty the carburettor by opening the drain screw.
4. Disconnect all attachments (carburettor, exhaust,...) from the 2
engine.
5. Unplug all electrical cables, remove the clutch wire, the drive
chain cover (1), the drive chain (2), the shift linkage (3) and
the rear brake lever.
NOTE
Take care about the fuel residues and the position of the cable
plugs and hoses.
ENGINE REMOVAL 4
If you need to remove the entire engine follow points 1 to 5 -

engine preparation - and go ahead with point 6.
4
6. Support the engine and vehicle from below before starting to

remove the engine hanger and hanger bolts.
7. Remove the hanger nuts (4) and hanger bolts.
NOTE 4
Now the engine is without an fixation and can be removed.
! WARNING
Avoid that the engine falls down otherwise the alloy cast parts of
the engine may be damaged.
63
ENGINE/ DISASSEMBLING/ TOP END
CYLINDER COVER REMOVAL 3
1
1. Remove the spark plug (1), the thermo switch (2), the
temperature sensor (3) and the four nuts (4).
4 2
5
2. Remove the cylinder head (5) and gaskets (6).
NOTE
Loosen each nut (4) 1/4 turn, and remove them after all nuts are
loosened. 6
Renew the gaskets (6).
CYLINDER REMOVAL
1. Remove the cylinder head (1) by pulling the cylinder head off.
PISTON REMOVAL
! WARNING 1
Before start to disassembling the piston is recommended to

secure the crankcase opening with a rag.
1. Remove the C-type piston pin clip (1).
2. Push out the piston pin (2).

3. Remove the piston (3). 3
2
64
ENGINE/ DISASSEMBLING/ RIGHT CRANKCASE
OIL PUMP REMOVAL

2
1. Remove the two bolts (1) and remove the oil pump (2). 1
WATER PUMP REMOVAL

2
1. Remove the three bolts (1) and remove the water pump (2).
CRANKCASE COVER (RIGHT) REMOVAL
NOTE
1
Drain the engine oil before start with the disassembling.
1. Remove the screw (1) to slacken the kick starter.
2. Remove the bolts (2) and detach the crank case cover (3).
3
NOTE
It is recommended to loosen the bolts crosswise before complete

removal.
2
3. Controll the gears and if a gear is damaged please renew this

one (picture 4). 4
65
ENGINE/ DISASSEMBLING/ CLUTCH
CLUTCH REMOVAL
1. Remove the four clutch screws (1) with their springs.
2. Remove the clutch pressure plate (2) and the friction plates
(3).
2
3
3. Rotate the engine and pull out the clutch push rod (4) with the
bearing ball (5) and the bolt (6).
4
NOTE 6
Watch out not to lose the bearing ball.
4. Loose the secure washer (5) for clutch nut and remove the
8
clutch nut (6) and the secure washer.
5. Pull out the inner clutch basket (7) and the outer clutch bas- 7
ket (8) .
6. Also remove the washer (9). It is possible that the washer is

pinched on the rear side of the basket.
9
66
ENGINE/ CRANKCASE
CRANKSHAFT GEAR AND MAIN SHAFT GEAR REMOVAL
2
1. Remove the two nuts (1) and remove the two gears (2).
NOTE
Watch out not to lose the dowel pins.
MEMBRANE REMOVAL
3
1. Remove the three screws (1) and the secure screw (2). 2
2. Remove the mebrane (3).
3. Controll the membrane to their thickness. Hold up the mem-

brane and look if light shine through (picture 1). 1
SPROCKET REMOVAL
1. Remove the circlip (1) and remove the sprocket (2).

1
2. Remove the second circlip (3).
3
67
ENGINE/ DISASSEMBLING/ LEFT CRANKCASE
CRANKCASE COVER (LEFT) REMOVAL
1. Remove the socket head cap screws (1) to remove the left
crankcase cover.
NOTE
1
It´s recommended to loosen the screws crosswise before

complete removal.
STARTER REMOVAL
1. Remove the two screws (1).
1. Remove the screw (2) and pull the starter down to remove
the starter.
STARTER GEAR REMOVAL
2
1. Remove the starter gear nut.
2. Remove the starter gear (1) by using a puller M20x1.5 (2).
Special tool see page 12-15. 1
STATOR REMOVAL
2
1. To extend the stator (1), remove the bolts (2).

2. To extend the pick up (3), remove the screws (4).
1 4
3
68
ENGINE/ DISASSEMBLING/ CRANKCASE
CRANKCASE SEPARATION
1. Rotate the engine 180° and remove the bolt (1) to the right
side.
2. Rotate the engine back to the left engine side.

3. Remove the nine bolts (2).
NOTE
It is recommended to loosen the bolts crosswise before complete 2

removal. 2
4. Pull off the left crankcase (3).
NOTE
• If it is necessary use a soft hammer to tap on the case half. 3

• Tap only on reinforced portions of case.
• Don’t tap on gasket mating surface.
• Work slowly and carefully.
• Make sure the case halves separate evenly. If the cases don’t
separate, check for a remaining case screw or fitting.
• Don’t force.
CRANKSHAFT REMOVAL
1. Pull out the crankshaft (1) of the left crankcase.
1
69
ENGINE/ DISASSEMBLING/ TRANSMISSION
TRANSMISSION DISASSEMBLY
NOTE
After removal of the crank case first check the position of the
2 1
transmission washer (1).
1. Remove the balancer shaft (2).
2. Turn the shift drum (3) till you can pull out the shift shaft (4).
3. Lift the shifting fork shaft (5).
4. Pull back the preload device (6) till it is possible to remove

the shift drum (7).
5. Remove the drive shaft (8) and driven shaft (9) together.
8
9
70
ENGINE/ TRANSMISSION
NOTE
• In Case of a defect of a transmission gear replace always in

a pair.
• Remove damaged bearings if necessary with a bearing pull-
er.
• Use only genuine spare parts.
• Before assembling the engine clean the crankcase and all
sealing surfaces carefully.
• Wash all used parts before install again and apply clean en-
gine oil to all moving and sliding parts.
• Replace all gaskets and check the condition and function of
each part during assembly carefully.
INSPECTION OF TRANSMISSION AND GEAR SHIFT

MECHANISM
NOTE
1
Check respectively wear of tooth surface (1) and drive pawls (2).
If they are seriously worn or damaged, replace them. Remove
bearing and oil seal on left crankcase. Check if bearing and oil
seal are injured. Replace if necessary. 2
71
EXPLODED VIEW / PART LOCATION - PRIMARY SHAFT ASSY/SECONDARY SHAFT ASSY
2
3
4
25 5 1
24 23 6
7
22
21 16 6
8
20
16
19
18
17
16
15 9
14
13
10 12
11
PART LIST - PRIMARY SHAFT

ASSY/SECONDARY SHAFT ASSY
10. Secondary shaft assy 20. Gearwheel 6th gear
1. Primary shaft assy 11. Secondary shaft 21. Gearwheel 2nd gear
2. Circlip 12. Spacer 22. Spacer
3. Spacer 13. Bush 23. Circlip
4. Drive wheel 2nd gear 14. Gearwheel 1st gear 24. Engine drive sprocket 11 T
5. Drive wheel 6th gear 15. Gearwheel 5th gear 25. Circlip
6. Circlip 16. Circlip
7. Drive wheel 3rd and 4th gear 17. Gearwheel 3rd gear
8. Drive wheel 5th gear 18. Spacer
9. Primary shaft 19. Gearwheel 4th gear
72
EXPLODED VIEW / PART LOCATION - SHIFT MECHANISM
2 1
20 3
4
5
21 6
19
7
18 8
29
9
17
28
10
23
11
22
15
16 3 12
27 24
25 14
26
13
PART LIST - SHIFT MECHANISM
1. Gear shift shaft assy 11. Spring bracket 21. Shift fork
2. Circlip 12. Spacer 22. Star washer
3. Washer 13. Stop lever 23. Detent
4. Washer 14. Bush 24. Steel ball
5. Spring 15. Spring 25. Spring
6. Female 16. Shaft 26. Sleeve
7. Washer 17. Nut M6 27. Shift frok
8. Plate gear shift shaft 18. Guid shaft shift fork 28. Guid shaft shift fork
9. Gear shift shaft 19. Shift fork 29. Shift fork
10. Spring 20. Spacer
73
EXPLODED VIEW / PART LOCATION - REDUCTION GEAR
3
6
5 7
4
10
9
PART LIST- REDUCTION GEAR

4. Shift shaft set 8. Shift drum
1. Primary shaft assy 5. Middle fork 9. Left and right fork shaft
2. Secondary shaft assy 6. Middle fork shaft 10. Left and right fork
3. Pin of return spring 7. Fixer set
74
TRANSMISSION AND SHIFT MECHANISM INSPECTION
ITEM STANDARD VALUE (mm) ALLOWABLE LIMIT (mm)

Bore diameter of shift fork 7.825 - 7.845 7.91
Shift fork thickness 3.95 - 4.05 3.9
Shift mechanism
Shift drum outer diameter 41.8 - 42 41.75
Locked groove width of shift drum 6.05 - 6.15 6.3
Check the shift fork shaft (1) with an micrometer.
Allowable limit: 7.91 mm 1
Check the bore diameter of the shift fork (2) with an subito.
2
Allowable limit: 7.91 mm
Check the thickness of the shift fork (3) with an square caliper. 3
Check the diameter of the shift drum (4) with an Micrometer.

4
Check the width of gearshift drum lock groove (5) with an square
caliper. 5

75
TRANSMISSION ASSEMBLING
1
1. Install the primary shaft assy (1) and the secondary shaft 2
assy (2).
3
2. Pull back the preload device (3) and install the shift drum (4).
NOTE
Watch out to the position of the preload device.

4
3. Install the balance shaft (5) and the shift shaft set (6).
5
NOTE
Do not forget the washer (7) of the secondary shaft assy.
7
6
NOTE
Watch out to the position of the return spring (8).
TROUBLESHOOTING
FAILURE CAUSE TO DO
Worn or destroyed gearshift fork Replace
Hard to engage gear Broken shift fork guide pin Replace
Worn gear pawl Replace

Check the clutch mechanism as
Clutch does not separate com-
well the clutch discs and conditions
pletely
Difficult gearshift of the oil
Defect transmission pull spring Replace
Worn gearshift drum lock groove Replace
Connecting pawl is worn and its Replace
edge turns round
Automatic gearshift
Weak transmission unit return
Replace
spring
Worn gearshift drum and shift fork Replace
76
ENGINE/ CRANKSHAFT
NOTE
1. Inspect and clean all parts carefully before assembling.

2. Check all used bearings and replace if necessary. Install the
bearing only with the right tool.
3. If you are not proficient, leave the job an specialist.
CRANKSHAFT INSPECTION
ITEM STANDARD VALUE (mm) ALLOWABLE LIMIT (mm)

Clearance of connecting rod big end in
0.1 - 0.35 0.55
right and left direction
Crankshaft Axial clearance of connecting rod big end
0 - 0.008 0.05
in vertical angle
Vibration --- 0.1
1. Remove the bearings off the crankshaft by using an universal 1

bearing puller (pictue 1).
2. Measure the connecting rod axial side clearance (1).
Allowable Limit : 0.55 mm
3. Measure the connecting rod radial clearance in X and Y di-

rection.
Allowable Limit (X/Y): 0.05 mm X
Y
77
ENGINE/ CRANKSHAFT
4. Measure the run-out at the bearing pins of the crankshaft.
Allowable Limit (A/B): 0.1 mm
5. Check the crankshaft bearings for excessive play. The bear-

A
ings must be replaced if they are noisy or have excessive
play.
B
NOTE
If the crankshaft, transmission shaft and balance shaft installed

in the left crankcase put some surface sealant thin on the plane
surfaces of the left crankcase (arrow). Please note that there is 1
no separate gasket available.
Installation of right crankcase should work smooth and without
additional force. Watch out the shafts move to the right position
before fixing the crankcases with screws. Disassemble and as-
semble again if the engine parts do not fit together smooth.
If necessary heat up the right crankshaft bearing before assem-
bling.
Tighten all screws (1) with the specific torque in reversed order
of disassembling.
Do not forget the screw on the right engine side.
TORQUE LIST
PART NO. TORQUE
1 10 - 12 Nm
TROUBLESHOOTING
FAILURE CAUSE TO DO
Loosen or damaged parts (bear-
Noise out from the crankcase Replace
ings, gears,....) in the crankcase
78
ENGINE/ TOP END
TOP END PARTS INSPECTION
NOTE
Before reinstall the piston and piston pin measure all dimensions
if they are within the limits.
STANDARD VALUE ALLOWABLE LIMIT

ITEM
[mm] [mm]
Cylinder inner diameter 40.27 - 40.28 40.3
Cylindrically --- 0.05
Cylinder
Roundness --- 0.05
Flatness --- 0.05
Piston pin hole inner diameter 12.002 - 12.008 12.04
Piston pin outer diameter 11.994 - 12 11.96
Piston outer diameter 40.22 - 40.23 40.2
Clearance between piston and piston pin 0.002 - 0.014 0.08
Piston
Clearance between the piston Top ring 0.015 - 0.05 0.9
ring and piston ring groove Second ring 0.015 - 0.05 0.9
Top ring 0.1 - 0.25 0.5
Joint clearance of piston ring
Second ring 0.1 - 0.25 0.5
Connecting rod small end inner diameter 14.995 - 15.006 15.06
Connection rod
Clearance between linkage rod and piston pin 0.002 - 0.014 0.08
CYLINDER INSPECTION
1. Inspect the abrasion and the wear of the cylinder inner wall.
2. Measure the cylinder bore with an subito at three levels of A,
B and C.
Allowable service limit: 40.3 mm

A
3. Check if the cylinder is broken. Check for any carbon deposi- B

tion. If necessary replace it. C
79
ENGINE/ TOP END
1. Inspect the flatness of the cylinder. (1. Ruler, 2. Measuring
gauge, 3. Cylinder)
Allowable limit A: 0,05 mm
A
1
2
NOTE
1
Inspect the cylinder head in the same way.
2. Inspect the flatness of the cylinder head. (1. Ruler, 2. Meas-

uring gauge, 3. Cylinder head)
B
Allowable limit B: 0,05 mm
2 3
3. The measuring position and the piston pin form an angle of

90 degree, and 15.5mm (C) below the skirt of piston.
Allowable limit C: 40.2 mm

C
4. Measure the bore diameter of the piston pin hole. Measure

both X and Y directions.
X
Allowable limit X/Y: 12.04 mm Y
5. Measure the outer diameter of the piston pin at three levels

of A, B and C.
A
Allowable limit: 11.96 mm B
C
80
ENGINE/ TOP END
6. Measure the clearance (X) between piston ring (1) and

piston ring groove (2) with an spacer gauge.
1
Allowable limit: Top ring: 0.09 mm
Second ring: 0.09 mm
X
7. Measure the bore diameter (X) of the connecting rod small

end inner diameter with an subito.
Allowable limit: 15.06 mm X
PISTON INSTALLATION
1
1. Put some oil on each piston ring and the piston.
2. Install the piston ring by aligning it with the guide pin (1) on 2
the piston.
(2): Top ring

(3): Second ring
NOTE 3
The piston should not be scratched and the piston ring should not
be broken.
The piston ring should be assembled with its marked side up-
ward.
3. Install according to the arrow mark (4) on the piston top.
! WARNING
The retaining ring should not fall into the crankcase. 4

81
ENGINE/ TOP END
CYLINDER INSTALLATION
4. Install the cylinder gasket (1).

5. Add some fresh engine oil on the piston, piston ring and the
inner cylinder wall.
NOTE
A piston ring pincer helps to install the piston in the cylin-

der (2). Handle with care not to damage or scratch any part.
CYLINDER COVER INSTALLATION
NOTE
5
Before reinstall the cylinder head check all parts. 1
• Constant temperature set (1)

• Spark plug (2)
• Temperature controller (3)
• Temperature sensor (4)
NOTE
Improperly tightened cylinder head bolts may result in gasket

leaks, stud failure and distortion of the cylinder and/or cylinder
head.
All the components shall be cleaned before installation, and 4

purged with high-pressure air. A
C
1. Use new gaskets (5).
2. Apply a small dab of medium strength threadlocker to th-
reads .
3. Alternately turn each cylinder head bolt until finger tight. 3
4. Tighten the cylinder head bolts in the sequence (A-B-C-D)
shown in the picture. D 2 B
TORQUE LIST
PART. NO. TORQUE
A,B,C,D 18 - 22 Nm
2 8 - 12 Nm
3 8 - 12 Nm
4 8 - 12 Nm
82
ENGINE/ LEFT CRANKCASE
LEFT CRANKCASE ASSEMBLING
1. Install the stator (1) and the pick up (2).

Tighten the srews in specific torque.
NOTE
If there is any signal fault of generator or pick up replace the sta- 1

tor together with the pickup.
3
2. Install the starter gear (3).
TORQUE LIST
4
PART. NO. TORQUE
4 35 - 40 Nm
3. Pull the starter (5) in the crankcase and tighten the screws (6)
in specific torque.
4. Alternately turn each bolt until finger tight.

2
5. Tighten the bolts in sequence (1-5) shown in the picture.
TORQUE LIST
3
PART NO. TORQUE
1-5 10 - 12 Nm
4
5
1
83
ENGINE/ LEFT-RIGHT CRANKCASE
SPROCKET INSTALLATION
1. Assemble the sprocket in reverse order of removal (see page

65)
MEMBRANE INSPECTION
1
1. Controll the membrane to their thickness. Hold up the mem-
brane as shown in the picture (1) and look if light shines
throug. If light shines throug the membrane renew the mem-
brane.
MEMBRANE INSTALLATION
1. Install the membrane (1) and thighten the three bolts (2) in
specific torque. 1
2. Tighten the secure bolt till the head (3) of the bolt brakes 2
away.
3
RIGHT CRANKCASE ASSEMBLING

1
1. Install the dowel pins.
2. Install the crankshaft gear (1) and the primary shaft gear (2)
together. Do not use any additional force like a rubber ham-
mer. If necessary heat up the crankcase and cool down the
crankshaft. Install the crankshaft together with the primary
shaft gear at the following marking (Picture 1).
3. Tighten the two nuts (3).

4. Before continue assembling check the clutch. 2
3
84
ENGINE/ CLUTCH
CLUTCH INSPECTION 1 2
1. Check if there are burs or broken parts on the center bracket

(1) or pressure plate (2) of clutch. If there are, fix and adjust
with a file.
2. Check if teeth of pressure plate and center bracket are injured.
If they are, replace them.
3. Check the thickness of clutch friction plates (3).

X
Allowable limit X: 2,6 mm
3
4. Check the metal discs.
5. When the metals worn, wrapped or glazed, replace it.
6. Check the free length of pressure spring (4).

4
Allowable limit Y: < 29,7 mm.
7. When one of the springs is below the allowable limit or very

weak replace it.
NOTE
Replace clutch friction plates or clutch metal discs always as set. Y

85
ENGINE/ CLUTCH
EXPLODED VIEW / PART LOCATION - CLUTCH
13 15
14
12
11
10
9
7
16
17
5
1 2 4
3
PART LIST - CLUTCH
1. Clamp nut 7. Locknut 13. Housing set

2. Adjustment bolt 8. Fixing gasket 14. Dish gasket
3. Bolt and gasket 9. Wearing plate 15. Washer
4. Pressure spring 10. Iron friction plate 16. Bearing ball
5. Pressure cover 11. Center 17. Inward release lever
6. Outward release lever 12. Internal gasket
NOTE
Before start to assemble the clutch, install the washer (15) first.
15
86
ENGINE/ CLUTCH
CLUTCH ASSEMBLING
1. Install housing set (1) and the internal gasket (2).
2
1
2. Install the center (3), the secure washer (4) and the nut (5).
5
NOTE
3
Watch out to the position of the secure washer.
3. Tighten the locknut (5) an fix the secure washer (4).
TORQUE LIST
PART NO. TORQUE 4
5 50 - 60 Nm
4. Insert inward release lever (6), bearing ball (7) and outward
release lever (8) afterwards. 8 7 6
5. Start assembling the clutch with a wearing plate. Alternately

clutch wearing plate and iron friction plate (picture 1). 1
6. Afterwards install the pressure plate (9).

2
NOTE
Watch out to the position of the pressure cover.

The arrow on the pressure cover had to show to the point on the
center (picture 2).
9
87
ENGINE/ CLUTCH/ RIGHT CRANKCASE
7. Install the springs (10) and the screws (11). 8

8. Tighten the screws.
TORQUE LIST 12
PART. NO. TORQUE 11
11 10 - 16 Nm
OUTWARD RELEASE LEVER ADJUSTMENT

10
1. Pull out the release lever (8). The clearance should be about
1mm.
2. If the clearance is not 1mm, loosen the nut (12) and screw
in or out.
1 3
3. Tighten the nut (12).
ACTUATING LEVER INSPECTION
1. Inspect the elasticity of the return spring (1) and ratchet

spring (3) and if there is damage, replace them.
2
2. Inspect the actuating lever (2), the ratchet (4) and the actuat- 4 5
ing gear (5) and if there is damgae, replace them.
ACTUATING LEVER ASSAMBLING

1
1. Assemble the actuating lever as shown in picture (1).
2. Take special care about the assemble of the return spring
and the ratchet.
NOTE
The return spring tap had to get in the bore of the actuating lever.
The second return spring tap should be in a axial line witch the
ratchet tap.
3. Install the actuating lever. 2

4. The second return spring should be in the middle between
the clutch and the guid pin as shown in picture (2).
RIGHT CRANKCASE ASSEMBLING

1 4
5. Alternately turn each bolt until finger tight. 2
6. Tighten the bolts in sequence (2-7) shown in the picture.
TORQUE LIST
PART. NO. TORQUE 7
2-7 10 - 12 Nm
3
5
6
88
ENGINE/ ACTUATING LEVER
ACTUATING LEVER ADJUSTMENT
1. Turn the actuatin lever (1) 180° counter clockwise (arrow).
2. After turning the actuating lever, screw in the bolt (2).
TROUBLESHOOTING
FAILURE CAUSE TO DO
Clutch cable defect, twisted or contaminated Replace or clean it
Tight clutch release lever
Defect push rod or lifter bearing Replace it
To less clutch clearance Adjust it
Worn clutch disc Replace it
Weak clutch spring Replace it
Clutch slips at acceleration
Sticky push rod Replace or clean it
Oil wasted or level incorrect Adjust level or replace it
Clutch cable incorrect adjusted Adjust it
Worn or broken clutch pads Replace it
Gearshift difficult Clutch springs weak or broken Replace it
Oil wasted or level incorrect Adjust level or replace it
Wrong oil type or level incorrect Adjust level or replace it
Clutch not released or motorcycle
Too big push rod clearance Adjust it
drags when clutch released
Clutch cabel incorrect adjusted Adjust it
89
ENGINE/ ASSEMBLING/ OIL PUMP
EXPLODED VIEW / PART LOCATION - OIL PUMP
12
11
10 9
8
6
7 14
1 2
13
3 4
PART LIST OIL - PUMP
1. Throttle handle set 6. Circlip 11. Oilpump cover

2. Torsion spring 7. Piston 12. Bolt
3. Camshaft 8. Piston spring 13. Worm gear
4. Oil pump body 9. Worm wheel 14. Oil seal
5. Regulating plate 10. Oil pump cover gasket
OIL PUMP INSPECTION
1. Inspect wear and tear of the worm wheel and worm gear. 7
Severe wear and replace.
2. Inspect wear and tear of the camshaft. Severe wear and re- 1
place.
3. Measure the outer diameter (1) of the piston (7).
OIL PUMP ASSEMBLING

1
1. Install the oil pump (1) on the right crankcase and check free
2
movement.
2. Tighten the bolts (2).
TORQUE LIST 2
PART NO. TORQUE
2 8 - 12 Nm
90
ENGINE/ LUBRICATION SYSTEM
LUBRICATION SCHEME
5
PART LIST - LUBRICATION SYSTEM
1. Oil tank NOTE

2. Oil pump When the engine oil pump is removed, clean care-
3. Carburettor fully all the components and purge them with high-
4. Crankshaft pressure air.
5. Crankcase During engine oil pump removal and installation, pay
attention not to drop anything into the crankcase.
Oil flow direction
91
ENGINE/ COOLING SYSTEM/ WATER PUMP
COOLING SYSTEM SCHEME
PART LIST - LUBRICATION SYSTEM
1. Water pump
2. Connected to the water tank
3. Flow back to the water tank
Water flow direction
WATER PUMP INSPECTION
1. Inspect the wear and tear of the impeller set (1). Severe
wear and replace it.
WATER PUMP ASSEMBLING
1. Install the oil pump (1) on the right crankcase and check free
movement. 2
2. Tighten the bolts (2).
NOTE
Renew the gasket.

TORQUE LIST 1
PART NO. TORQUE
2 8 - 12 Nm
92
ENGINE/ WHEELS AND TIRES
NOTE
Assemble the engine to the frame in reversed order of removal.
! WARNING
Add oil and water before starting the engine. Double check
engine oil amount by engine oil niveau screw.
EXPLODED VIEW / PART LOCATION - FRONT WHEEL
3
10
1 4
4 11
2 9
5
PART LIST - FRONT WHEEL
1. Axle 7. Valve/ dust cap

2. Speedometer 8. Brake disc
3. Oil seal 22x35x7 9. Mounting bolts
4. Rolling bearing 6202-2RS 10. Middl shaft sleeve
5. Tire 100/80-17 11. Left shaft sleeve
6. Rim 2.25x17
93
WHEELS AND TIRES
EXPLODED VIEW / PART LOCATION - REAR WHEEL
10
11
12 13
2
1 4 6 4
8
14
3 5 7
5 3
9
15
PART LIST-REAR WHEEL
1. Axle 6. Mounting bolts of chain 11. Rim 3.00x17

2. Press plate wheel 12. Brake disc
3. Left sleeve 7. Chain wheel 55T 13. Mounting bolts of brake
4. Oil seal 22x35x7 8. Bearing sleeve disc
5. Rolling bearing 6202- 9. Chain 420DX-1x128 14. Fixing nut M14x1.5
2RS 10. Tire 130/80-17 15. Valve/dust cap
ITEM DIMENSION PRESSURE/ BAR MINIMUM TREAD DEPTH

Front tire 100/80 - 17 Technically - 1,6 mm
2.25 Legal value may be different
Front rim 2.50 x 17
Rear tire 130/80 - 17 Technically - 1,6 mm
2.5 Legal value may be different
Rear rim 3.00 x 17
TROUBLESHOOTING
FAILURE CAUSE TO DO
It’s hard to move the wheels or wob- One wheel bearing is damaged Replace the bearing
bly Front Wheel The tire air pressure is to low Adjust the air pressure
Rim damaged Replace the rim
Wheel unbalanced
Tire worn Replace the tire or Balance the wheel
Wheel bearing loosened or worn Replace the bearing
Abnormal or scratching noise
Speedometer drive defect Replace the speedometer drive
94
WHEELS AND TIRES
WHEELS (RIMS)
The wheel rims should be checked for cracks, bends. If any dam-
age is found replace the rim. Do not attempt even the smallest
repair of the wheel. The wheel should be balanced whenever
either the tire or the rim has been changed or replaced. An unbal-
anced wheel can result in poor performance, adverse handling
characters, and a shortened tire life.
TIRES
The tires must be checked during each workshop visit. If a tire

tread shows crosswise lines (minimum tread depth), the tire has
a fragments in it, the sidewall is cracked then replace the tire im-
mediately. Operating the motorcycle with excessively worn tires
will decrease the riding stability and can lead to loss of control.
Please replace the excessive worn tires immediately. X
NOTE
Allowable tread limit X : Technically - 1,6 mm
WHEEL BEARING REPLACEMENT FRONT WHEEL
The wheels rotate with difficulties. The wheel-axle bearing or the

gear seats are in failure. To find the error, the wheel must be
removed.
1. Stand the motorcycle reliably.

3. Remove front axle (2), take down speedometer gear assem-
bly (3) and front wheel. 2 4
4. If necessary screw off bolts and remove front mudguard and
lead wire of odometer. 1
5. Remove oil seal (4) and bearing (5).

TORQUE LIST 2 4 5 5 4
PART NO. TORQUE
1 5-9 Nm
2 55-62 Nm
.
3
95
WHEELS AND TIRES
WHEEL BEARING REPLACEMENT REAR WHEEL
1. Place the vehicle on a suitable repair stand. 1 4

2. Disconnect the chain (1).
3. Remove the fixing nut (2) and remove the axle (3).
4. Remove the rear wheel (4). 2
5. Remove the oil seal (5) and the bearing (6).

6
6
3 5 2
5
WHEEL BEARING INSPECTION
1. Examine the rolling condition of the bearing. Rotate inner A

race with a finger.
2. If it doesn’t roll, or the bearing is damaged, or out of
clearance (A,B) or loosened or rough spot it should be B
replaced.
WHEEL AXLE INSPECTION
1. Put the wheel axle on a V-shape seat and use dial indicator
to measure its eccentricity.
Allowable limit A: 0.2 mm
RIM INSPECTION
1. Place the wheel on a precise support and check the imbal-

ance with a dial indicator. B
2. Turn the wheel with your hands and read it from the dial
gauge.
A
Allowable limit: A: Axial: replace it, if it’s over 2.0 mm
B: Lateral: replace it, if it’s over 2.0 mm
3. If the rim is out of limit repair or replace it.

NOTE
Also check the wheel bearings. This could be the cause of the defect.
96
BRAKES
EXPLODED VIEW / PART LOCATION - FRONT BRAKE
! WARNING
THE BRAKING COMPONENTS MAY NOT BE SPOIL

BY OIL DURING INSTALLATION OR DISASSEMBLY.
RINSE WITH STIPULATED CLEANING AGENT IN ORDER TO
AVOID REDUCTION OF BRAKING QUALITY.
9
9
1 2 5 7
6
8
10
4
3
8
9
11 9
12
13
15
14
PART LIST - FRONT BRAKE 5. Master brake cylinder 11. Brake calliper bolts M 8 x 30
6. Master brake cylinder clamp 12. Brake calliper with anchor plate
1. Brake lever 7. Clamp bolt M 6 x 23 13. Brake pads
2. Brake lever bolt 8. Banjo bolt 14. Brake disc bolts M 6 x 16
3. Nut M 6 9. Gasket 15. Brake disc
4. Brake light switch 10. Brake hose
SPECIFICATION
ITEM STANDARD VALUE [mm] ALLOWABLE LIMIT [mm]
Thickness of front brake disc 4.0 3.0
Thickness of front brake pads 4.5 3.0
Diameter of front brake disc 280 -
TORQUE LIST
PART NO. TORQUE
Front brake / No. 2 3 Nm
Front brake / No. 7 5 - 9 Nm
Front brake / No. 8 22- 24 Nm
Front brake / No. 11 22- 29 Nm
Front brake / No. 14 22 - 29 Nm
97
BRAKES
EXPLODED VIEW / PART LOCATION - REAR BRAKE
12
17
14
13
5 15
3
4
7
18
19
16
9 10
6
8
11
PART LIST-REAR WHEEL
1. Brake system 8. Seal 15. Nut M8x20

2. Brake fluid reservoir 9. Brake line 16. Brake pads
3. Brake line 10. Banjo bolt 17. Cover master cylinder
4. Clamp 11. Seal 18. Bush
5. Brake light switch 12. Distance caliper 19. Nut M6x20
6. Master cylinder 13. Adapter plate
7. Caliper 14. Distance caliper
SPECIFICATION
ITEM STANDARD VALUE [mm] ALLOWABLE LIMIT [mm]
Thickness of front brake disc 4.0 3.0
Thickness of front brake pads 4.5 3.0
Diameter of front brake disc 280 -
TORQUE LIST
PART NO. TORQUE
Rear brake / No. 10 22-24 Nm
Rear brake / No. 15 22-29 Nm
98
BRAKES
SPECIAL TOOLS
See page 12-15.
TROUBLESHOOTING
FAILURE CAUSE TO DO
Unfavourable brake adjustment Adjust the brake system
Brake pads worn Replace the brake pads
Brake pads installed improperly Install the brake pads proper
Poor brake performance
Clean or replace the brake pads
Brake pads or brake disc contaminated
and clean the brake disc/ drum
Air in the front brake hose Bleed the brake hose
Gasket(s) leaky Replace affected gasket
Brake pads glazed Replace the brake pads
Burrs Grind away burr
Strange sound during braking
Clean or replace the brake pads
Brake pads or brake disc contaminated
and clean the brake disc/ drum
Brake disc worn Replace brake disc
Pulsing during braking
Brake drum worn Repalce the rear rim
BRAKE LEVERS / FRONT BRAKE LEVER
The front brake lever is located on the right side of the handle- 1
bar. 2
NOTE
This lever operated by hydraulic the front brake. It is not

possible to adjust the free-play of the front brake lever. When
the brake lever feels spongy or the brake performance is poor
the front brake system have to be bleeded.
It is possible to adjust the grip width by loosing the fixing nut (1)
and screwing the adjustment bolt (2) in or out.
See page 38.
BRAKE LEVERS / REAR BRAKE PEDAL
The rear brake pedal is located on the right side of the vehicle.
NOTE
This lever operated by hydraulic the rear brake. When the brake
pedal feels spongy, the brake performance is poor or the free
play (A) is not correct the rear brake system have to be adjust-
A
ed. See page 38.
99
BRAKES
BRAKE FLUID
! WARNING
1. Never use dirty or unspecified brake fluid or mix different

brake fluids because it will damage the brake system.
2. Brake fluid spilled on brake pads or brake disk will reduce the
braking effect. Clean the brake pads and brake disk with a
high quality brake degreaser.
3. When servicing the brake system, use shop towels to cover
plastic parts and coated surfaces to avoid damage caused by
splash of brake fluid.
4. Do not allow dust or water to enter the brake system during
refilling.
5. Brake fluid should be replaced at least every 2 years.
SPECIFICATION
Brake fluid type CASTROL SUPER DISK BRAKE FLUID DOT 4

Brake fluid boiling temperature > 170°C
Brake fluid water content < 3%
BRAKE HOSE
1. When the front/rear brake hose is leaking, cracked or worn

you had to replace it.
NOTE
Please consider that there is no need to remove the brake

calliper when you need to replace the brake hose.
2. When the brake hose need to be replaced use only genuine

parts.
3. For brake hose replacement see page 37.
FRONT/ REAR BRAKE PAD INSPECTION

pads in pair.
Front: See page 32

Rear: See page 33
100
BRAKES
BRAKE PEDAL REPLACEMENT
1. Remove the splint (1) and loosen the fixation nut (2) to re-
move the screw (3).
2. Remove the splint (4) and loosen the fixation nut (5) to re-
move the screw (6).
4 5
6
! WARNING
If you remove the screw (6), the brake pedal can be spring out. 2 3
1
NOTE
Look to the position of the spring (7) and the screw.
3. After removing the fixation nut (5) for the foot brake lever you
can pull off the foot brake pedal to the side.
4. Unscrew the adjustment screw (8). Screw the adjustment
screw in the new brake pedal in.
7
5. Assemble the new brake lever in reverse order.
8
101
SUSPENSION
EXPLODED VIEW / PART LOCATION - FRONT SUSPENSION

4
1
5 2
3
6
4
8
25
10
12 7 37
36
9
14 35
11 26
13 27
18
19
17 15
20
16
28 38
21 29 40
39
22 27
33
23
43
30
24 31 44
32 41
42
34
45
PART LIST - FRONT SUSPENSION
1. Screw M8x35 16. Lower triple tree assy 31. Bracket speedometer drive
2. Washer M8 17. Screw M5x12 cable
3. Upper handlebar clamp 18. Washer M5 32. Washer M5
4. Screw M5x30 19. Bracket 33. Nut M5
5. Screw M8x40 20. Screw M6x30 34. Screw M6x16
6. Upper triple tree 21. Lower triple tree 35. Screw M5x25
7. Bracket speedometer 22. Bracket head light 36. Nut M5
8. Locknut steering 23. Screw M5x12 37. Bracket indicator left
9. Nut 24. Bracket head light 38. Screw M5x25
10. Upper bearing race 25. Bracket indicator right 39. Nut M5
11. Lower bearing race 26. Shock absorber 40. Bracket brake hose
12. Bearing 6205-2RS 27. Oil seal 41. Dust ring
13. Bearing 30205 28. Dust ring 42. Screw M5x20
14. Seal 29. Fork cover right 43. Nut M5
15. Steering column 30. Screw M5x12 44. Fork cover left
45. Reflector orange
102
SUSPENSION
TORQUE LIST
PART NO. TORQUE
8 5-9 Nm
SPECIFICATION
ITEM DESCRIPTION VALUE

Fork travel Telescope unit (cartridge) - oil/ spring 110 mm max. travel
Upper bearing 6205-2RS
Lower bearing 30205
DESCRIPTION (VERSION 0) STANDARD NOTE

Air chamber length by fork rod (gas filling) 80 mm
Air chamber length by fork rod (spring) 95 mm FILLING WITHOUT SPRING
Oil 15 wt
Azotic 1.2 bar
DESCRIPTION (VERSION 1) STANDARD NOTE

Air chamber length by fork rod (gas filling) 80 mm
Air chamber length by fork rod (spring) 95 mm FILLING WITHOUT SPRING
Oil 15 wt
Azotic 1.5 bar
103
SUSPENSION
EXPLODED VIEW / PART LOCATION - ADJUSTABLE REAR

SUSPENSION
2
1
3
5 2
PART LIST-REAR SUSPENSION
1. Screw M10x1.25x50 4. Adjust nut

2. Nut M10x1.25 5. Lock nut
3. Shock absorber
SPECIFICATION
Rear shock absorbers Adjustable, spring loaded telescope units (cartridge) 60 mm max. travel
TORQUE LIST
PART NO. TORQUE
2 37 - 44 Nm
NOTE
By turning the lock nut (5) and adjustment nut (4) the suspension
setting is changeable. The factory setting is done for the driver
and passenger.
1. Open the lock nut (5).

2. Turn in or out the adjustment nut (4).
3. Secure the adjustment nut by closing the lock nut.
! WARNING
The adjustment must be the same on the left and right side. The
more the spring is compressed the harder the suspension. Never
exceed the max. payload - 150 kg.
104
SUSPENSION
SPECIAL TOOLS
There are no special tools recommended because defect

suspension elements may not be dissembled. Always´s replace
defect suspension elements.
TROUBLESHOOTING
FAILURE CAUSE TO DO
Insufficient tire pressure Adjust the tire pressure
Broken or bent fork leg Replace the affected fork leg
Vehicle difficult to steer
Control and adjust or replace af-
Uneven front shock absorbers
fected fork leg
Weak shock spring Replace the affected fork leg
Soft front shock absorber
Insufficient damper oil Replace the affected fork leg
Broken or bent fork leg Replace the affected fork leg
Front shock absorber noise
Loose fork fasteners Tighten the fasteners
Lack of lubrication Replace the affected fork leg
Leaking fork leg Gasket defect Replace the affected fork leg
Weak rear shock absorber
Spring worn or broken Replace the rear shock absorber
spring
Leaking rear shock absorber Gasket defect Replace the rear shock absorber
NOTE
Before each repair of a defect suspension element consider the

max. payload the vehicle.
FRONT SUSPENSION REPLACEMENT

2. Remove the brake calliper and brake line bracket, the front
1
wheel, the front fender and the handle bar.
NOTE
The fork legs have a second pair of internal fork leg bolts which
avoid that fork oil flow out.
3. Loosen the bolts (1) on the lower and upper triple tree on
both sides and the bolts (2) an the left side.
4. Drag the fork leg downwards. 2
5. Replace the affected fork leg.
6. Assemble in reversed order.
TORQUE LIST
2
PART NO. TORQUE
1
1 37-44 Nm
105
SUSPENSION
FRONT SUSPENSION WHOLE FORK REPLACEMENT

2. Remove the handlebar (1), head light (2), and upper triple 2
tree (3). 3
3. Remove the brake calliper and brake line bracket, 1
the indicator brackets, the front wheel, and the front fender.
4. Remove the fixation nut (4) and the dust cap (5).
5. Lift the vehicle or lower the front fork.

6. Remove the lower bearing components (6) from the removed
front fork.
NOTE
All clamps and brackets which screwed on the lower triple tree
6
must be also removed.

.
REAR SUSPENSION REPLACEMENT 1 4
1. Place the vehicle on a motorcycle stand on a flat surface to

raise the rear wheel up.
2. Remove the seat (1), the right side cover (2), the front right
side cover (3) and the tank (4). 2
3. Remove the rear fender cover (5).
5
106
SUSPENSION
1. Remove the lower bolt (6) first and upper bolt (7) of the
shock absorber.
2. Pull the shock absorber backwards and remove it to the left

side (Arrows).
3. Assemble the new shock in reverse order.
TORQUE LIST
PART NO. TORQUE
No. 6 37-44 Nm
No. 7 37-44 Nm
REAR SWING ARM REPLACEMENT
To replace the rear swing arm please follow the below men-
tioned steps:
1. Place the vehicle on a motocycle stand on a flat surface.

2. Open the chain lock and remove the chain.
3. Disassemble the rear brake parts which are connected to 1
the swing arm or the rear wheel.
4. Loose the rear wheel shaft and remove the rear wheel.
5. Remove the two bolts (1) of the rear suspension.
6. Lose the rear swing arm shaft nut (2) on the rigt side and
pull out the rear swing arm shaft (3) to the left.
7. Replace the chain case, the chain guid front, the chain guid 2
rear, the chain roller and the brake wire clamps and provide
the parts on the new swing arm.
8. Assemble the new swing arm in reverse order.
9. After assembling in reverse order adjust the chain tension,
check the rear brake operate correct and check if all nuts
are tightened securely.
3
107
STEERING
EXPLODED VIEW / PART LOCATION - STEERING
2
4
3
7
9
11 8
10
13
12
15
16
14
17
PART LIST - STEERING
1. Screw M8x35 7. Upper triple tree 13. Seal

2. Washer 8. Nut 14. Lower triple tree assy
3. Upper handlebar clamp 9. Upper bearing race 15. Steering column
4. Handlebar 10. Lower bearing race 16. Lower triple tree
5. Locknut steering 11. Bearing 6205-2RS 17. Screw M6x30
6. Screw M5x30 12. Bearing 30205
SPECIFICATION TORQUE LIST

ITEM DESCRIPTION PART NO. TORQUE
Upper bearing 6202-2RS 1 20 - 23 Nm
Lower bearing 30205 5 40 - 48 Nm
SPECIAL TOOLS
See page 12-15
TROUBLESHOOTING
FAILURE CAUSE TO DO
Steering bearing loose Retighten the bearing
Vehicle difficult to steer
Steering bearing worn Replace the steering components
108
STEERING
HANDLEBAR REPLACEMENT
In case of any damage of the handlebar you must replace it.
1. Remove the left (1) and right handle switch (2) as described
in the manual.
1
2
2. Loosen the four screws (3) and remove the handlebar

clamp (4). 4
3. Loosen the two screws (5) and remove the right handle
swicht by sliding to the right. If the wires are too short, put
the handlebar to the left.
4. Remove the two screws (6) of the front brake clamp (7) to
remove the front brake lever . It is not necessary to remove
the rear view mirror.
NOTE
If you remove the front brake handle do not apply the brake as
pulling the brake in a non horizontal position of the brake system
could let air get into the brake system which would lead to a loss
of brake pressure. 7
6
109
STEERING
5. Loosen the screw (8) and slide the left handle switch to the
right.
6. Pull off the left grip from the handle bar would be more dif-
ficult as the grip is normally glued with grip glue.
We suggest to use compressed air (9) and in same way
pull the grip to the left.
NOTE 8
9 10
We suggest buying a new left handle grip if it is necessary to
replace the handlebar.
7. Disconnect the choke cable (10) and slide the left handle
switch to the left. It is not necessary to remove the rear
view mirror.
8. Replace the damaged handlebar.
9. Assemble the handlebar in reverse order.
CLUTCH LEVER REPLACEMENT
1. Loose the secure nut (1) for the clutch lever and unscrew
the clutch lever bolt (2).
2
2. Rotate the clutch cable adjustment nut (3) and the secure
nut (4) till the grooves are in line.
3. Now it is possible to remove the complete clutch lever to-
gether with the clutch cable from the clutch coupling joint.
3 4
4. Unhinge the clutch cable (5) from the clutch lever to replace
the clutch lever.
5. Assemble the new clutch lever in reverse order.
5
110
STEERING/ EXHAUST
BRAKE LEVER REPLACEMENT 2
1. Loose the secure nut (1) for the brake lever and unscrew the
brake lever bolt (2) with a flat-headed screwdriver.
2. Now it is possible to remove the brake lever from the front
brake system.
3. Unscrew the adjustment screw (3). Screw the adjustment

screw in the new brake lever in.
4. Assemble the new brake lever in reverse order.
EXHAUST REPLACEMENT
In case of a damaged muffler remove the exhaust pear (1)

consisting of two parts or the silencer (2) and replace the damage
2
exhaust part with a new one.
NOTE
If you remove the muffler short after a ride take care as the
muffler could be still very hot.
1
Exhaust pear
1. Remove the two springs (3) and disconnect the hose (4) of
the secondary air system. 4
2. Loosen the screw (5) and the two screws (6).
6
111
EXHAUST
3. Remove the screw (7).
4. Pull the exhaust pear frontwards (arrows).
5. To disconnect the exhaust pear remove the three screws

(8). If you disconnect the exhaust pear always renew the
gasket (9) with a new one.
9
8
Silencer
12 10
1. Remove the seat, the side cover (10), the rear fender (11)
and the rear cover (12) .
NOTE
It is not nessecary to disconnect the seat lock cable from the 11

rear side cover (12).
13
112
EXHAUST/ SECONDARY AIR SYSTEM
4. Pull the silencer backwards (Arrow).

SECONDARY AIR SYSTEM INSPECTION
1. Remove the seat, the right side cover and the cover (1).
2. Disconnect the two hoses (2).
3. Remove the three screws (3) and remove the secondary air
system (4). 4
4. Remove the membrane cover (5).
5
113
SECONDARY AIR SYSTEM
5. Controll the membrane (6).

6. If the membrane is broken or work wrong please replace the
whole secondary air system. 6
7. Install the secondary air system in reverse order.
114
ELECTRICAL SYSTEM/ GENERAL
WIRING DIAGRAM
115
LOCATION - ELECTRICAL SYSTEM

4
3
5
1 2
7 11
8
9 10
13
12
PART LIST- ELECTRICAL SYSTEM

7. Regulator rectifier
1. Winker relay 8. Ignition coil
2. Main fuses 10 Ampere 9. CDI (capacitor discharge ignition)
3. Main switch/ power lock module 10. Starter relay
4. Speedometer 11. Batterie 12V / 3Ah
5. Front brake - brake light switch 12. Neutral sensor
6. Rear brake - brake light switch 13. Horn
116
LOCATION - LIGHTS / INSTRUMENTS SWITCHES
2 9
8
10
2
6
8
3
1
4
3 5
8
2 7
PART LIST - LIGHTS / INSTRUMENTS SWITCHES CERTIFICATION NO.
1. Head light PART NAME CE NO.

2. Turn signal front Head light E4 - 0011534
3. Side reflector Rear light E4 - 0011535
4. Instrument panel and indicators
Number plate light E11 - 0000066
5. Main switch/ power lock module
6. Handle switch right Indicators E4 - 000875
7. Handle switch left Side reflector E4 - 023273
8. Turn signal rear Rear reflector E11 - 023584
9. Rear light and brake light
10. Rear reflector and number plate light
117
SPECIFICATION
ITEM NOMINAL VALUE
Spark plug gap 0.6-0.7 mm
Primary coil 0.4 Ω±10%
With spark 8-11 KΩ
Resistance value of ignition coil (20°C)
plug cover
Secondary coil
Without spark 4.5 - 5.5KΩ
plug cover
Resistance value of trigger (20°C) 100-200 Ω (bl/w-gr/w)
Trigger voltage Above 1.7 V
Capacity 12 V / 3 AH
Voltage 13.1 - 12.3 V
Standard 0.4 A
Battery (Model: YT4L-BS/ 12 V, 3.0 Ah) Charging current
Quick 1.5 A
Standard 5-10 h
Charging period
Quick 1h
Capacity 80W/5000 rpm
Magneto Impedance value of
Between white and black 3.3-3.5 Ω
charging coil (20°C)
single-phase semi wave SCR charge, SCR
Type
semi wave short circuit mode
Voltage regulator 12.0-14.0 V / 5000 rpm
Lightning limit
Voltage limit 13.5 V / 5000 rpm
Charge limit 14-15 V / 5000 rpm
Fuse 2 Mainfuse 10 Ampere
SPECIAL TOOL
See page 12-15
118
ELECTRICAL SYSTEM/ FUSE/ BATTERY
FUSE REPLACEMENT
If the fuse is burned out, find the cause and repair it. The fuse
holder is located beside the battery below the seat.
1
1. Turn off the main switch and all electrical circuits.
2. Remove the seat.
3. Replace the blown fuse (1) and then install a new fuse of the
specified amperage.
! WARNING
Do not use a fuse of a higher amperage rating than recommen-

ded to avoid causing extensive damage to the electrical system
and possibly a fire.
SPECIFICATION
Fuses Two glass tube fuse 10 A
TROUBLESHOOTING
FAILURE CAUSE TO DO
Find the cause and repair it. Replace
Electrical circuit shorted
the blown fuse.
Fuse blown
Find the cause and repair it. Replace
Electrical circuit is overloaded
the blown fuse.
BATTERY GENERAL INFORMATION
The battery (1) is located on the right side of the vehicle. It is

recommended to extend the battery whenever it needs servicing.
Disconnect the battery poles (2) to extend the battery.
2
NOTE
1. The battery can be charged and discharged, and used repeat

edly. If a battery is laid aside after discharging, its service life 1
will be shortened and its performance is degraded. Perfor-
mance of a battery is usually reduced after about 2-3 years’
run. Voltage of the performance-reduced (capacity drops)
battery can be resumed, but the voltage will run down quickly
while loading.
2. Overcharging of battery: Usually overcharging is demonstrat-
ed by the battery itself. If short circuit occurs inside the bat-
tery, there will be no voltage or very low voltage on the termi-
nals of the battery. Adjuster fails: it indicates too high voltage
on the battery, the life-span of the battery will be shortened.
3. When the battery is not be used for a long period, it will self-
discharge and its capacitance will drop. The battery should
be recharged every two weeks.
4. Charging system inspection: please perform inspection in the
sequence listed in the fault diagnosis table.
5. If there is current going through the electric part, please do
not remove the connector, or the voltage will be very high
and electronic components inside the voltage adjuster will be
damaged. Set ignition switch at “Off” position and then begin
your operation.
119
ELECTRICAL SYSTEM/ CHARGING SYSTEM
6. Inspect the entire electric load.

7. Quick charging is forbidden except in emergency.
8. During quick recharging, the battery must be removed from
the motorcycle and recharged.
9. A voltmeter shall be employed to check recharged battery.
BATTERY REMOVAL
1. Remove the seat and the left side covers (1).

2. Disconnect the battery poles (2).
3. Remove the battery (3).
! WARNING
1
• Whenever you remove the battery from the vehicle, discon-
nect the negative wire first and the positive wire second.
• Assemble in reverse order and add battery pole grease be-
tween the battery poles and the wires.
• Keep the battery away from ignition sources 2
• Shut off the charger first once before connect or disconnect
the battery.
• If you do not shut off the charger first the flashes during con-
necting or disconnecting could cause an explosion. 3
• Do not exceed the above mentioned charging times at the
specific charging current.
• Fast charging cannot be used except in contingency situa-
tions.
• Do not measure the voltage within 30 minutes after charging.
TROUBLESHOOTING - BATTERY AND CHARGING SYSTEM
FAILURE CAUSE TO DO
Find the cause and replace the
Defect battery
battery.
Disconnected battery cable Connect the battery cable.
No power supply
Find the cause, repair it and re-
Fuse blown
place the fuse.
Faulty main switch Replace the main switch.
Weak battery Charge the battery or replace it.
Loose battery connection Tighten the connection.
Low power Check the components step by
Charging system failure
step and replace the defect parts.
Faulty regulator/rectifier Replace the regulator/ rectifier.
Loose battery cable connection Tighten the connection.
Loose charging system connection Tighten the connection.
Intermittent power
Loose connection or short circuit in ignition Tighten the connection and repair
system the affected component.
Tighten the connection and repair
Loose, broken or shorted wire or connector
the affected component.
Charging system failure Faulty regulator/rectifier Replace the regulator/ rectifier.
Check and replace the generator if
Faulty generator
necessary.
120
ELECTRICAL SYSTEM/ CHARGING SYSTEM
CHARGING SCHEME
CHARGING PERFORMANCE TEST
1. Remove the battery cover on the left side. V

2. Stop the engine and open the fuse box.
3. Disconnect the wire from the fuse. Connect an ampere meter
(A) between the wire and fuse terminal.
4. Connect the battery positive (+) to the voltmeter (V) positive
(+) probe and battery negative (-) to the voltmeter negative
(-) probe. A
5. Start the engine. Gradually increase engine speed to test the
output. If the clamping voltage exceeds the specified value
inspect the regulator rectifier.
6. Inspect the clamping voltage of lightning system.
121
ELECTRICAL SYSTEM/ IGNITION SYSTEM
REGULATOR - RECTIFIER INSPECTION
Disconnect the plug from the regulator rectifier.

Check continuity between main wiring terminals in the following
way.
Multimeter White (W) Red (R) Pink (PK) Black (B)

- + Unit: MΩ
White (W) 27.04 15.15 25.40 PK
Red (R) 0 0 0
R
Pink (PK) 21.35 0 22.33
Black (B) 5.07 22.68 3.63
W B
Item (wire color) Judging Method

Between battery positive (red)
-> Battery voltage
and body ground
Between battery negative (black)
-> Lead wire
and body ground
Between charging coil (white)
-> No power flowing
and body ground
Between charging coils (white 1, 2 and 3)
-> Resistance between the coils
and body ground
GENERATOR CHARGING COIL
Inspection:
Conduction test between generator and vehicle ground:
1. Use a multimeter for a check between the white cable of the

generator and vehicle block.If there is conduction at any of
the white cable the generator has to be replaced.
Charging test:
1. Start the engine and run the engine on idle.
2. Measure the voltage between the white cables of generator
and vehicle block.
3. The voltage at idle speed should be above 30V.
NOTE
Switch to alternating current on your multimeter to measure the

Voltage of Generator.
! WARNING
Inspection of alternator charging coil can be performed on the

engine.
For the generator replacement please check Engine

disassembling and assembling manuel.
122
IGNITION SYSTEM
PREPARATORY DATA
Precautions on operation
1. Ignition system inspection: Please perform inspection in the

sequence listed in the fault diagnosis table.
2. Ignition system uses electronic-type automatic timing de-
vice, which is solidified in the CDI assembly, so it is unnec-
essary to adjust the ignition time.
3. Ignition system CDI shall not be dropped and hung, or heav-
ily knocked (this is also the main reason for its failure). Pay
special attention to this while removing it.
4. Most of the ignition system problem due to poor contact of
sockets. Please check first if parts of the connector are well
contacted.
5. Check if heat value of spark plug is proper. Improper spark
plug may result in unsmooth engine running or burn of spark
plug
6. The maximum voltage is taken to introduce inspection items
in this Part. Inspection methods for impedance value of igni-
tion coil are also recorded and judged.
7. Check ignition switch according to the continuity test table.
8. Remove magneto and stator on operation instructions.
123
SPECIFICATION
Item Standard Value
Spark plug clearance 0.6-0.7mm
Primary coil Black/White-black 0.4 Ω ± 10%
8-11 KΩ
White spark plug cap (bl – spark plug cover)
Ignition coil impedance value (20°C) Secondary
coil 4.5-5.5 KΩ
Without spark plug cap (bl – ignition cable)
Impedance value of trigger (20°C) Blue/white - white/green 100 - 200Ω

Trigger voltage Higher than 1.7V
FAULT DIAGNOSIS
ITEM FAILURE CAUSE TO DO
The interior resistance is too low and test it
Replace
with a designated tester.
The cranking speed is too low. Search for error and repair
If the voltage measured for sev-
High voltage to The tester is disturbed. eral times is above standard,
Ignition coil
low then the value is normal.
Poor contact of ignition system wire Check and repair
Bad act of the ignition coil Check and replace
Bad act of the charge coil Peak voltage test
Connecting error in tester Check and repair
Bad act of the main switch Check and replace
Poor contact of CDI joint Check and repair
No high voltage, Short circuit or poor contact of CDI ground wire Check, repair or replace
off-and-on high Bad act of charge coil Peak voltage test
voltage Bad act of trigger Peak voltage test
Side voltage
Bad act of connector for high voltage wire Check, repair or replace
Bad act of CDI group (when items abnormal or
Replace
when there is no spark in the spark plug)
Bad act of spark plug or power leak in second-
Normal high volt- Check and replace
ary coil
age, no spark
Bad act of ignition coil Check and replace
The interior resistance is too low. Test it with a designated tester.
No high voltage
Bad act of the charge coil (no abnormality in
Charge coil Peak voltage test
Items)
No high voltage, Bad act of the ignition coil Check and replace
off-and-on high
voltage Bad act of the charge coil Check and replace
High voltage too The cranking speed is too low. Search for error and repair
Trigger
low Bad act of the charge coil (no abnormality in
Peak voltage test
Items)
124
IGNITION SYSTEM INSPECTION

NOTE
When there is no spark from the spark plug, check if compo-

nents of wiring are loosened or badly connected and make sure
if all the voltage values are normal.
There are many brands of multimeters (1) with different interior

impedance. The values they measured may not be exactly the
same. 1
PRIMARY VOLTAGE OF IGNITION COIL
If an old spark plug is removed and replaced with a good one,

make sure the plug is tighten correctly.
! WARNING
Inspect when spark plug is installed on the cylinder head and

compression pressure is normal.
NOTE
Voltage of ignition coil cannot be measured.
Function of Ignition coil can be tested in the following way:

1. Remove the spark plug from the cylinder head.
2. Remove the spark plug cap from ignition coil.
3. Connect the dynamic spark tester between ignition cable
and engine ground (-)
4. Press the start button and check the ignition spark gap.
5. Spark gap at a good working ignition system should reach
~15mm.
! WARNING
Please do not touch the metal parts with your fingers while
measuring the voltage, or you will be shocked. Please take
care.
TRIGGER (PICK UP)
Inspect when spark plug is installed on the cylinder head and

compression pressure is normal.
1. Disconnect the pick up cable from the main wire.

2. Disconnect the clamp (1) to ease the measurement.
3. Connect the multimeter to the pick up cable
Positive (+) to blue/white and negative (-) black cable
4. Set multimeter to alternating current
1
5. Turn on the ignition and press the start button.
Minimum voltage should be above 1.7 V
125
TRIGGER INSPECTION
Inspect of the trigger can be conducted on the engine.
1. Disconnect the pick up cable from the main wire.

2. Connect the multimeter on the to the pick up cable
3. Positive (+) to blue/white and negative (-) green/white cable
4. Set multimeter to resistance check Ω.
5. Standard is between 200 – 300 Ω
6. If the value is above or below the measured value replace
the stator
If the measured voltage is below 1V please replace the PICK UP.

! WARNING
The metal area of the multimeter mustn`t be touched by fingers

to prevent electroshock.
CDI ASSEMBLY b bl/w

bl/b
System Inspection
bl/w
Remove CDI assembly and check components related to the ig-
nition system at the wiring terminal.
r/w
Inspection
Remove CDI assembly and check if connectors are loosend or
corrosive.
b- black
bl/w - black/white
bl/b - blue/black
r/w - red/white
bl/w - blue/white
IGNITION COIL
IGNITION COIL REMOVAL
1. Remove the Fuel tank.

2. Remove the spark plug cap from spark plug.
3. Remove the wires of ignition coil (1). 1
4. Disassemble the ignition coil fixing bolts and take off the
ignition coil.
Install it in reverse order of removal.
PRIMARY COIL INSPECTION

1
Measure impedance between terminals of primary coil as shown
in picture (1).
Standard value: 0.7 Ω ± 10% (20°C)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil.

-> Replace coil.
126
ELECTRICAL SYSTEM/ STARTING SYSTEM
SECONDARY COIL
2
Measure the impedance between lead-wire side of spark plug
cap and terminal as shown in picture (2).
Standard value: 8-11 KΩ (20°C)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil.
STARTING SYSTEM
PREPARATORY DATA
Precautions on operation.
Starting motor removal can be performed on the engine.
Starting clutch removal refers to removal instruction.
TORQUE LIST
PART TORQUE
Starting motor clutch cap bolt 12 Nm
Starting motor clutch locknut 95 Nm
127
ELECTRICAL SYSTEM/ STARTING SYSTEM
FAULT DIAGNOSIS
FAILURE CAUSE TO DO
Fuse blown Replace fuse
Power shortage in battery Replace battery
Bad acts of main switch Check and replace
Bad act of startup clutch Check and repair - replace if nessecary
Unable to start up
Bad act of brake switch Check and replace
Bad act of start relay Check and replace
Poor contact of connecting wire Check and repair
Bad act of starter motor Check and replace
Power shortage in battery or battery empty Replace or charge
Rotating force of starter motor too Poor contact of connecting wire Check and repair
weak Gear of the starter motor jammed with foreign Check and repair
body.
Bad act of startup clutch Check and repair
No force of starter motor Reverse revolution of starter motor Replace
Power shortage in battery or battery empty Replace or charge
STARTING MOTOR
! WARNING
Before removing starting motor (1), the ignition switch must be 1

set at “OFF” position. Disconnect battery grounding wire and then
turn on the power supply to check if starting motor runs to confirm
your operation is safe.
Disconnect the starter wire (2).

Remove the starter motor as described in the part for engine 2
disassembling in this manual (page 66).
STARTING MOTOR INSPECTION
1. Disassemble the starter (1).

2. Connect a full charged battery (2) to the starter motor and
check for operation.
If the starter does not operate correct -> replace the starter 1
motor.
3. Check the starter shaft. If it’s worn replace the starter motor.
4. Install starter back in engine. (-) (+)
STARTING RELAY ACTUATION INSPECTION
1. Disassemble related cover parts.

2. Turn on the main switch, check the Engine “stop switch” is
turned on too and press the start button.
-> No action:
Inspect the start relay (1) – replace if necessary.
NOTE
Before doing further tests with the start relay disconnect the 1
starter cable from starter motor and make sure the cable does not
touch the engine or any frame part.
128
ELECTRICAL SYSTEM/ LIGHTNING SYSTEM
STARTING RELAY VOLTAGE INSPECTION
1. Disconnect the plug (green/yellow) (1).

2. Turn on the main switch, check the Engine “stop switch” is
turned on too.
3. Press the start button and measure the voltage between the
ground wire of frame and green/yellow wire of start relay.
Measured voltage should be same as battery voltage.
When there is no voltage at wire terminal of starting relay, inspect 1

start button, engine “stop switch” and lead wire.
ACTUATION INSPECTION 1
1. Connect starting relay with battery and connect terminal of

starting motor with multimeter (picture 1).
2. Connect the fully charged battery between the orange/red
line and green/ yellow line of the relay. At this point the relay
should give out a “Click” sound and the ohmmeter resistance
reads “0”.
BULBS REPLACEMENT GENERAL INFORMATION
PREPARATORY DATA
Precautions on operation:
While trouble shooting electric faults, please check continuity of
electric component as current flowing over it.
Confirm state of battery before any inspection, including battery
voltage.
FAULT DIAGNOSIS
1. Turn on the main switch and the light switch.

2. Check rear light, front position light and low beam.
3. Turn on high beam and check if high beam is working.
4. Apply the front brake and check if brake light is working.
5. Apply the rear brake and check if brake light is working.
6. Turn on the left and right winker and check all winkers are
working.
If the relative light is not working a reason could be:

1. A defect bulb.
2. A defect light switch.
3. The connector has a poor contact or the wire is broken.
4. The battery voltage is low.
5. If there is no electric power at all main fuse could be burned
also.
129
LIGHTNING SYSTEM
HEADLAMP BULB REPLACEMENT
1. Remove the two headlight screws (1).
2. Remove the four screws (2) of the front fender (3).
3. Remove the rubber cap (4) from the head light mask (5).
4. Twist the lock plate (6) counterclockwise till you can remove
it.
5
130
LIGHTNING SYSTEM
5. Pull the bulb (7) in and twist it clockwise till you can remove it.
6. Replace the defect bulb and reassemble in reverse order.
POSITION LIGHT BULB REPLACEMENT
To replace the position light bulb follow the below listed points of
1. and 2.
1
3. Pull out the position light plug (1).
4. Replace the defect bulb (2) and assemble in reverse order.
! WARNING
2
When the bulb is lit, keep your hands and inflammable materials
some distance away from it. Lighting bulb is hot, touch it when it
cools down.
Avoid touching bulb glass with your bare hands during installation
and staining it with oil, which may affect transparency, service life
and luminous flux of bulb.
If oil is adhered to the bulb, clean it with a cloth
moistened with alcohol or highly volatile rubber
solution.
WHOLE HEADLIGHT REPLACEMENT
1. If it’s necessary to replace the whole headlight disconnect the

headlight plug. 1
2. Remove the two screws (1) on the left and right side.
3. Disconnect the two parts of the headlight.
NOTE
Only one side (left side) is shown.

131
4. Remove the three screws (2) and replace the whole head-
light. 2
5. Install the new headlight in reverse order.

6. Adjust the height of the low beam. (See page 45)
REAR WINKER REPLACEMENT
1. Remove the rear fender cover (1).
2. If it is need to replace the whole rear winker, disconnect the

winker cables (2) first.
The plugs for right or left rear winker are located
below the rear fender cover .
2
3. Thread a 14mm flat wrench (3) and loosen the winker fixation
nut (4).
FRONT WINKER REPLACEMENT
1. To replace the front winker it is first necessary to remove the

whole head light (1).
2. Disconnect the winker cables (2) from the main wire and un- 3
screw the winker fixation nut by using a 14mm flat wrench (3).
3. Assemble the new winker and the whole head light in reverse 2
order.
1
132
BULB WINKER REPLACEMENT
1. Turn off the ignition switch.

2. Screw off the self-tapping screw (1) on the turn signal lamp.
3. Remove the indicator lens (2).
4. To replace the bulb (3) press the bulb and rotate clockwise
until you can pull out the bulb.
5. Install the bulb in the reverse order of removal.
BULB TAILLIGHT REPLACEMENT
1. Screw off the two screws (1) and remove the taillight lens.
1
2. To replace the bulb (3) press the bulb and rotate counter-
clockwise until you can pull out the bulb.
3. Assemble the new rear light in reverse order.
3
133
TAILLIGHT REPLACEMENT
1. Remove the rear fender cover.

2. Disconnect the taillight cable (1).

5. Pull the taillight out of the cover.
6. Reassemble in reverse order. 3
LICENSE PLATE BULB REPLACEMENT
1. Remove the rear fender cover. 1

2. To remove the license plate light bulb you have to rotate the
white rubber cap (1) 45° counterclockwise and pull out the
plug.
3. Pull the bulb (2) out of the white rubber cap .

4. Install the license plate bulb in reverse order of
2
removal.
134
ELECTRICAL SYSTEM/ SPEEDOMETER
SPEEDOMETER DESCRIPTION 1 2 3 4
1. Speedometer
2. Engine coolant tell-tale
3. Engine oil tell-tale
4. Main-beam headlamp tell-tale
5. Dipped-beam headlamp tell-tale
5
6. Direction tell-tale
7 6
7. Neutral tell-tale
8. Odometer 8
SPEEDOMETER REPLACEMENT
1. Remove the headlight before removing the speedometer.

2. Remove the two screws on the left and right side to discon- 1
nect the headlight bracket and the speedometer bracket.
3. Disconnect the cables (1).
4. Unscrew the six hexagonal (2) bolts from underneath.
5. Replace the whole instrument panel if necessary.
6. Install the instrument orderly in the reverse order of removal.
! WARNING 2
It is not possible to repair the Instrument panel.
If you face any defect of the panel please replace the whole In-
strument.
IGNITION SWITCH INSPECTION
1. Remove the headlight.

2. Disconnect the ignition switch plug.
3. Use a continuity tester to measure the ignition switch (1) as
shown in the illustration.
4. If the main switch does not work correct replace it.
“ ” (OFF) position: All the circuits are broken.

“ ” (ON) position: Ignition circuit is switched on and engine can
be started. When the switch is at this position, the key cannot be
pulled out.
IGNITION SWITCH REPLACEMENT

2. Disconnect the ignition switch plug. 1
3. Remove the two bolts (1).
4. Assembly in reverse order.
STEERING LOCK 2
1. The steering lock (2) is located in the ignition switch.

2. If the steering lock does not work correct, replace the ignition
switch (see above).
135
ELECTRICAL SYSTEM/ INSTRUMENTS
ELECTRIC HORN INSPECTION
1. Disconnect the horn wire (1) from the horn (2).

2. The horn is works correct if it sounds when a 12V battery is 2
connected to the plugs.
If the horn does not work correct replace it.
ELECTRIC HORN REPLACEMENT 3

1
1. Remove the seat, the side covers the tank and the oil/water
tank.
2. Loosen the screw (3) (size: 13) and replace the horn.
! WARNING
If the horn works while it is connected to the battery but not when
pressing the handle switch check the cables and the
horn switch (4).
LEFT HANDLE SWITCH
1. Light switch
2. Winker switch
3
3. Horn switch
RIGHT HANDLE SWITCH
1. Start switch
1
136
ELECTRICAL SYSTEM/ INSTRUMENTS
LEFT HANDLE SWITCH INSPECTION

1
2. Disconnect the cables of the left handle switch as shown in
the picture (1).
3. Use a continuity tester to measure the switches as shown in
the illustrations below.
4. In case of damage the handle switch need to be replaced.
Green / Black Brown Blue Light Blue Pink Black Orange Green / White Red / White
Flash light switch
Dimmer switch
High beam switch
Horn
Winker left
Winker right
LEFT HANDLE SWITCH REPLACEMENT
1. Remove the headlight. 1

2. Disconnect the cables of the left handle switch.
3. Remove the screw (1) of the left handle switch.
4. Lift the left handle switch (2) in the height and pull it back-
wards.
5. Assemble the new handle switch in reverse order.
! WARNING 2
Watch out, not to bend or twist the cable.
RIGHT HANDLE SWITCH INSPECTION

1
2. Disconnect the cable of the left handle switch as shown in
the picture (1).
3. Use a continuity tester to measure the switches as shown in
the illustrations below.
4. In case of damage the handle switch need to be replaced.
Purple Green / Yellow

Startor
137
ELECTRICAL SYSTEM/ SWITCHES AND SENSORS
RIGHT HANDLE SWITCH REPLACEMENT

2. Disconnect the cables of the right handle switch.
3. Remove the screw (1) of the right handle switch.
1
4. Pull the right handle switch (2) downwards.

5. Assemble the new handle switch in reverse order.
! WARNING
Watch out, not to bend or twist the cable.
FRONT BRAKE LIGHT SWITCH INSPECTION /

REPLACEMENT
1

2. Disconnect the cables of the front brake light switch.
3. Loosen the screws (1) to remove the switch from the right
handle.
4. Before replacing the front brake switch, double check its

function. 1
Check with a continuity tester (picture 1) :

Switch pressed: no continuity
Switch released: continuity
5. Assemble the new switch in reverse order.

138
REAR BRAKE LIGHT SWITCH INSPECTION
1. Disconnect the two plugs (1) of the brake light switch from
the main wire. 1
The two plugs are located on the top of the rear brake master.
Check the brake light switch with a continuity tester:

Brake pedal pressed: continuity
Brake pedal released: no continuity
2. If the switch is still not working correct replace the rear brake
light switch.
3. Assemble in reverse order.
REAR BRAKE LIGHT SWITCH REPLACEMENT
In case the rear brake light switch is not working correct please 2
replace the switch. For a correct replacement please follow the
below mentioned steps.
1
2. Remove the two bolts (1) of the master cylinder cover (2).
3. Disconnect the two plugs (3).

4. Remove the rear brake light switch (4). 3
4
NOTE
If you can not loosen the rear brake light switch, screw on the two
bolts (1) without the master cylinder cover (2).
5. Pull down the brake hose (5) and the sealing rings (6).
NOTE
5
Please also renew the sealing rings (6).
4
6
139
NEUTRAL SENSOR INSPECTION
1. If it is not possible to reach the water residenze plug (1),

remove the seat, the side covers, the tank and the oil/water
tank.
2. Disconnect the plug coming from the engine.
3. Use a continuity tester to measure the switch as shown in the 1
illustrations below.
Black Grey
Neutral
A Gear
NOTE
Controll the measure:

Shift in a gear and controll the illustartion.
4. In case of damage the switch need to be replaced.

NEUTRAL SENSOR REPLACEMENT
If you need to replace the neutral sensor please follow the below
mentioned steps.
2
1. Remove the chain protection (1) and the gear shift (2).
2. Remove the screw (3) and the neutral sensor (4) with a 16 3
nut. 4
! WARNING
3. Replace the neutral sensor and assemble in reverse order.
NOTE
Do not tighten the neutral sensor too strong.

140
SPEED SENSOR INSPECTION

1
1. The speed sensor plug (picture 1) is located behind the
headlight.
2. Remove the headlight and disconnect the plug.
3. Disconnect the plug and use a continuity tester to measure
the sensor as described.
Switch the multimeter to DC - Voltage

1. Connect a 2kΩ resistor between the power line and the sig-
nal line of the speed sensor.
2. Connect a 12V Battery (+ to the red cable and – to the black

cable) to the sensor.
3. Link one pin of multimeter to the signal line (blue) and the
other pin to minus (black).
4. Turn the speed sensor and check if the value changes.

If the values don’t change the speed sensor is damaged.
Replace the sensor.
SPEED SENSOR REPLACEMENT
1. Place the vehicle on a suitable stand to lift the front wheel.

2. Unplug the speed sensor.
3. Loosen the bolts (1).
4. Screw out the front axle (2) and lower the front wheel till you 2
can remove the speed sensor (3). 3
5. Assemble the new speed sensor in reverse order.
1
141
NOTE
• Loose cable is a hidden trouble to electrical safety. After

clamped check each cable to ensure electrical safety.
• It is not allowed to leave any wire clip bending towards bond-
ing points.
• Bind each cable to its designated position.
• It is not allowed to lay a cable to end or a sharp corner on
frame.
• It is not allowed to lay a cable to end of a bolt or screw.
• When laying a cable, keep it away from any heat source or
any place where may bite it when it is moving.
• When laying a cable along a handle, avoid it being strained
too tightly or loosely and it can not interfere with any adjacent
part at any turning point.
• All cables should be laid smoothly without twist or knot.
• Before butt-jointing a connector, check if its sheath has been
damaged and if it is overstretched.
• If a cable is at a sharp corner or outer corner, use tape or
hose to protect it.
• After a cable is repaired, use tape to bind it securely.
• Keep all control cables from bend or twist because dumb
control will result in case any control cable is damaged.
O: CORRECT
X: INCORRECT
142
FAULT DIAGNOSIS
ITEM FAILURE CAUSE TO DO
The interior resistance is too low and test it with
Replace
a designated tester.
If the voltage measured for
High voltage to The tester is disturbed several times is above stand-
Ignition coil
low ard, then the value is normal.
Poor contact of ignition system wire Check and repair
Bad act of the ignition coil Check and replace
Bad act of the charge coil Peak voltage test
Connecting error in tester Check and repair
Bad act of the main switch Check and replace
Poor contact of CDI joint Check and repair
No high voltage, Short circuit or poor contact of CDI ground wire Check, repair or replace
off-and-on high Bad act of charge coil Peak voltage test
voltage Bad act of trigger Peak voltage test
Side voltage
Bad act of connector for high voltage wire Check, repair or replace
Bad act of CDI group (when items abnormal or
Replace
when there is no spark in the spark plug)
Bad act of spark plug or power leak in second-
Normal high volt- Check and replace
ary coil
age, no spark
Bad act of ignition coil Check and replace
If the voltage measured for
No high voltage The tester is disturbed several times is above stand-
ard, then the value is normal.
Charge coil
Peak voltage test
Items)
off-and-on high
High voltage too If the voltage measured for
low The tester is disturbed several times is above stand-
ard, then the value is normal.
Trigger
Peak voltage test
Items)
off-and-on high
143
CHASSIS
COVER REPLACEMENT
SEAT REMOVAL
1. Turn the key clockwise (arrow) and lift the seat up.
2. To get off the seat, lift (1) the seat and pull it back (2).
3. Install the seat in reverse order
1
2
LEFT/RIGHT SIDE COVER REMOVAL
1. Remove the seat.

1
2. Remove the screws (1).
3. Remove the left/right side cover (2).
4. Install the left/right side cover in reverse order.
NOTE
Only one side (left side) is illustrated. 2
LEFT/RIGHT LOWER SIDE COVER REMOVAL
1. Remove the screws (1).

2. Remove the lower side cover (2). 2
3. Install the left/right lower side cover in reverse order.
NOTE 1
Only one side (left side) is illustrated.

144
CHASSIS
LEFT/RIGHT TANK SIDE COVER REMOVAL
1. Remove the five screws (1). 1
2. Remove the two screws (2) of the protection mesh.

3. Remove the left/right tank side cover.
4. Install the left/right tank side cover in reverse order.
NOTE
1
REAR BODY PANEL REMOVAL
1. Remove the seat and the side covers.

2. To remove the rear body panel (1) it is necessary to remove 2
the rear side covers.
3. Remove the three bolts (2).
4. Pull the left rear side cover to the left and the right rear side
cover to the right (arrows).
1
5. Now pull it to the left side as shown in picture (1).

1
6. Remove the four screws (3).

7. Pull the side covers first forward and then pull it up.
8. Install the rear body panel in reverse order.
3
145
CHASSIS
REAR SIDE COVER REMOVAL
1. Follow the steps 1-4 of rear body panel removal.
! WARNING
Before you remove the rear cover you must to uncouple the seat
lock from the cable. Lift the seat lock cable (1) afterwards turn it to 1
the right. When the cable and the slot of the seat lock are in line
you can remove the cable.
2. Follow the steps 6-7 of rear body panel removal.

3. Install the rear side covers in reverse order.
REAR FENDER REMOVAL
1. Remove the rear side cover with the rear body panel.
2. Remove the four screws (1) on the left and the four screws
on the right side. 1
NOTE
3. Remove the four screws (2) and remove the inner rear fender
(3).
3
4. Remove the left and right turn signal rear (4), the rear light
(5) and the rear reflector with number plate light (6).
5. Install the rear fender in reverse order. 6
5
146
CHASSIS
FRONT FENDER REMOVAL
1. To remove the front fender (1), remove the four screws (2).
1
HEADLIGHT COVER REMOVAL
1. Remove the front fender.

3. Remove the screw (2) on the left and right side.

2
NOTE
4. Remove the headlight cover by removing two screws (3) and

3
the one screw (4).
5. Install the headlight cover in reverse order.
4
147
CHASSIS
COVER FRONT SHOCK ABSORBER LEFT REMOVAL

1
NOTE
Look to the nut on the rear.
2. Thread of the breaking hose (2).
3. To remove the cover front shock absorber left (3) remove the
two screws (4).
3
4. To remove the side reflector (5), press together the clip and
pull the side reflector sidewards.
5. Install the cover front shock absorber left in reverse order.
5
148
CHASSIS
COVER FRONT SHOCK ABSORBER RIGHT REMOVAL
1. To remove the speedsensor cable (1), remove the screw (2).

1
NOTE
Look to the nut on the rear.
2. To remove the cover front shock absorber right (3) remove

the two screws (4).
3
3. To remove the side reflector (5), pull down the clip and pull
the side reflector sidewards.
4. Install the cover front shock absorber right in reverse order.
! WARNING
When ever you remove a cover where a light or an electrical

component is installed disconnect those parts from the main
harness.
Do not damage any body cover during installation or

disassembly.
Do not damage the knuckle on body cover during installa-
tion or disassembly.
Align the panel and cover plate on the body cover with
their own grooves.
Correctly install the knuckle of each part in assembly.
No spare parts should be damaged in installation of the
cover.
149
MIRROW
BACK VIEW MIRROWS
At all repairs in the area of the handle bar is advised to remove

the back view mirrors.
To prevent damage during installation of the back view mirror
consider that on the right side is a left-handed thread and vice
versa.
BACK VIEW MIRROWS REMOVAL
1. Remove the cap (1) by pulling it out (arrow).
2. Remove the bolt (2).

3. Install the mirrow in reverse order. 2
NOTE
! WARNING
RIGHT SIDE = LEFT SIDE THREAD

LEFT SIDE = RIGHT SIDE THREAD
150
SECOND SPEEDOMETER
SECOND SPEEDOMETER
PART LIST SECOND SPEEDOMETER
5
4 6
1. Left button
2. Temperature - Red light
3 7
3. Turn signal - Green light
4. High beam - Blue light
5. Display
6. Oil light - Red light
2 8 7. Neutral light - Green light
8. Engine light - Yellow light
9. Right button
1 9
SWITCH BUTTON FUNCTION LIST
Function Power Dsiplay Left button Right button Action

KEY-ON ODO <3seconds Switch to TRIP
KEY-ON TRIP <3seconds Swtich to TIME
Function switch When error code appear, screen display

KEY-ON TIME <3 seconds will switch to DTC. If not, the screen wil
be switch to ODO
KEY-ON DTC <3 seconds Switch to ODO
Trip clear KEY-ON TRIP >3 seconds Trip reset
Oil light ODO Oil maintenance reset (Oil lights shut
KEY-ON ODO (Oil light light up) >3 seconds
record clea down)
DTC checking KEY-ON DTC <3 seconds Switch to error code
KEY-ON km/h (ODO/TRIP/TIME) >3 seconds Switch to mph
Unit switch
KEY-ON Mph (ODO/TRIP/TIME) >3 seconds Switch to km/h
Back light color KEY-ON Blue (ODO/TRIP/TIME) <3 seconds Switch to Yellow
switch
KEY-ON Yellow (ODO/TRIP/TIME) <3 seconds Switch to Blue
KEY-ON Main screen >3 seconds >3 seconds Enter hour setting, hour digital flashing
KEY-ON hour digital flashing <3 seconds Adjust clock, digital from 0-23
Enter minutes setting, minutes digital
KEY-ON hour digital flashing <3 seconds
Enter setting flashing
KEY-ON minutes digital flashing <3 seconds Adjust minutes, digital 0-59
Enter Tire setting, hundreds` digital
KEY-ON minutes digital flashing <3 seconds
flashing
KEY-ON 4th digital flashing <3 seconds Adjust thousands separator from 0-2
Enter tire setting, hundreds` digital flash-
KEY-ON 4th digital flashing <3 seconds
ing
Tire setting KEY-ON 3rd digital flashing <3 seconds Adjust hundreds` digital from 0-9
KEY-ON 3rd digital flashing <3 seconds Enter tire setting, tens` digital flashing
KEY-ON 2nd digital flashing <3 seconds Adjust tens` digital from 0-9
KEY-ON 2nd digital flashing <3 seconds Enter tire settings, first digital flashing
Version 0 (Trigger X) Default 2207 mm
Default setting KEY-ON
Version 1 (Trigger SM) Default 1859 mm
KEY-ON Default flashing <3 seconds Adjust Default, digital from 0-9
Sensor point
Enter cycle and piston setting, The func-
setting KEY-ON Default flashing <3 seconds
tion can be set will flashing
Adjust cycle and piston setting, digital
Cycle and piston KEY-ON Default flashing <3 seconds
from: P-0.5,1,2,3,4,5,6
setting
KEY-ON Default flashing <3 seconds Quite setting screen back to main screen
151
! WARNING
THE REMOVAL OF POWER LIMITATION IS IN THE MOST

COUNTRIES NOT LEGAL. IN CAUSE OF DETHROTTLING
ALL CLAIMS OF WARRANTY EXPIRE AND ALL DAMAGES
OF THE VEHICLE IS IN YOUR OWN RESPONSIBILITY.
There are 2 levels of dethrottling.
Level 1 ( about 50-60 Km/h) 1
1. Remove the exhaust pear.

2. Cut off the throttle at the first weld as shown in the picture (1).
3. Install the exhaust pear in reverse order.
Level 2 ( about 65-70 Km/h)

2
1. Remove the exhaust pear.
2. Cut off the complete throttle as shown in the picture (2).
3. Install the exhaust pear in reverse order.
4. Remove the carburettor.

5. Remove the carburettor cover (1). 1
6. Replace the main jet 95 (2) with a main jet 102.
7. Install the carburetto in reverse order.
8. Remove the spark plug.
9. Replace the spark plug NGK/BR8ES with a spark plug
NGK/BR7ES.
10. Install the spark plug in reverse order.
2
KSR Moto is a trademark of
KSR Group GmbH
Gewerbeparkstrasse 11
3500 Krems, Austria
www.ksr-group.com

D01 - Service Manual - ENG - Vers 2015 01 - Klein

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REPAIR MANUAL

D01 - TRIGGER 50 Vers. 2015_01

KSR Motot Motorcycles is a registered brand by KSR Group GmbH.

© 2012 by KSR Group GmbH, Krems Austria

KSR Group GmbH

ENGINE FUEL SYSTEM

CLUTCH FUEL SUPPLY

REMOVAL OF POWER LIMITATION

NOTES AND WARNINGS

FUEL AND LUBRICANTS

SPARE PARTS AND ACCESSORIES

VIN (CHASSIS NUMBER) AND FRAME PLATE

ANTI TEMPERING LABEL

DECRYPTING THE VEHICLE IDENTIFICATION NUMBER

VA4 - WORLD MANUFACTURER INDEX (NAME OF MANUFACTURER)

ENGINE OIL QUANTITIY

TIRES (Version 0 = Trigger X)

TIRES (Version 1 = Trigger SM)

LIGHT AND BULBS

High beam indicator light: 12 V, 2 W

MODULE PART TORQUE / Nm

MAXIMUM TORQUE IN NM REFERRING ISO 898/1 FOR METRIC

Fig. 21a Fig. 21b

Fig. 22a Fig. 22b

Fig. 23a Fig. 23b

Following special tools are not used for 2-stroke engines:

* Model specific deviations are possible

Oil/ Oil pump

Item Standard Service Limit

Item Standard value [mm] Allowable limit [mm]

Item Standard value

Item Standard Tolerance

Item Standard value [mm] Allowable limit [mm]

Item Standard value

Item Standard value Allowable limit

Item Specification Tire pressure (bar)

Measuring position Item Standard value (mm) Service limit (mm)

Replacement of the air filter element.

If the motorcycle is frequently driven on bad road or in rain, it

THROTTLE WIRE INSPECTION/ ADJUSTMENT

Check the smoothness of accelerator pull wire.

The main adjusting position is on the throttle grip.

The second adjusting position is on the carburettor.

FUEL HOSE INSPECTION

When working on the carburettor, engine and during each main-

If the fuel line is brittle or leaking it must be replaced immediately.

FUEL FILTERS CLEANING

ENGINE OIL LEVEL INSPECTION

When it is necessary to refill engine oil please only use the

Recommended engine oil

Under regular conditions the engine oil consumption is approxi-

Engine oil level inspection 1

ENGINE OIL LEVEL SENSOR INSPECTION

1. Remove the front left side cover (4). 3

OIL PUMP INSPECTION

The lubricating system supplies oil to the wear surfaces to reduce

Disconnet the oil pump cable (2).

1. Is the oil pump leaking (1)?

1. Does the oil pump leak (1)?