Manual de Taller GD250 Exiv (1) Mantenimiento y Motor

SERVICE MANUAL
99000HC8110
FOREWORD GROUP INDEX
This manual contains an introductory description on

HYOSUNG 『』 and procedures for its
inspection/service and overhaul of its main
GENERAL INFORMATION 1
components.
Other information considered as generally known is
not included.
PERIODIC MAINTENANCE 2
R e a d G E N E R A L I N F O R M AT I O N s e c t i o n t o
familiarize yourself with outline of the vehicle and
MAINTENANCE and other sections to use as a guide
for proper inspection and service.
ENGINE 3
This manual will help you know the vehicle better so
that you can assure your customers of your optimum
and quick service. EI SYSTEM DIAGNOSIS 4
❖This manual has been prepared on the basis of
the latest specification at the time of
publication.
FUEL SYSTEM AND THROTTLE BODY 5
If modification has been made since then,
difference may exist between the content of
this manual and the actual vehicle. COOLING SYSTEM 6
❖Illustrations in this manual are used to show
the basic principles of operation and work
procedures.
They may not represent the actual vehicle
ELECTRICAL SYSTEM 7
exactly in detail.
WARNING
CHASSIS 8
This manual is intended for those who have
enough knowledge and skills for servicing
HYOSUNG vehicles. Without such knowledge and
SERVICING INFORMATION 9
skills, you should not attempt servicing by relying
on this manual only.
Instead, please contact your nearby authorized
HYOSUNG motorcycle dealer.
Ⓒ COPYRIGHT S&T Motors Co., Ltd.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE
LOOKING FOR :
1. The text of this manual is divided into sections.
2.As the title of these sections is listed on the previous
page as GROUP INDEX, select the section where you are
looking for.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. On the first page of each section, its contents are listed.
Find the item and page you need.
COMPONENT PARTS
Example : Front wheel
SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servicing.
The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.

Apply THREAD LOCK .
Data beside it indicates specified torque.
Apply oil.
Apply or use brake fluid.
Use engine oil unless otherwise specified.
Apply GREASE. Measure in voltage range.
Apply SILICONE GREASE. Measure in resistance range.
Apply MOLY PASTE. Measure in current range.
Apply GASKET BOND. Measure in diode test range.
Use fork oil. Measure in continuity test range.
Use engine coolant. Use special tool.

NOTE
Difference between photographs and actual motorcycles depends on the markets.
ABBREVIATIONS USED IN THIS MANUAL
A L
ABDC : After Bottom Dead Center LCD : Liquid Crystal Display
AC : Alternating Current LED : Light Emitting Diode
API : American Petroleum Institute LH : Left Hand
ATDC : After Top Dead Center
M
B Max : Maximum
BBDC : Before Bottom Dead Center Min : Minimum
BDC : Bettom Dead Center
BTDC : Before Top Dead Center O
O2 Sensor : Oxygen Sensor (O2S)
D
DC : Direct Current R
DOHC : Double Over Head Camshaft RH : Right Hand
RO Switch : Roll Over Switch
E
ECU : Engine Control Unit, S
EI Control Unit SAE : Society of Automotive Engineers
EI : Electric fuel Injection, S/W : Switch
Electric fuel Injector
F T
TDC : Top Dead Center
FP : Fuel Pump
TP Sensor : Throttle Position Sensor (TPS)
G
GP Switch : Gear Position Switch W
WT Sensor : Water Temperature Sensor
(WTS)
I
IAP&T Sensor : Intake Air Pressure &
Temperature Sensor
(IAP&TS)
IG : Ignition
ISC Solenoid : Idle Speed Control Solenoid
WIRE COLOR
B : Black Gr : Gray Sb : Light blue

L : Blue Lg : Light green W : White
Br : Brown O : Orange Y : Yellow
G : Green R : Red

BL : Black with Blue tracer BBr : Black with Brown tracer
BG : Black with Green tracer BO : Black with Orange tracer
BR : Black with Red tracer BW : Black with White tracer
BY : Black with Yellow tracer LB : Blue with Black tracer
LG : Blue with Green tracer LR : Blue with Red tracer
LW : Blue with White tracer LY : Blue with Yellow tracer
BrB : Brown with Black tracer BrW : Brown with White tracer
GB : Green with Black tracer GR : Green with Red tracer
GY : Green with Yellow tracer GrB : Gray with Black tracer
GrR : Gray with Red tracer GrW : Gray with White tracer
OB : Orange with Black tracer OL : Orange with Blue tracer
OG : Orange with Green tracer OR : Orange with Red tracer
OW : Orange with White tracer OY : Orange with Yellow tracer
RB : Red with Black tracer RW : Red with White tracer
WB : White with Black tracer WL : White with Blue tracer
WR : White with Red tracer YB : Yellow with Black tracer
YL : Yellow with Blue tracer YG : Yellow with Green tracer
YR : Yellow with Red tracer

GENERAL INFORMATION
1
CONTENTS
INFORMATION LABELS………………………………………………… 1- 1
GENERAL PRECAUTIONS……………………………………………… 1- 2
SERIAL NUMBER LOCATION… ……………………………………… 1- 3
FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS… … 1- 4
BREAK-IN PROCEDURES……………………………………………… 1- 6
FOUR SIDES OF EXTERIOR ILLUSTRATION…………………… 1- 7
SPECIFICATIONS… ……………………………………………………… 1- 8
1-1 GENERAL INFORMATION
WARNING / CAUTION / NOTE

Please read this manual and follow its instructions carefully.
To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special
meanings.
Pay special attention to the messages highlighted by these signal words.
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in vehicle damage.
NOTE
Indicates special information to make maintenance easier or instructions cleaner.
Please note, however, that the warning and cautions contained in this manual cannot possibly cover all potential
hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNING and CAUTION
stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to
perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL INFORMATION 1-2
GENERAL PRECAUTIONS
WARNING
❖ Proper service and repair procedures are important for the safety of the service machanic and the safety
and reliability of the vehicle.
❖ When 2 or more persons work together, pay attention to the safety of each other.
❖ When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
❖ When working with toxic or flammable materials, make sure that the area you work in is well-ventilated
and that you follow all of the material manufacturer’s instructions.
❖ Never use gasoline as a cleaning solvent.
❖ To avoid getting burned, do not touch the engine, engine oil, exhaust system or radiator until they have
cooled.
❖ After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all lines and fittings related
to the system for leaks.
WARNING
❖ If parts replacement is necessary, replace the parts with HYOSUNG Genuine Parts or their equivalent.
❖ When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and orientation.
❖ Be sure to use special tools when instructed.
❖ Make sure that all parts used in reassembly are clean, and also lubricated when specified.
❖ When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
❖ When removing the battery, disconnect the ⊖ battery lead wire first and then the ⊕ battery lead wire.
When reconnecting the battery, connect the ⊕ battery lead wire first and then the ⊖ battery lead wire.
Finally, cover the ⊕ battery terminal with the terminal cover.
❖ When performing service to electrical parts, if the service procedures do not require use of battery power,
diconnect the ⊖ battery lead wire at the battery.
❖ Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller
diameter, from inside to outside diagonally, to the specified tightening torque.
❖ Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, circlips, and
certain other parts as specified, be sure to replace them with new ones.
Also, before installing these new parts, be sure to remove any material left over from the mating surfaces.
❖ Never reuse a circlip.
When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip
over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and
securely fitted.
❖ Do not use self-locking nuts a few times over.
❖ Use a torque wrench to tighten fasteners to the torque values when specified.
Wipe off grease or oil if a thread is smeared with them.
❖ After reassembly, check parts for tightness and operation.
WARNING
❖ To protect environment, do not unlawfully dispose of used engine oil and other fluids: batteries, and tires.
❖ To protect Earth’s natural resouces, properly dispose of used vehicles and parts.
SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) is stamped on the right side of the steering head tube.
The engine serial number is stamped on the left downside of the crankcase assembly.
These numbers are required especially for registering the machine and ordering spare parts.
⊙ frame serial number
⊙ engine serial number
GD250-000010
FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS

⊙ FUEL
Gasoline should be used a graded 91 octane (Research Method) or higher.
An unleaded gasoline type is recommended.
⊙ ENGINE OIL
■ ENGINE OIL SPECIFICATION
Classification system Grade 20W50
API Over SL 15W40 15W50
SAE 10W/40 ENGINE OIL 10W40 10W50
10W30
※ If a SAE 10W/40 motor oil is not available, select an
alternative according to the following chart. 5W30
℃ -30 -20 -10 0 10 20 30 40

Temperature
Use the chart to select a viscosity rating based on ℉ -22 -4 14 32 50 68 86 104
temperature range in your area.
WARNING
❖Don’ t mix the unrecommended oil. It could damage the engine.
❖When refilling the oil, don’
t allow the dust to get inside.
❖Wipe the spilled oil up immediately.
⊙ BRAKE FLUID
■ SPECIFICATION AND CLASSIFICATION : DOT4
WARNING
This motorcycle uses glycol-based brake fluid.
Do not use or mix different types of brake fluid, otherwise serious damage will result in the brake system.
Do not spill any brake fluid on painted or plastic surfaces as it will damage the surface severely.
Never use any brake fluid that has been stored in a used or unsealed container. Never reuse brake fluid
left over from the last servicing and stored for long period as it absorbs moisture from the air.
⊙ FRONT FORK OIL

■ USE FORK OIL : TOP #15 or SAE 0W
⊙ ENGINE COOLANT
Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.
■ WATER FOR MIXING

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.
■ ANTI-FREEZE/ENGINE COOLANT
The engine coolant perform as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine coolant
should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.
H
yosung recommends the use of HYOSUNG COOLANT anti-freeze/engine coolant. If this is not available, use an
equivalent which is compatible with an aluminum radiator.
■ LIQUID AMOUNT OF WATER/ENGINE COOLANT

For engine coolant mixture information, refer to cooling system section, page 6-1
CAUTION
Mixture of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce its efficiency.
If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting performance is greatly reduced.
Be sure to mix it above 50% even though the atmospheric temperature does not go down to the freezing
point.
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very high
standard but it is still necessary to allow the moving parts to“BREAK-IN”before subjecting the engine to maximum
stresses.
The future performance and reliability of the engine depends on the care and restraint exercised during its early life.
The general rules are as follows :

● Keep to these break-in procedures :
Interval Maximum throttle opening
Initial 800 km (500 miles) Less than 1/2 throttle
Up to 1,600 km (1,000 miles) Less than 3/4 throttle
● Upon reaching an odometer reading of 1,600 km (1,000 miles) you can subject the motorcycle to full throttle operation.
● Do not maintain constant engine speed for an extended period during any portion of the break-in.
Try to vary the throttle position.
‫׳‬ᯕ
1,047 (Height)
320
ᱥႊႊ⨆ḡ᜽॒
(Turn signal lamp)
820 ᱥ॒᳑
(Head lamp)
135
ႊ⨆ḡ᜽॒
900 (Turn signal lamp)
1,358
1,955
ʙᯕ
⇶eÑญ
↽ᱡḡᔢŁ
840 (License plate lamp)

ჩ⪙॒
(Length)
(Wheel base)
740 (License plate)
॒ಾჩ⪙❱
(Ground clearance)
340
FOUR SIDES OF EXTERIOR ILLUSTRATION

⬥ႊႊ⨆ḡ᜽॒
(Turn signal lamp)
⬥ᇡၹᔍʑ
780 (Rear reflector)

թእ
793 (Width)
800 ႊ⨆ḡ᜽॒
(Turn signal lamp)

ᱽ࠺॒ ⬥ၙ॒
925 (Brake & Tail lamp)

Unit : mm
SPECIFICATIONS
⊙ DIMENSIONS AND DRY MASS

ITEM
Overall length 1,955 mm (77.0 in)
Overall width 793 mm (31.2 in)
Overall height 1,047 mm (41.2 in)
Wheelbase 1,358 mm (53.5 in)
Ground clearance 135 mm (5.3 in)
Mass of vehicle in running order 153 kg (337 lbs)
⊙ ENGINE
ITEM
Type Four-stroke, DOHC, Liquid-cooled
Number of cylinder 1 cylinder
Bore 73.0 mm (2.87 in)
Stroke 59.6 mm (2.35 in)
Piston displacement 249.5 ㎤ (15.2 in3 )
Fuel system Electric fuel injection
Starter system Electric starter
Lubrication system Wet sump
⊙ TRANSMISSION
ITEM
Clutch Wet multi-plate type
Transmission 6-speed constant mesh
Gearshift pattern 1-down, 5-up
Final reduction ratio 2.95
1st 2.46
2nd 1.56
Gear ratio 3rd 1.19
4th 1.00
5th 0.88
6th 0.80
Drive chain RK520STX, 110 Links
⊙ CHASSIS
ITEM
Front suspension Telescopic type
Rear suspension Swingarm type
Steering angle 28˚(right & left)
Caster 23.5˚
Trail 93.6 mm (3.69 in)
Front brake Disk brake
Rear brake Disk brake
Front tire size 110/70 - R17 54S
Rear tire size 150/60 - R17 66S
Front fork stroke 120 mm (4.7 in)
⊙ ELECTRICAL
ITEM
Ignition type ECU
Ignition timing BTDC 13˚/ 2,000 rpm and BTDC 30˚/ 6,000 rpm
Spark plug CR8E
Battery 12V 10Ah (MF)
Fuse Refer to page 9-26
Head lamp 12 V - H4 : 60/55 W × 1
Position lamp 12 V - W5 W × 1
Turn signal lamp 12 V - RY10 W × 4
Brake / Tail lamp LED type
License plate lamp 12 V - W5 W × 1
※ LED : Light Emitting Diode
⊙ CAPACITIES
ITEM
Fuel tank 11.0 ℓ
Oil change 1,100 ㎖
Engine oil capacity Oil and filter change 1,300 ㎖
Engine overhaul 1,500 ㎖
Front fork oil capacity (One side) 345 ± 2 cc
NOTE
The specifications are subject to change without notice.
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE… ……………………… 2- 1 2
PERIODIC MAINTENANCE CHART…………………………………… 2- 1
LUBRICATION POINTS… ……………………………………………… 2- 2
MAINTENANCE PROCEDURES… ………………………………… 2- 3

VALVE CLEARANCE… ………………………………………………… 2- 3
SPARK PLUG……………………………………………………………… 2- 5
EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT… ……… 2- 7

AIR CLEANER… ………………………………………………………… 2- 7
ENGINE IDLE SPEED …………………………………………………… 2- 9
THROTTLE CABLE PLAY… …………………………………………… 2- 9
FUEL HOSE… …………………………………………………………… 2-10
CLUTCH… ………………………………………………………………… 2-10
ENGINE OIL AND ENGINE OIL FILTER… …………………………… 2-13
ENGINE COOLANT… …………………………………………………… 2-16
RADIATOR HOSE………………………………………………………… 2-18

DRIVE CHAIN……………………………………………………………… 2-19
BRAKE SYSTEM… ……………………………………………………… 2-22
STEERING… ……………………………………………………………… 2-26
FRONT FORK……………………………………………………………… 2-26
REAR SUSPENSION…………………………………………………… 2-26
TIRE………………………………………………………………………… 2-27
CHASSIS BOLTS AND NUTS…………………………………………… 2-27
COMPRESSION PRESSURE…………………………………………… 2-28
OIL PRESSURE…………………………………………………………… 2-29

2-1 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep the
motorcycle operating at peak performance and economy.
CAUTION
More frequent servicing should be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART

■ ENGINE
Interval Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Air cleaner element Clean every 3,000 km Replace every 12,000 km 2-7
Exhaust pipe nuts and
Tighten Tighten ─ 2-7
muffler mounting bolt
Valve clearance adjust Inspect Inspect ─ 2-3
Cylinder head bolt Tighten Tighten ─ 3-57
Spark plug Clean Clean Replace 2-5
Inspect Inspect ─
Fuel hose 2-10
Replace every 4 years
Engine oil filter Replace Replace ─ 2-13
Engine oil Replace Replace ─ 2-13
Throttle cable Inspect Inspect ─ 2-9
Idle speed Inspect Inspect ─ 2-9
Clutch Inspect Inspect ─ 2-10
Engine coolant Replace every 2 years 2-16
─ Inspect ─
Radiator hoses 2-18
■ CHASSIS
Interval Initial 1,000 km Every 4,000 km Every 8,000 km page
Item
Drive chain Clean and lubricate every 1,000 km 2-19
Brake Inspect Inspect ─ 2-22
Inspect Inspect ─
Brake hoses 2-22
Inspect Inspect ─
Brake fluid 2-22
Tires Inspect Inspect ─ 2-27
Steering Inspect Inspect ─ 2-26
Front forks ─ Inspect ─ 2-26
Rear shock absorber ─ Inspect ─ 2-26
Chassis bolts and nuts Tighten Tighten ─ 2-27
General lubrication Lubricate Lubricate ─ 2-2
CAUTION
Using poor quality replacement parts can cause your motorcycle to wear more quickly and shorten its useful life.
Use only genuine Hyoung replacement parts or their equivalent.
PERIODIC MAINTENANCE 2-2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
❶ ❷ ❸
❻ ❺ ❹
❼
❷
❽
① Clutch lever holder and clutch cable ⑥ Speedo sensor

② Footrests pivot ⑦ Front brake lever holder
③ Passenger footrests pivot ⑧ Throttle cable
④ Drive chian ⑨ Rear brake pedal pivot
⑤ Side stand pivot and spring hook
O - Motor oil, G - Grease
NOTE
❖ Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
❖ Lubricate exposed parts which are subject to rust, with either engine oil or grease whenever the
motorcycle has been operated under wet or rainy condition.
MAINTENANCE PROCEDURES
This section describes the service procedures for
each item mentioned in the Periodic Maintenance chart.
VALVE CLEARANCE
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km thereafter.
CAUTION
The clearance specification is for COLD state.
Excessive valve clearance results in valve noise and
insufficient valve clearance results in valve damage and ①
reduce power.
Check the intake and exhaust valve clearances at the

distances indicated above and adjust the valve
clearances to specification, if necessary.
The valve clearance specification is different for

intake and exhaust valves.
Valve clearance adjustment must be checked and
adjusted :
1) at the time of periodic inspection,
2) when the valve mechanism is serviced, and
3) w hen the camshafts are removed for servicing. ③
● Remove the front center cover and front side cover &
fuel tank side cover assembly, right and left.
(Refer to page 8-1 ~ 2)
● Remove the air cleaner case. (Refer to page 3-1)
● Remove the spark plug. (Refer to page 2-5)
● Remove the cylinder head cover ①. ②
● Remove the magneto cover plug ② and the valve
timing inspection plug ③.
● Rotate the magneto rotor counter-clockwise with a
socket wrench to set the piston at TDC (Top Dead
Center) of the compression stroke.
(Rotate the magneto rotor until the“ ”line on the
magneto rotor is aligned with the“ ”mark on the
magneto cover.)
● To inspect the valve clearance, insert a thickness
gauge to the clearance between the camshaft and
the tappet.
Valve clearance Standard (When cold)
IN. 0.10 ~ 0.20 mm (0.004 ~ 0.008 in)
EX. 0.20 ~ 0.30 mm (0.008 ~ 0.012 in)
Thickness gauge : 09900-20806

● If the clearance is out of specification, first remove the

cam chain tension adjuster, camshaft housing,
camshaft.
To install the tappet shim at original position, record
the shim NO. and clearance to present by“A”,“B”,
“C”,“D”mark on the cylinder head.
Select the tappet that agree with tappet clearance

(vertical line) and shim NO.(horizontal line) as refer to
the tappet shim selection chart.
(Refer to page 9-41·42)
Adjust valve timing, and install the camshaft housing

and the cam chain tension adjuster. A B
After rotating the crankshaft about 10 times, measure
the valve clearance.
If the clearance be not correct, adjust the standard
clearance as the same manner above.
● If there is no the tappet shim selection chart, how
to adjust is as follows. C D

For example, if the intake clearance is 0.4 mm and
the shim is 170 (1.70 mm), select 195 (1.95 mm) of
the shim which add the exceeded 0.25 mm to 170
(1.70 mm) of the shim when adjusting 0.15 mm as
the intake standard clearance is 0.10 ~ 0.20 mm.
CAUTION
❖Valve clearance should be checked when the
engine is cold.
❖ If you don’ t rotate the crankshaft about 10
times before measuring the valve clearance,
there is no meaning of valve clearance.
SPARK PLUG
Inspect Interval
Clean Initial 1,000 km and Every 4,000 km thereafter.
Replace Every 8,000 km.
● R emove the left front side cover & fuel tank side
cover assembly ①. (Refer to page 8-1 ~ 2) ①
● Remove the two ECU mounting bolts.
● Disconnect the spark plug cap.

● Remove the spark plug ②.
SPARK PLUG
TYPE SPECIFICATION
Hot type CR7E
Standard type CR8E
Cold type CR9E
②
■ CARBON DEPOSITS
Check to see if there are carbon deposits on the
spark plug.
If carbon is deposited, remove it using a wire or pin
with a pointed end.
■ SPARK PLUG GAP

Measure the spark plug gap using a thickness
gauge.
If the spark plug gap is out of specification, adjust the
gap.
0.7 ~ 0.8 mm
Spark plug gap (0.028 ~ 0.032 in)
Thickness gauge : 09900-20806 0.7 ~ 0.8 mm

(0.028 ~ 0.032 in)
■ ELECTRODE
Check to see the worn or burnt condition of the elec-
trodes.
If it is extremly worn or burnt, replace the spark plug
with a new one.
And also replace the spark plug if it has a broken
insulator, damaged thread, etc.
CAUTION
To avoid damaging the cylinder head threads ;
first, finger tighten the spark plug, and then
tighten it to the specified torque using the spark
plug wrench.
● Insert the spark plug and finger tighten it to the

cylinder head and then tighten it to the specified
torque.
Spark plug
: 15 ~ 20 N·m (1.5 ~ 2.0 kgf·m)
EXHAUST PIPE NUTS AND ①

MUFFLER MOUNTING BOLT
Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km thereafter.
● Tighten the exhaust pipe nuts ①, muffler plate

bracket bolt ②, muffler connecting bolt ③ and
muffler mounting bolt ④ to the specified torque.
Exhaust pipe nut

: 18 ~ 28 N·m (1.8 ~ 2.8 kgf·m)
Muffler plate bracket bolt
: 18 ~ 28 N·m (1.8 ~ 2.8 kgf·m)
Muffler connecting bolt
: 18 ~ 28 N·m (1.8 ~ 2.8 kgf·m)
Muffler mounting bolt
: 20 ~ 30 N·m (2.0 ~ 3.0 kgf·m)
②
③
④
AIR CLEANER
Inspect Interval
⑤
Clean Every 3,000 km,
Replace Every 12,000 km.
If the air cleaner is clogged with dust, intake

resistance will be increased, with a resultant
decrease in power output and an increase in fuel
consumption.
Check and clean the air cleaner element in the

following manner :
● Remove the front center cover ⑤.
(Refer to page 8-1)
● Loosen the four air cleaner element screws ①.

● Remove the air cleaner element ②.
① ①
Clean the air cleaner element for the following :

● When the air cleaner element clean with the air gun,
necessarily blow at the inside by compressed air.
● Carefully examine the air cleaner element for tears during
cleaning. Replace it with a new one if it is torn.
● Assemble the element completely or damage severely
the engine.
● Be careful not to allow water to go inside the air clea-
ner element.
CAUTION ②
❖ Inspect the air cleaner element for tears.
A torn element must be replaced.
❖ If driving under dusty conditions, clean the air
cleaner element more frequently. The surest
way to accelerate engine wear is to operate
the engine without the air cleaner element or
with the torn air cleaner element. Make sure
that the air cleaner element is in good
condition at all times. Life of the engine
depends largely on this component!
■ AIR CLEANER OIL DRAIN PLUG ③

Inspect the air cleaner oil drain plug ③ and drain
water and oil at the periodic maintenance interval.
The air cleaner oil drain plug ③ is located beneath
the air cleaner case.
ENGINE IDLE SPEED

Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km
thereafter.
NOTE
Make this inspection when the engine is hot.
● C o n n e c t a n e n g i n e t a c h o m e t e r t o t h e h i g h
tension cord.
S tart the engine and inspect the engine idle
speed between specified range.
Engine idle speed 1,500 ~ 1,700 rpm
Engine tachometer : 09900-26006
CAUTION
Never operate the idle screw ① to avoid
variations of the carburetion setting. ①
THROTTLE CABLE PLAY

③
Inspect Interval
Inspect Initial 1,000 km and Every 4,000 km
④
thereafter.
There should be 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) play on
the throttle cable.
To adjust the throttle cable play : Ⓐ

● Hold the motorcycle vertically.
● Uncover the protection ②.
②
● Loosen the lock nut ③.
● Turn the adjuster ④ in or out until the throttle cable
play is between 0.5 ~ 1.0 mm (0.02 ~ 0.04 in). CAUTION
● Tighten the lock nut ③ while holding the adjuster ④. Inadequate throttle cable play can cause engine
● Check free play again. speed to rise suddenly when you turn the throttle
●C over the protection ②. grip. This can lead to loss of rider control.
Throttle cable 0.5 ~ 1.0 mm
play Ⓐ (0.02 ~ 0.04 in)
CAUTION
After the adjustment is completed, check that
throttle grip movement does not raise the engine
idle speed and that the throttle grip returns
smoothly and automatically.
FUEL HOSE
Inspect Interval
Replace every 4 years.
● Remove the seat.

●R emove the front side cover & fuel tank side cover
assembly, right and left. (Refer to page 8-1 ~ 2)
● Remove the fuel tank cover. (Refer to page 8-2)
● Remove the fuel tank. (Refer to page 5-2)
Inspect the fuel hoses for damage and fuel leakage.
If any defects are found, the fuel hoses must be
replaced with a new one.
⑤
CLUTCH ②
Inspect Interval
Clutch play should be 4 mm (0.16 in) as measured at

the clutch lever holder before the clutch begins to
disengage.
If the play in the clutch is incorrect, adjust it in the
following way :
● A basis adjustment be allowed by the clutch lever
① Ⓑ
adjuster ②.
● Uncover the rubber boot ⑤.
● Loosen the lock nut ① counter-clockwise.
● Turn the clutch lever adjuster ② in or out to acquire ③
the specified play.
● A fter end of adjustment, tighten the lock nut ①
clockwise fully while holding the clutch lever adjuster
② and cover the rubber boot ⑤.
● If not adjust by the clutch lever adjuster ②, adjust by
the clutch cable adjuster ④.
● Loosen the clutch cable adjuster lock nuts ③.
● Turn the clutch cable adjuster ④ in or out to acquire ④
the specified play.
● After end of adjustment, tighten the lock nut ③ while
holding the clutch cable adjuster ④.
● The clutch cable should be lubricated with a light
weight oil whenever it is adjusted.
Clutch cable play Ⓑ 4 mm (0.16 in)
■ GEARSHIFT LEVER HEIGHT

ADJUSTMENT
● Loosen the lock nuts ⑥.
● Adjust the gearshift lever height by turning the link
rod ⑦. ⑥ ⑦ ⑥
● Tighten the lock nuts ⑥.
■ FOOTREST POSITION
ADJUSTMENT ③ ①
『』 has 2 type of the footrest position, right
and left.
To change the position, remove the M10 footrest
mounting bolts ①, ② and spacer ③, and install the
bolts ④, ⑤ by using the hexagon spanner 8 mm.
② F
L
Change the left footrest position with the same manner

of the right footrest. ③
『』is delivered from the factory on position Ⓐ.
WARNING
When adjusting the footrest position, the M10
footrest mounting bolts should be torqued to the
①
proper specification.
If they are not, the footrest can come off
unexpectedly.
Footrest mounting bolt ③

: 40 ~ 50 N·m (4.0 ~ 5.0 kgf·m)
②
POSITION Ⓐ
⑤
F
L
⑤
POSITION Ⓑ
■ GEARSHIFT LINK ROD

When the footrests in position Ⓑ, exchange the
gearshift link rod for appropriate riding position.
● Position Ⓐ
: Install the gearshift link rod ⑥
● Position Ⓑ
: Install the gearshift link rod ⑦
❼
ENGINE OIL AND

ENGINE OIL FILTER
Inspect Interval
Replace Initial 1,000 km and Every 4,000 km thereafter.
①
Necessary amount of engine oil
Oil change 1,100 ㎖
Oil and filter change 1,300 ㎖
Engine overhaul 1,500 ㎖
SAE 10W/40
Engine oil type
API Over SL
The engine oil should be changed while the engine is

warm.
The engine oil filt e r r e p l a c e m e n t a t t h e a b o v e
intervals, should be done together with the engine
oil change.
● Keep the motorcycle upright.
● Place an oil pan below the engine.
● Remove the engine oil filler plug ①.
● Drain the engine oil by removing the drain plug ②
located on the left downside of the engine. ②
CAUTION
GD250-0000
Necessarily, confirm and clean the engine oil
strainer Ⓐ by removing the engine oil strainer
cap Ⓑ when replace the engine oil (specially,
when first replacement).
CAUTION
More frequent servicing may be performed on Ⓑ
motorcycles that are used under severe
conditions.
Ⓑ
● Reinstall the gasket and engine oil drain plug ①.

Ti g h t e n t h e e n g i n e o i l d r a i n p l u g ① t o t h e
specified torque.
Engine oil drain plug GD250-000010
: 35 ~ 45 N·m (3.5 ~ 4.5 kgf·m) ❶
● Loosen the engine oil filter ② counter-clockwise

and remove it using a 30mm socket wrench.
● Wipe off the mounting surface on the engine
where the new engine oil filter will be seated with
a clean rag.
● Smear a little engine oil around the rubber gasket
of the new engine oil filter.
● Screw on the new engine oil filter by hand until
the filter gasket contacts the mounting surface (a
small resistance will be felt).
②
CAUTION
❖ When reassembling the engine oil filter, make
sure that the engine oil filter is installed
correctly.
If the engine filter is installed improperly,
serious engine damage may result.
❖ When replacing the engine oil filter, it is highly
recommended that you use a genuine
HYOSUNG oil filter designed for your
motorcycle, as other filters may have different
design and thread specifications which could
cause engine damage or oil leaks.
● Pour the new engine oil through the oil filler hole.
When performing an engine oil change (with an
engine oil filter replacement), the engine will hold
about 1,300 ㎖ of an engine oil.
Use an engine oil that meets the API service
classifications of over SL and that has a viscosity
rating of SAE 10W/40.
● Install the engine oil filler plug ①.

● S tart the engine and allow it to run for a few
minutes at idling speed. ①
Check to see that no the engine oil is leaking from
the engine oil filter and engine oil drain plug.
F
L
●T
urn off the engine and wait about three minutes,
then check the oil level through the inspection win-
dow.
I f the level is below the mark “L”, add oil to “F”
level.
If the level is above the mark “F”, drain oil to “F”
level.
CAUTION F
L
Never operate the motorcycle if the engine oil

level is below the“Lower line mark (L)”in the
engine oil inspection window.
Never fill the engine oil above the“Upper line
mark (F)”.
Engine oil level being most suitable about 1 mm
under the“Upper line mark (F)”of the engine oil
inspection window. In case of the engine oil
pouring in excessively, the engine output being
made insufficient.
Be careful not to pour the engine oil excessively
into engine.
ENGINE COOLANT
Inspect Interval
Replace Every 2 years.
■ ENGINE COOLANT LEVEL CHECK

● Keep the motorcycle upright.
● Check the engine coolant level by observing the “F”
(Full) and “L” (Low) level lines on the engine coolant
reserve tank.
● If the level is below the “L” (Low) level line, add the
engine coolant until the level reaches the “F” (Full)
level line, through the engine coolant reserve tank
filler ①.
Engine coolant capacity
Reserve tank side Approx. 100 ㎖
Radiator side Approx. 500 ㎖
Engine side Approx. 630 ㎖
①
WARNING
❖E ngine coolant may be harmful if swallowed or
if it comes in contact with the skin or eyes. If
engine coolant gets into the eyes or contacts
the skin, flush the eyes or wash the skin
thoroughly, with plenty of water. If engine
coolant is swallowed, induce vomiting and call
a physician immediately.
❖Keep out of the reach of children and animals.
CAUTION
❖U se distilled water only.
Water other than distilled water can corrode
and clog the aluminum radiator.
❖ T he 50 : 50 mixture of distilled water and
ethylene glycol anti-freeze will provide the
optimum corrosion protection and excellent
heat protection, and will protect the cooling
system from freezing at temperatures above
-31℃ (-24℉).
NOTE
Bleed air from the cooling circuit when the engine
overheat.
■ ENGINE COOLANT
REPLACEMENT
WARNING ②
Do not open the radiator cap when the engine is
hot, as you may be injured by escaping hot liquid
or vapor.
● Remove the right side radiator cover ① by loosening

the two mounting bolts ②.
● Remove the radiator cap ③.
● R emove the coolant reserve tank filler cap ④ by

turning it counter-clockwise.
④
● Place a pan below the water pump, and then drain

the engine coolant by removing the coolant drain bolt
⑤.
● Flush the radiator with the fresh water, if necessary.
● Tighten the coolant drain bolt ⑤ to the specified
torque.
Coolant drain bolt
: 11 ~ 14 N·m (1.1 ~ 1.4 kgf·m)
● P our the specified engine coolant through the
radiator cap inlet up to the inlet neck.
NOTE
For engine coolant information, refer to page 6-1
● B leed the air from the engine coolant circuit as ⑤

following procedure.
■ AIR BLEEDING THE COOLING

CIRCUIT
● Add the engine coolant up to the raditor cap inlet.
●S upport the motorcycle upright.
● S lowly swing the motorcycle, right and left, to
bleed the air trapped in the cooling circuit.
● Add the engine coolant up to the radiator cap inlet.
● Loosen the air bleeding bolt ① on the cylinder.
● Start up the engine and bleed air from the radiator

cap inlet and the air bleeding bolt ① on the cylinder
completely.
● Add the engine coolant up to the radiator cap inlet.
● Repeat the above procedure until no air bleed from
the radiator cap inlet and the air bleeding bolt ① on
the cylinder .
①
● Close the radiator cap and tighten the air bleeding
bolt ① on the cylinder securely.
● A fter warming up and cooling down the engine
several times, add the engine coolant up to the “F”
(Full) level line of the reserve tank.
CAUTION
Repeat the above procedure several times and
make sure that the radiator is filled with engine
coolant up to the “F” (Full) level line of the
reserve tank.
RADIATOR HOSE
Inspect Interval
Inspect Every 4,000km,
Replace Every 4 years.
Inspect the radiator hoses for crack, damage or engine

coolant leakage.
If any defects are found, replace the radiator hoses with
new ones.
DRIVE CHAIN
Inspect Interval
Clean and Lubricate Every 1,000 km.
Visually check the drive chain for the possible defects

listed below. (Support the motorcycle by the jack or
block, turn the rear wheel slowly by hand with the trans-
mission shifted to Neutral.)
● Loose pins
● Excessive wear
● Damaged rollers
● Improper chain adjustment
● Missing “O-ring” seals
● Dry or rusted links
● Kinked or binding links
If any defects are found, the drive chain must be

replaced.
Damage to the drive chain means that the sprocket may
also be damaged.
If any defects are found, the sprocket must be replaced.
Inspect the sprockets for the following :
● Excessively worn teeth Normal wear Excessive wear
● Broken or damaged teeth
● L oose sprocket mounting nuts
NOTE ①
When replacing the drive chain, replace the
drive chain and sprocket as a set.
②
■ INSPECTION OF DRIVE CHAIN ④

LENGTH
● Loosen the axle nut ①.
● Loosen the lock nuts ②, ③.
● Tense the drive chain fully by turning both chain
adjusters ④, ⑤.
③
⑤
● C ount out 21 pins (20 pitches) on the chain and

measure the distance between the two points.
If the distance exceeds the service limit, the chain
must be replaced.
Service limit
Drive chain
20 pitch length 319.4 mm
(12.58 in)
■ ADJUSTMENT OF DRIVE CHAIN

SLACK ①
● Place the motorcycle on a jack or block for accurate
adjustment.
②
WARNING
Improper jacking may cause damage to the frame ⑥
or engine.
● Loosen the axle nut ①.

● Loosen the lock nuts ②, ③.
● Loosen or tighten both chain adjusters ④, ⑤ until the ④
chain has 20 〜 30 mm of slack in the middle
between the engine and rear sprockets. The marks
⑥, ⑦ on both chain adjusters must be at the same
position on the scale to ensure that the front and rear
wheels are correctly aligned.
20 〜 30 mm
Drive chain slack (0.79 ~ 1.18 in)
● After adjusting the drive chain, tighten the axle nut

① to the specified torque. ⑦
Rear axle nut ⑤ ③
: 90 ~ 140 N·m (9.0 ~ 14.0 kg·m)
● Tighten both chain adjuster lock nuts ②, ③ securely.
● R echeck the drive chain slack after tightening the

rear axle nut.
20 ~ 30 mm
■ CLEANING AND LUBRICATING

● Wash the drive chain with kerosine. If the drive chain
tends to rust quickly, the intervals must be shortened.
K
erosene is a petroleum product and will provide
some lubrication as well as cleaning action.
● After washing and drying the chain, oil the links with a
Hyosung chain lube or an equivalent.
CAUTION
The drive chain for this motorcycle is made of the
special material.
The chain should be replaced with a RK520STX
for『』.
Use of another chain may lead to premature
chain failure.
CAUTION
Some drive chain lubricants contain solvents and
additives which could damage the “O-rings” in
your chain.
Use Hyosung chain lube or an equivalent that is

specifically intended for use with “O-rings”
chains.
CAUTION
Cleaning the chain with gasoline or commercial
cleaning solvents can damage “O-rings” and ruin
the chain.
Clean the drive chain with kerosene only.

BRAKE SYSTEM
Inspect Interval
[ BRAKE ]
[ BRAKE HOSES & BRAKE FLUID ]
Replace the brake hoses Every 4 years, CAUTION
Replace the brake fluid Every 2 years. Do not spill any brake fluid on the brake pad or
disk.
■ BRAKE FLUID LEVEL CHECK
● Keep the motorcycle upright and place the handle-
bars straight.
● Check the brake fluid level by observing the lower
limit line (LOWER) on the front or rear brake fluid
reservoir.
● When the level is below the lower limit line (LOWER),
replenish with brake fluid that meets the following
specification.
Specification and Classification

: DOT 4
WARNING Front Brake

The brake system of this motorcycle is filled with
a glycol-based brake fluid. Do not use or mix dif-
ferent types of the brake fluid, otherwise serious
damage will result in the brake system.
Do not use any brake fluid taken from old, used or
unsealed containers.
Never re-use brake fluid left over from the last
servicing or stored for a long period.
WARNING
Brake fluid, if it leaks, will interfere with safe
running and immediately discolor painted Rear Brake
surfaces.
Check the brake hoses and hose joints for cracks
and oil leakage before riding.
■ BRAKE PAD WEAR

he extent of brake pad wear can be checked by
T
observing the grooved limit Ⓐ on the pad.
When the wear exceeds the grooved limit, replace
the pads with new ones.
CAUTION Ⓐ Approx. 2 mm
Replace the brake pad as a set, otherwise
braking performance will be adversely affected.
■ FRONT AND REAR BRAKE PAD

REPLACEMENT
● Remove the brake caliper.
FRONT BRAKE
● Remove the brake pad mounting bolt’s E-ring ①.
● Remove the brake pad mounting bolts ② and spring ③.
REAR BRAKE
● Remove the brake pad mounting pin's cotter pin ④.
● Remove the brake pad mounting pin ⑤ and spring ⑥.
CAUTION
Do not operate the brake lever or pedal while
Front Brake
dismounting the pads.
● Remove the brake pads. ① ③ ①

● To reassemble, reverse the above sequence.
Front brake caliper mounting bolt

: 21 ~ 31 N·m (2.1 ~ 3.1 kgf·m)
Rear brake caliper mounting bolt
: 21 ~ 31 N·m (2.1 ~ 3.1 kgf·m)
②
②
NOTE
After replacing the brake pads, pump or press the
brake lever or pedal few times to check for proper
brake operation and then check the brake fluid
level.
Front brake pad mounting bolt

: 10 ~ 15 N·m (1.0 ~ 1.5 kgf·m)
Rear Brake
⑤ ④
⑥
■F
RONT AND REAR BRAKE FLUID
REPLACEMENT
● Place the motorcycle on a level surface and keep the
handlebars straight.
● Remove the master cylinder reservoir cap and diaph-
ragm.
● Suck up the old brake fluid as much as possible.
● Fill the reservoir with new brake fluid.
Specification and Classification

: DOT 4
● Connect a transparent hose to the air bleeder valve
① and insert the other end of the hose into a
receptacle.
● L oosen the air bleeder valve and pump the brake

lever until the old brake fluid is completely out of the
brake system.
● C lose the air bleeder valve and disconnect the

transparent hose. Fill the reservoir with new brake
fluid to the upper line.
● Replace the rear brake’s fluid with the same manner
of the front brake.
Front brake caliper air bleeder valve
: 4 ~ 7 N·m (0.4 ~ 0.7 kgf·m)
Rear brake caliper air bleeder valve
: 4 ~ 7 N·m (0.4 ~ 0.7 kgf·m)
■ AIR BLEEDING OF THE BRAKE

FLUID CIRCUIT
Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus interferes with the full brak-
ing performance of the brake caliper. The presence of
air is indicated by“sponginess”of the brake lever and
also by lack of braking force. Considering the danger
to which such trapped air exposes the machine and
rider, it is essential that, after remounting the brake
a n d restoring the brake system to the normal
condition, the brake fluid circuit be purged of air in the
following manner :
● Fill the master cylider reservoir to top of the inspec-
tion window. Replace the reservoir cap to prevent dirt
from entering it. ①
● Attach a hose to the air bleeder valve ①, and insert
the free end of the hose into a receptacle.
● Bleed air from the brake system.
● Squeeze and release the brake lever several times

in rapid succession and sqeeze the lever fully
without releasing it. Loosen the bleeder valve by
turning it a quarter of a turn so that the brake fluid
runs into the receptacle, this will remove the
tension of the brake lever causing it to touch the
handlebar grip. Then, close the air bleeder valve,
pump and squeeze the brake lever, and open the
valve. Repeat this process until the fluid flowing into
the receptacle no longer contains air bubbles.
NOTE
While bleeding the brake system, replenish the
brake fluid in the reservoir as necessary.
Make sure that there is always some fluid visible
in the reservoir.
● Close the air bleeder valve, and disconnect the hose.

Fill the reservoir with brake fluid to the upper line.
● Bleed the rear brake’s air with the same manner of
front brake.
Front brake caliper air bleeder valve
: 4 ~ 7 N·m (0.4 ~ 0.7 kgf·m)
Rear brake caliper air bleeder valve
: 4 ~ 7 N·m (0.4 ~ 0.7 kgf·m)
CAUTION
Handle brake fluid with care : the fluid reacts
chemically with paint, plastics, rubber materials,
etc.
■ REAR BRAKE LAMP SWITCH

Adjust the rear brake lamp switch ① so that the brake
lamp will come on just before pressure is felt when the
brake pedal is depressed.
STEERING ①
Inspect Interval
The steering should be adjusted properly for smooth

turning of handlebars and safe running. Overtight
steering prevents smooth turning of the handlebars
and too loose steering will cause poor stability.
Check that there is no play in the steering stem while
grasping the lower fork tubes by supporting the
machine so that the front wheel is off the ground, with
the wheel straight ahead, and pull forward. If play is
found, perform steering stem nut adjustment as
described in page 8-29 of this manual.
FRONT FORK
Inspect Interval
Inspect Every 4,000 km.
Inspect the front forks for oil leakage, scoring or scratch-

es on the outer surface of the inner tubes.
Replace any defective parts, if necessary.
REAR SUSPENSION
Inspect Interval
Inspect Every 4,000 km.
Inspect the rear shock absorber for oil leakage and

mounting rubbers for wear and damage.
Replace any defective parts, if necessary.
(Refer to page 8-41)
TIRE
Inspect Interval
■ TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will Tire wear Tire wear indicator
decrease riding stability and can lead to loss of control. indicator mark
● Inspect shortage of tire thread’s depth by the 『tire
wear indicator』.
TW I
● Replace the front and rear tires at once when appear
I
TW
TW
the 『tire wear indicator』.
I
■ TIRE PRESSURE TWI
If the tire pressure is too high or too low, steering will be

adversely affected and tire wear increased. Therefore,
maintain the correct tire pressure for good enter key
roadability or shorter tire life will result. Cold inflation
tire pressure is as follows.
COLD INFLATION SOLO RIDING DUAL RIDING

TIRE PRESSURE kPa kgf/cm2 psi kPa kgf/cm2 psi
Front 200 2.00 29.0 200 2.00 29.0
Rear 211 2.11 30.0 225 2.25 32.0
CAUTION
The standard tire on『』is
110/70 - R17 54S for front and
150/60 - R17 66S for rear.
The use of tires other than those specified may
cause instability. It is highly recommended to use
a HYOSUNG Genuine Tire.
CHASSIS BOLTS AND NUTS

Inspect Interval
Tighten Initial 1,000 km and Every 4,000 km thereafter.
Check that all chassis bolts and nuts are tightened to

their specified torque. (Refer to page 9-19)
COMPRESSION PRESSURE
The compression pressure reading of a cylinder is a Low compression pressure can indicate some of the
good indicator of its internal condition. following conditions :
The decision to overhaul the cylinder is often based on ● Excessively worn cylinder wall
the results of a compression test. Periodic maintenance ● Worn-down piston or piston rings
records kept at your dealership should include ● Piston rings stuck in grooves
compression pressure reading for each maintenance ● Poor seating of valves
service. ● Ruptured or otherwise defective cylinder head gasket
Compression pressure
Standard 11 kgf/cm2 (at 500 rpm)
NOTE
Service limit 10 kgf/cm2 (at 500 rpm) When the compression pressure goes below
specification, check the engine for conditions
listed above.
■ COMPRESSION TEST PROCEDURE

NOTE
❖ B efore testing the engine for compression
pressure, make sure that the cylinder head
bolts are tightened to the specified torque
values and valves are properly adjusted.
❖ Have the engine warmed up by idling before
testing.
❖ Make sure that the battery is fully-charged.
Remove the concerned parts and test the

compression pressure in the following manner.
● Remove the air cleaner case. (Refer to page 3-1)
● Remove the spark plug.
● F it the compression gauge in the plug hole while
taking care that the connection is tightened.
● Keep the throttle grip in full-open position.
● Crank the engine a few seconds with the starter, and
Overhaul the engine in the following cases :
record the maximum gauge reading as the compres-
● Compression pressure in the cylinder is less than 10
sion of cylinder.
kgf/cm2.
Compression gauge : 09915-64511 ● Compression pressure readings are nearly 10 kg/cm2
even when it measure more than 10 kgf/cm2.
OIL PRESSURE
Check the engine oil pressure periodically. This will give a good indication of the condition of the moving parts.
Standard
Oil pressure 1.7 ~ 2.7 kgf/cm2
(at 60℃·3,000 rpm)
If the engine oil pressure is lower or higher than the specification, the following causes may be considered.
■ LOW OIL PRESSURE

● Clogged oil filter
● Oil leakage from the oil passage
● Damaged O-ring
● Defective oil pump
● Combination of above items
①
■ HIGH OIL PRESSURE
● Engine oil viscosity is too high
● Clogged oil passage
● Combination of the above items
■ OIL PRESSURE TEST

PROCEDURE
Check the engine oil pressure in the following manner.
●R emove the engine oil pressure check plug ① and
install the adapter of the oil pressure gauge at the
removed position.
● Connect an engine tachometer.
● Warm up the engine as follows :
Summer : 10 min. at 2,000 rpm.
Winter : 20 min. at 2,000 rpm.
● A fter warming up, increase the engine speed to
3,000 rpm. (with the engine tachometer), and read
the oil pressure gauge.
Engine tachometer : 09900-26006
Oil pressure gauge : 09915-74511
● Tighten the engine oil pressure check plug ① to the
specified torque.
Engine oil pressure check plug

: 35 ~ 45 N·m (3.5 ~ 4.5 kgf·m)
ENGINE
CONTENTS
ENGINE REMOVAL AND REMOUNTING… ……………………… 3- 1
ENGINE REMOVAL………………………………………………………… 3- 1
ENGINE REMOUNTING…………………………………………………… 3- 7 3
ENGINE DISASSEMBLY ………………………………………………… 3- 9
STARTER MOTER ………………………………………………………… 3- 9
THERMOSTAT ……………………………………………………………… 3- 9
CYLINDER HEAD COVER … …………………………………………… 3-10
PISTON ……………………………………………………………………… 3-14
MAGNETO COVER………………………………………………………… 3-14
MAGNETO ROTOR … …………………………………………………… 3-15
CLUTCH COVER…………………………………………………………… 3-16
CLUTCH … ………………………………………………………………… 3-16
PRIMARY DRIVE GEAR…………………………………………………… 3-18
OIL PUMP…………………………………………………………………… 3-20
GEARSHIFT SHAFT… …………………………………………………… 3-20
ENGINE COMPONENT INSPECTION AND SERVICE………… 3-23

ENGINE REASSEMBLY… ……………………………………………… 3-42
CAUTION
❖ M ark an identification of assembly location on each removed part so that each will be restored to
the original position during reassembly.
❖ Wash clean and dry the removed parts before inspecting and measuring.
❖ Oil the rotating or sliding parts before assembly.
❖ Make sure to use the correct type of lubricant where specified.
❖ Check that each rotating or sliding part moves or operates smoothly after assembly.
❖ Make sure to follow the bolt tightening order where specified.
❖ If the correct length of the bolt is confused when tightening the crankcase or cover, insert all the bolts and
check that the tightening margin is equal in each bolt.
3-1 ENGINE
ENGINE REMOVAL AND

REMOUNTING
ENGINE REMOVAL
NOTE
If the engine is dirtied, wash the machine with ①
a suitable cleaner before removing the engine.
● Remove the front seat.

● Disconnect the battery ⊖ lead wire ①.
CAUTION
First, disconnect the ⊖ lead wire.
● Remove the fuel tank cover. (Refer to page 8-2)
● Remove the air cleaner case by loosening the clamp
screw ②.
● Remove the fuel tank. (Refer to page 5-2)
②
● Drain the engine oil. (Refer to page 2-13)
GD250-000010
● Remove the engine oil filter ③. (Refer to page 2-14)

● Drain the engine coolant. (Refer to page 2-17)
③
ENGINE 3-2
■ RADIATOR
● Remove the radiator cover ① by loosening the four
radiator cover mounting bolts, right and left.
●D
isconnect the radiator outlet hose ②.
●R
emove the three radiator mounting bolts.
● Disconnect the cooling fan thermo-switch lead wire

coupler ③.
●D isconnect the radiator inlet hose ④.
③
3-3 ENGINE
● Disconnect the reserve tank hose.

● Disconnect the cooling fan motor lead wire coupler
①.
● Remove the radiator.
CAUTION
Be careful not to bend the radiator fin. ①
■ SENSORS
● Remove the all sensor couplers.
(Refer to chapter 4 and 5)
● D isconnect the fuel injector hoses ②.
■ THROTTLE BODY
● R emove the intake pipe mounting bolts and then
remove the intake pipe together with the throttle body
③.
③
ENGINE 3-4
●R
emove the O-ring ①, insulator ② and O-ring ③.
③
①
■ CLUTCH CABLE
● D isconnect the clutch cable end out of the clutch
lever.
● Disconnect the clutch cable end out of the clutch
release arm.
■ EXHAUST PIPE AND MUFFLER

● A fter removing the exhaust pipe nuts ④, muffler
plate bracket bolt ⑤, muffler connecting bolt ⑥
and muffler mounting bolt ⑦, remove the exhaust
pipe and muffler.
⑤
⑥ ⑦
3-5 ENGINE
■ ELECTRIC PARTS
● With take out the spark plug cap, remove the spark
plug.
● Remove the starter motor lead wire.
● Remove the engine ground lead wire ①.
● Disconnect the magneto couplers ②.

● Disconnect the GP switch terminal ③.
②
ENGINE 3-6
● Disconnect the side stand switch lead wire coupler

①.
■ ENGINE SPROCKET
● Remove the engine sprocket cover ②.
● Remove the breather hose ③.
● Remove the link rod by loosening the bolt.

● Flatten the lock washer.
● Remove the engine sprocket nut ④ and lock washer.
NOTE
When loosening the engine sprocket nut,
depress the brake pedal.
④
3-7 ENGINE
● Remove the engine sprocket.
NOTE
If it is difficult to remove the engine sprocket,
loosen the rear axle nut, chain adjusters ①·②
to provide additional chain slack.
(Refer to page 2-19)
① ②
● Support the engine using an engine jack.

● Remove the engine mounting nuts and bolts.
● Remove the engine from the frame.
CAUTION
Remove the throttle body when removing or
installing the engine necessarily.
Remove the throttle body together with the
intake pipe by loosening the intake pipe
mounting bolts.
ENGINE REMOUNTING
Remount the engine in the reverse order of engine
removal.
● Support the engine assembly with a proper engine
jack.
● Install the engine mounting bolts and nuts.
● Tighten the engine mounting bolts and nuts to the
specified torque.
Engine mounting nut
: 40 ~ 60 N · m (4.0 ~ 6.0 kgf · m)
■ ENGINE SPOCKET Ⓐ
● Loosen the rear axle nut Ⓐ and chain adjusters Ⓑ,
Ⓒ, right and left.
● Install the engine sprocket.
Ⓑ
ENGINE 3-8
● Tighten the engine sprocket nut ① to the specified

torque.
Engine sprocket nut
: 80 ~ 100 N·m (8.0 ~ 10.0 kgf·m)
NOTE
When tightening the engine sprocket nut, ①
depress the rear brake pedal.
● Bend the lock washer securely.
● Install the gearshift arm and adjust the gearshift lever

height. (Refer to page 2-10)
● Install the breather hose and engine sprocket cover.

● Connect each electric part and its couplers.
(See pages 9-30 through 38)
● Connect the all sensor and its couplers.
(Refer to chapter 4 and 5)
● Install the exhaust pipe and muffler.
● Install the throttle body and air cleaner.
(Refer to page 5-9)
● Install the radiator and radiator cover.
● After remounting the engine, the following adjust-

ments are necessary.
✽ Engine idling speed inspect . ............................................... Refer to page 2-9
✽ Throttle cable play ............................................................... Refer to page 2-9
✽ Clutch cable play ................................................................. Refer to page 2-10
✽ Drive chain . ......................................................................... Refer to page 2-19
✽ Gearshift lever height .......................................................... Refer to page 2-10
✽ Engine oil level .................................................................... Refer to page 2-15
✽ Engine coolant . ................................................................... Refer to page 2-16
3-9 ENGINE
ENGINE DISASSEMBLY
CAUTION
❖ Put the removed parts from the engine in order
in each component part.
❖ B e careful not to cause damage on the
removed parts when handling.
STARTER MOTOR
● Remove the starter motor.
● Remove the GP switch.

● Remove the contact ① and spring ②.
THERMOSTAT
● Remove the thermostat case ③.
NOTE
Thermostat inspection and servicing :
Refer to page 6-10
③
ENGINE 3-10
CYLINDER HEAD COVER

● Remove the cylinder head cover.
● Set the piston at TDC (Top Dead Center).
CAUTION
Rotate the magneto rotor counter-clockwise
using a socket wrench to set the piston at TDC
of the compression stroke.
Rotate the magneto rotor until the “-” line on
the magneto rotor is aligned with the “ ” mark
on the magneto cover.
● Remove the cam chain tension adjuster ①.
● Remove the cam chain guide NO.2 ② by loosening

the two bolts.
②
3-11 ENGINE
● Remove the camshaft housing ① by loosening the

bolts.
NOTE ①
Mark an identification of assembly location
on each removed parts so that each will be
restored to the original position during
reassembly.
● R emove the dowel pins, intake camshaft ② and

exhaust camshaft ③.
②
NOTE
Do not drop the dowel pins and camshaft
drive chain into the crankcase.
③
● Remove the two coolant hoses ④, ⑤.

● Loosen the three cylinder head base nuts ⑥.
⑥
⑤
● L oosen the four cylinder head bolts in diagonal

stages.
NOTE
When loosening the cylinder head bolts,
loosen each bolt little by little diagonally.
ENGINE 3-12
● Remove the cam chain guide NO.1 ① and cylinder

head ②.
②
● Remove the tappet ③ and the shim ④.
CAUTION
Draw out the tappet and shim using the
strong magnet not to be scratched.
CAUTION ④
The tappet and shim should be lined so that each
will be restored to the original position during
reassembly.
③
3-13 ENGINE
● C ompress the valve spring, and then remove the

valve cotter from the valve stem by using the special
tool.
Valve spring compressor

: 09916-14510
Valve spring compressor attachment
: 09916H35C00
● Remove the valve spring retainer ① and valve spring

②.
● Pull out the valve ③ from the other side.
● Remove the oil seal ④ using the long-nose pliers.
● Remove the valve spring seat ⑤. ① ②
⑤
④
③
● Remove the cylinder head gasket ⑥ and dowel pins
⑦.
⑥
● L oosen the two cylinder base nuts ⑧ and then

remove the cylinder ⑨.
CAUTION ⑨
If the cylinder does not come off easily, lightly
tap it by using a plastic hammer.
⑧
ENGINE 3-14
● Remove the cylinder gasket ① and dowel pins ②.
②
①
PISTION
● Place a clean rag over the cylinder base to prevent
the piston pin circlip from dropping into the
crankcase.
● Remove the piston pin circlip using the long-nose
pliers.
● Remove the piston pin by using the special tool and

then remove the piston.
Piston pin puller : 09910-34510
MAGNETO COVER
● Remove the magneto cover ③.
③
3-15 ENGINE
● Remove in the order of the spacer ①, starter idle

shaft ② and starter idle gear ③.
①
③
②
MAGNETO ROTOR
● L oosen the magneto rotor nut by holding the
crankshaft immovable with the special tool.
Conrod holder : 09910-20115
● Remove the magneto rotor by using the special tool.
Rotor remove sliding shaft

: 09930-30102
Rotor remover : 09930-30162
● Remove the key ④.

● Remove the starter driven gear ⑤.
④
⑤
ENGINE 3-16
CLUTCH COVER
● Remove the clutch release arm .
● Remove the clutch cover bolts.

● Remove the clutch cover ①.
CLUTCH
● Remove the clutch spring mounting bolts diagonally
by holding the crankshaft immovable with the
special tool.
Conrod holder : 09910-20115 ②
● Remove the clutch pressure plate ②.
● Remove the clutch drive and driven plates.

3-17 ENGINE
● Flatten the lock washer ①.
● R emove the clutch sleeve hub nut by holding the

clutch sleeve hub immovable with the special tool.
Clutch sleeve hub holder

: 09920-53710
● Remove the clutch sleeve hub ② and primary driven

gear assembly ③. ②
③
ENGINE 3-18
● Loosen the crank balancer nut ①.

● Remove the two washers ②, ③ and spacer ④.
● Remove the crank balancer driven gear ⑤.
②,③
PRIMARY DRIVE GEAR

● L oosen the primary drive gear nut ⑥ by holding the
crankshaft immovable with the special tool.
CAUTION ⑥
This nut has left-hand thread.
if turning it counter-clockwise( ), it may
cause damage.
Pay attention at the primary drive gear nut ⑥
with the two washers.
● Remove the two washers ⑦, ⑧.
⑦, ⑧
3-19 ENGINE
● Remove the primary drive gear ①.
● Remove the cam chain ②.
● L oosen the crank balancer drive gear nut ③ by

using the special tool.
③
Crank balancer socket wrench
: 09940HP7600
CAUTION
This nut has left-hand thread.
if turning it counter-clockwise( ), it may
cause damage.
● Remove the crank balancer drive gear ④.
④
ENGINE 3-20
OIL PUMP
● Remove the circlip ①, washer ②, oil pump idle gear
③ and washer ④. ④
②
①
● Remove the oil pump with the oil pump driven gear
⑤ by loosening the three screws.
GEARSHIFT SHAFT
● Draw out the gearshift shaft ⑥.
⑥
● Draw out the gearshift cam guide ⑦ and lifter ⑧ by
loosening the gearshift cam guide and lifter ⑧
screws.
● Remove the gearshift cam driven gear ⑨.
CAUTION
Pay attention to not lost the gearshift pawl, pin,
spring while removing the cam driven gear. ⑨
⑦
3-21 ENGINE
● Remove the washer, spring and stopper by loosening

the neutral cam stopper plug.
● Remove the crankcase securing bolts.
NOTE
Loosen the crankcase securing bolts diagonally.
● Separate the crankcase into 2 parts, right and left,

by using a special tool.
Crankcase separator : 09920-13120
CAUTION
When separating the crankcase, necessarily, remove
it after installed the special tool (Crankcase
separator) on the side of clutch.
In case separate oppositely, the gearshift cam
stopper will be damaged in the side of magneto.
NOTE
Fit the crankcase separater, so that the tool
arms are in parallel with the side of the
crankcase. ④ ① ⑤
● R emove the gearshift fork shafts ① and gearshift
forks ②.
● Remove the gearshift cam ③.
● R emove the driveshaft assembly ④, countershaft
assembly ⑤.
● Remove the oil pump idle gear shaft ⑥. ②
⑥
③
②
ENGINE 3-22
● Remove the balancer shaft ①.
● Remove the crankshaft by using the special tool.
Crankcase separator : 09920-13120

3-23 ENGINE
EN GINE COMPONENT

INSPECTION AND SERVICE
CAUTION
Be sure to identify each removed part as to its
location, and lay the parts out in groups
designated as“Exhaust”,“Intake”, so that each
will be restored to the original location during
assembly.
◉ CYLINDER HEAD DISTORTION

Decarbonate in combustion chamber.
Check the gasketed surface of the cylinder head for dis-
tortion with a straightedage and thickness gauge, taking
a clearance reading at several places as indicated. If the
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder head.
Cylinder head Service limit
distortion 0.05 mm (0.002 in)
◉ VALVE FACE WEAR

Visually inspect each valve face for wear. Replace any
valve with an abnormally worn face. The thickness of
the valve face decreases as the face wears. Measure
the valve head Ⓣ. If it is out of specification, replace the
valve with a new one.
Valve head Service limit

thickness 0.5 mm (0.02 in)
Vernier calipers : 09900-20101 Ⓣ
◉ VALVE STEM RUNOUT

Check the valve stem for abnormal wear or bend.
Place the valve on the V-blocks and measure runout.
If the service limit is exceeded or abnormal condition
exists, replace the valve.
Service limit
Valve stem runout
0.05 mm (0.002 in)
D
ial gauge : 09900-20606
Magnetic stand : 09900-20701
V-block : 09900-21304
ENGINE 3-24
◉ CAMSHAFT (T.D.C)
(B.T.D.C)
The camshaft should be checked for runout and also for Intake open (A.T.D.C)
Exhaust close
wear of cams and journals if the engine has been noted
to produce abnormal noise or vibration or a lack of out- 13。
16。
put power. Any of these abnormality could be caused by
a worn camshaft.
55。 58。
(B.B.D.C)
Exhaust open
(A.B.D.C)
Intake close
(B.D.C)
valve timing diagram
■ CAMSHAFT WEAR
Worn-down cams are often the cause of mistimed valve
operation resulting in reduced output power.
The limit of cam wear is specified for both intake and
exhaust cams in terms of cam height Ⓗ, which is
measured with a micrometer. Replace camshafts if
found it worn down to the limit. Ⓗ
Cam height Service limit
Intake cam 35.00 mm (1.378 in)
Exhaust cam 34.90 mm (1.374 in)
Micrometer(25~50 mm) : 09900-20202
◉ TAPPET & SHIM WEAR

When measuring the valve clearance, the clearance
should be within the standard range.
Valve clearance Standard (When cold)
0.10 ~ 0.20 mm
Intake valve (0.004 ~ 0.008 in)
0.20 ~ 0.30 mm
Exhaust valve (0.008 ~ 0.012 in)
● Inspect the tappet for wear and scratch.

If modification or scratch is present, replace the tap-
pet.
● When you checked the valve clearance, if the valve
clearance is wide please replace the present shim
into thicker one, if the valve clearance is narrow
please replace the present shim into thinner shim.
(Refer to page 9-41·42)
■ SHIM KIND
There are 41 kinds of shim which thickness is
increased by each 0.025 mm from 1.20 mm to 2.20
mm.
3-25 ENGINE
◉ VALVE HEAD RADIAL

RUNOUT
Place a dial gauge as shown and measure valve head
radial runout.
If the service limit is exceeded, replace the valve.
Valve head radial Service limit

runout 0.03 mm (0.0012 in)
Dial gauge : 09900-20606

V-block : 09900-21304
◉ VALVE GUIDE - VALVE
STEM CLEARANCE
Measure the clearance in the valve guide - valve stem,
by r i g g i n g u p t h e d i a l g a u g e a s s h o w n . I f t h e
clearance is measured exceeds the limit specified
below, then determine whether the valve or the guide
should be replaced to reduce the clearance to within
the standard range :
Valve guide - valve Standard
stem clearance
0.020 ~ 0.047 mm
IN. (0.0008 ~ 0.0019 in)
0.030 ~ 0.057 mm
EX. (0.0012 ~ 0.0022 in)
Dial gauge : 09900-20606
◉ VALVE STEM DIAMETER
Measure the valve stem outside diameter.
If the diameter measured exceeds the standard, replace
the valve.
Valve stem diameter Standard
4.465 ~ 4.480 mm
IN. (0.1758 ~ 0.1764 in)
4.455 ~ 4.470 mm
EX. (0.1754 ~ 0.1760 in)
Micrometer(0~25 mm) : 09900-20201

◉ VALVE SPRING
The force of the coil spring keeps the valve seat tight.
A weakened spring results in reduced engine power
out-put and often accounts for the chattering noise
coming from the valve mechanism.
Check the valve springs for proper strength by measur-
ing their free length and also by the force required to
compress them. If the spring length is less than the
service limit or if the force required to compress the
spring does not fall within the specified range, replace
the spring.
ENGINE 3-26
Valve spring free Standard

length 40.06 mm
(IN. & EX.) (1.577 in)
Venier calipers : 09900-20101
Standard
Valve spring
tension
45.9 kgf (102 lbs)
(IN. & EX.)
at length 31.8 mm (1.25 in)
◉ CYLINDER DISTORTION
Check the gasketed surface of the cylinder for distortion
with a straightedge and thickness gauge, taking a
clearance reading at several places as indicated.
If the largest reading at any position of the
straightedge exceeds the limit, replace the
cylinder.
Service limit
Cylinder distortion
0.05 mm (0.002 in)
◉ CYLINDER BORE
Measure the cylinder bore diameter at six place.
If any one of the measurements exceeds the limit,
replace the cylinder.
Standard Service limit

Cylinder
bore 73.000 ~ 73.015 mm 73.080 mm
(2.8740 ~ 2.8746 in) (2.8772 in)
Cylinder gauge set : 09900-20508
◉ CAM CHAIN TENSION

ADJUSTER
Check that the push rod slides smoothly with the lock
shaft handle ① clockwise.
If it does not slide smoothly, replace the cam chain ten-
①
sion adjuster with a new one.
3-27 ENGINE
◉ CAM CHAIN TENSIONER

Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
◉ CAM CHAIN AND CAM CHAIN

GUIDE
Check the cam chain for wear, damage and kinked or bind-
ing links.
If any defects are found, replace it with a new one.
Check the cam chain guide for wear and damage.
If it is found to be damaged, replace it with a new one.
◉ PISTON DIAMETER
INSPECTION
Measure the outside diameter of the piston in the direction
perpendicular to the piston pin axis at the height from the
skirt as shown in the illustration using a micrometer.
If the measurement is found less than the service limit,
replace the piston.
Service limit
Piston diameter 72.880 mm
(2.8693 in) 15 mm (0.6 in)
Micrometer(50~75 mm)
: 09900-20203
◉ PISTON - CYLINDER
CLEARANCE
To determine the piston - cylinder clearance, calculate
the difference between the cylinder bore and outside
diameter of the piston.
Piston - Standard Service limit

cylinder 0.05 ~ 0.06 mm 0.120 mm
clearance (0.0020 ~ 0.0024 in) (0.0047 in)
ENGINE 3-28
◉ PISTON PIN HOLE BORE

Using a dial calipers, measure the piston pin hole bore
both in the vertical and horizontal directions.
If the measurement exceeds the service limit, replace
the piston.
Service limit
Piston pin hole bore
19.030 mm (0.7492 in)
Dial calipers : 09900-20605
◉ PISTON PIN DIAMETER

INSPECTION
Using a micrometer, measure the piston pin outside
diameter at three position, both the ends and the center.
If any of the measurements is founds less than the ser-
vice limit, replace the pin.
Service limit
Piston pin diameter
18.980 mm (0.7472 in)
Micrometer(0~25 mm) : 09900-20201

◉P
ISTON RING FREE END
GAP INSPECTION
Before installing piston rings, measure the free end gap
of each ring using a vernier calipers. If the gap is less
than the service limit, replace the ring.
Piston ring free Standard

end gap
1st Approx. 9.5 mm (0.374 in)
2nd Approx. 8.0 mm (0.315 in)
Piston ring free

Service limit
end gap
1st 8.0 mm (0.315 in)
2nd 6.8 mm (0.268 in)
Vernier calipers : 09900-20101

◉ PISTON RING END GAP
INSPECTION
Insert the piston ring squarely into the cylinder using the
piston head.
Measure the end gap with a thickness gauge.
If the gap exceeds the service limit, replace the piston ring.
Piston ring end gap
Standard
(Assembly condition)
0.10 ~ 0.30 mm
1st (0.004 ~ 0.012 in)
0.35 ~ 0.50 mm
2nd (0.014 ~ 0.020 in)
3-29 ENGINE
Piston ring end gap Service limit

(Assembly condition)
1st 0.50 mm (0.020 in)
2nd 0.50 mm (0.020 in)

◉ PISTON RING - GROOVE
CLEARANCE INSPECTION
Remove carbon deposit both from the piston ring and its
groove.
Fit the piston ring into the groove. With the ring com-
pressed and lifted up, measure the clearance on the
bottom side of the ring using a thickness gauge.
Piston ring - groove Service limit
clearance
1st 0.180 mm (0.007 in)
2nd 0.150 mm (0.006 in)
Piston ring groove Standard

width
1.01 ~ 1.03 mm
1st (0.040 ~ 0.041 in)
1.01 ~ 1.03 mm
2nd (0.040 ~ 0.041 in)
2.01 ~ 2.03 mm
Oil (0.079 ~ 0.080 in)
Piston ring thickness Standard

0.970 ~ 0.990 mm
1st (0.0382 ~ 0.0390 in)
0.970 ~ 0.990 mm
2nd (0.0382 ~ 0.0390 in)
Micrometer(0~25 mm) : 09900-20201

T
hickness gauge : 09900-20806
◉ CONROD SMALL END

INSIDE DIAMETER
INSPECTION
Using a dial calipers, measure the conrod small end
inside diameter both in vertical and horizontal directions.
If any of the measurements exceeds the service limit,
replace the conrod.
Standard Service limit
Conrod small
end I.D. 19.006 ~ 19.014 mm 19.040 mm
(0.7483 ~ 0.7486 in) (0.7496 in)
Dial calipers : 09900-20605

ENGINE 3-30
◉ CONROD DEFLECTION
INSPECTION
Move the small end sideways while holding the big end
immovable in thrust direction.
Measure the amount of deflection.
Turn the conrod and see if it moves smoothly without
play and noise. This method can check the extent of
wear on the parts of the conrod’
s big end.
Service limit
Conrod deflection
3.0 mm (0.12 in)
Dial gauge : 09900-20606

V-block : 09900-21304
◉ CONROD BIG END SIDE
CLEARANCE INSPECTION
Push the big end of the conrod to one side and
measure the side clearance using a thickness gauge.
If the clearance exceeds the service limit, replace the
crankshaft assembly with a new one or bring the
deflection and the side clearance within the service
limit by replacing the worn parts (conrod, big end
bearing, crankshaft, crank pin, etc.) with new ones.
Conrod big Standard Service limit

end side 0.10 ~ 0.45 mm 1.00 mm
clearance (0.004 ~ 0.018 in) (0.040 in)
◉ C R ANKSHAFT RUNOUT
INSPECTION
With the right and left crank journals supported by
using a V-block, turn the crankshaft slowly.
At this time, measure the crankshaft end runout by
using a dial gauge.
If the runout exceeds the service limit, replace the
crankshaft with a new one.
Service limit
Crankshaft runout
0.01 mm (0.0004 in)
Dial gauge : 09900-20606

V-block : 09900-21304
◉ CRANKSHAFT REASSEBLY
Measure the width between the webs referring to the fi-
gure below when rebuilding the crankshaft.
Standard
Width between webs 51.0 ± 0.1 mm
50.9 ~ 51.1 mm (2.008 ± 0.004 in)
(2.004 ~ 2.012 in)
3-31 ENGINE
◉ CRANK BALANCER AND BALANCER DRIVEN GEAR

■ DISASSEMBLY
● D isassemble the crank balancer and balancer driven gear as shown in the illustration.
■ REASSEMBLY
● Reassemble the crank balancer and balancer driven gear in the reverse order of disassembly.
ENGINE 3-32
◉ MAGNETO COVER
■ MAGNETO INSPECTION
☞ Refer to page 7-4
①
■ DISASSEMBLY
● Remove the stator ①.
◉ STARTER CLUTCH
Install the starter driven gear onto the starter clutch and
turn the starter driven gear by hand(the gear turns in
only one direction). The starter driven gear should turn
smoothly. If excessive resistance is felt while turning the
starter driven gear, inspect the starter clutch. Also,
inspect the surface of the starter driven gear which
contacts the starter clutch, for wear or damage. If any
wear or damage is found, replace the defective parts.
■ DISASSEMBLY
● W ith the magneto rotor held immovable, remove
the starter clutch bolts.
■ REASSEMBLY
● Apply a small quantity of the THREAD LOCK to the
starter clutch bolts and tighten them to the specified
torque while holding the rotor.
Thread Lock
Starter clutch bolt
: 15 ~ 20 N·m (1.5 ~ 2.0 kgf·m)
3-33 ENGINE
◉ STARTER DRIVEN GEAR

■ STARTER DRIVEN GEAR BUSH
②
Install the starter driven gear bush ① and gear ②
onto the crankshaft and turn the starter driven gear by
hand.
Inspect the starter driven gear bush for smooth rotation
and any abnormal noise.
If the bush does not turn smoothly or there is any
abnormal noise, replace it.
①
◉ DISASSEMBLY
● Remove the bush using the special tool.
Bearing remover(20~35 mm)

: 09923-74510
◉ OIL JET
■ REMOVAL
●R
emove the oil jet ③ from the right crankcase
half.
NOTE ③
If it is difficult to remove the oil jet, use a
sting.
■ INSPECTION AND CLEANING

● Check the oil jet for clogging.
● I f it is clogged, clean its oil passage with a proper
wire and compressed air.
ENGINE 3-34
■ INSTALLATION
● Fit the new O-ring to the oil jet. ①
CAUTION
Use the new O-ring to prevent oil leakage.
● Apply the engine oil to the O-ring.

● Install the oil jet ① to the oil hole of crankcase.
NOTE
Push the oil jet to the crankcase until it stops.
◉ CLUTCH COVER
■ OIL FILTER REPLACEMENT
☞ Refer to page 2-13
■ DISASSEMBLY
● Remove the retainer and right crankshaft oil seal.
Oil seal remover : 09913-50121
■ REASSEMBLY
● Drive in the oil seal by using the special tool.
Bearing installer : 09913-75820
● Install the retainer.
3-35 ENGINE
◉ CLUTCH DRIVE PLATES

Measure the thickness and claw width of the clutch drive
plates using a vernier calipers. If a clutch drive plate is
not within the service limit, replace the clutch plates
as a set.
Standard
Clutch drive plate
thickness 2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
Clutch drive plate Service limit

thickness 2.6 mm (0.102 in)
Clutch drive plate Standard

claw width 11.8 ~ 12.0 mm
(0.465 ~ 0.472 in)
Clutch drive plate Service limit

claw width 11.0 mm (0.433 in)
◉ CLUTCH DRIVEN PLATES

Measure each clutch driven plate for distortion by
using the thickness gauge. If a clutch driven plate is not
within the service limit, replace the clutch plates as a
set.
Clutch driven plate Service limit

distortion 0.1 mm (0.004 in)
◉ CLUTCH SPRING FREE

LENGTH
Measure the free length of each clutch spring by
using a vernier calipers. If any spring is not within the
service limit, replace all of the spring.
Clutch spring free Service limit

length 36.2 mm (1.43 in)

ENGINE 3-36
◉ CLUTCH RELEASE BEARING

Inspect the clutch release bearing for any abnormality,
especially cracks. When removing the bearing from the
clutch, decide whether it can be reused or if it should be
replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.
◉ PRIMARY DRIVEN GEAR

Inspect the primary driven gear bearing for any damage.
If any abnormal condition are found, replace the primary
driven gear.
◉ OIL PUMP
Turn the oil pump shaft and check that rotation is
smooth.
If any abnormal condition is found, replace the oil
pump with new one.
◉ GEARSHIFT SHAFT
Disassemble and reassemble the gearshift shaft as
shown in right picture.
3-37 ENGINE
◉ TRANSMISSION
■ INSPECTION
▷ GEARSHIFT FORK
Using a thickness gauge, check the clearance between
in the groove of its gear and shifting fork.
The clearance for each of the three shifting forks plays
an important role in the smoothness and positiveness of
shifting action.
If the clearance checked is noted to exceed the limit
specified, replace the fork or its gear, or both.
Shift fork - Standard Service limit

groove 0.10 ~ 0.30 mm 0.50 mm
clearance (0.004 ~ 0.012 in) (0.020 in)
Shift fork groove

Standard
width
5.0 ~ 5.1 mm
NO.1 & NO.2 (0.197 ~ 0.201 in)
5.0 ~ 5.1 mm
NO.3 (0.197 ~ 0.201 in)
Shift fork
Standard
thickness
4.8 ~ 4.9 mm
NO.1 & NO.2 (0.189 ~ 0.193 in)
4.8 ~ 4.9 mm
NO.3 (0.189 ~ 0.193 in)

■ REASSEMBLY
Assemble the countershaft and drive shaft in the reverse
order of disassembly. Pay attention to following points :
NOTE
Before installing the gears, coat lightly engine oil
to the driveshaft and countershaft.
ENGINE 3-38
CAUTION
❖ Never reuse a circlip. After a circlip has been
removed from a shaft, it should be discarded Thrust
and a new circlip must be installed.
❖ W hen installing a new circlip, care must be
taken not to expand the end gap larger than
required to slip the circlip over the shaft.
❖ After installing a circlip, always ensure that it
is completely seated in its groove and securely
fitted.
● W hen installing a new circlip, pay attention to the
direction of the circlip. Fit it to the side where the
thrust is as shown in figure.
■ TRANSMISSION GEARS AND RELATED PARTS
Thickness for washer,

circlips and spacers
Ⓐ 1.0 mm
Ⓑ 0.5 mm
Ⓒ 1.2 mm
Ⓓ 0.5 mm
3-39 ENGINE
◉ CRANKCASE play play

■ BEARING INSPECTION
Rotate the bearing inner race by finger to inspect for
abnormal play, noise and smooth rotation while the
bearings are in the crankcase.
Replace the bearing in the following procedure if there is
anything unusual.
■ DISASSEMBLY
▷ RIGHT CRANKCASE BEARING
①
● Remove the bearing retainer bolt ①.
● Remove the bearing retainer.
● Remove the bearings ②, ③ and ④.

④ ③
Bearing remover (12 mm)
: 09921-20210
: 09923-73210
Bearing remover (20~35 mm)
: 09923-74510
● Remove the bearing ⑤.
B
earing installer : 09913-76010
CAUTION
⑤
The removed bearing should be replace with a
new one.
ENGINE 3-40
▷ LEFT CRANKCASE BEARING

● Remove the oil seals ① and ②. ③
Oil seal remover : 09913-50121 ①
● Remove the oil guide ③.
● Remove the bearing retainer bolt ④.

● Remove the bearing retainer.
● Remove the bearings ⑤, ⑥ and ⑦.

: 09921-20210 ⑥
: 09923-73210
Bearing remover (20~35 mm)
: 09923-74510
⑤ ⑦
● Remove the bearings ⑧.
⑧
3-41 ENGINE
■ REASSEMBLY
▷ RIGHT CRANKCASE BEARING ①
● Drive in the bearings ①, ②, ③ and ④.

B
earing installer : 09913-76010 ② ③
▷ LEFT CRANKCASE BEARING

● Drive in the bearings ⑤, ⑥, ⑦, and ⑧.
⑤⑥
⑦
● Install the oil seals ⑨ and ⑩.

● Apply the GREASE on the lip of oil seal. ⑩
GREASE
⑨
ENGINE 3-42
ENGINE REASSEMBLY
The engine reassembly can be performed in the reverse
order of disassembly procedures. However, the follow-
ing points must be observed in the reassembly opera-
tion.
CAUTION
Make sure to coat the rotating and sliding sec-
tions with engine oil.
◉ CRANKSHAFT
● Using the special tool, press in the crankshaft into the
left crankcase.
C
rankshaft installer : 09910-32812
CAUTION
Never fit the crankshaft into crankcase by
striking it with a plastic hammer.
Always use the special tool, otherwise crankshaft
alignment accuracy will be affected.
● Install the balancer shaft ①.
◉ TRANSMISSION
● Install the transmission.
3-43 ENGINE
■ GEARSHIFT CAM AND

GEARSHIFT FORKS
● Install the gearshift fork NO.1 ①, NO.2 ②, and NO.3
③.
③ ①
② ②
① ⑥ ⑦
⑤
● Install the gearshift cam ④ and gearshift fork shaft
⑤, ⑥.
● Install the oil pump idle gear shaft ⑦.
● Install the dowel pins ⑧.

● Before assembling the crankcase, apply the engine
⑧
oil to each gear and bearing.
● Apply the GASKET BOND to the right crankcase.

GASKET BOND
CAUTION
❖ A pplication of the GASKET BOND must be
performed within a short period of time.
❖ Take extreme care not to let the GASKET
BOND enter into the oil hole or bearing.
ENGINE 3-44
● Install the crankcase.

● Install the crankcase bolts.
Crankcase bolt
: 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
NOTE
❖ A f t e r t h e c r a n k c a s e b o l t s h a v e b e e n
tightened, make sure that the crankshaft,
countershaft and driveshaft rotate smoothly.
❖ If these shafts do not rotate smoothly, try to
free it by tapping with a plastic hammer.
● Apply the GREASE to the driveshaft O-ring and oil

seal lip.
GREASE
● Install the driveshaft spacer.
● Install the oil seal retainer.

3-45 ENGINE
■ GEARSHIFT CAM DRIVEN GEAR

● W h e n i n s t a l l i n g t h e g e a r s h i f t p a w l i n t o t h e
gearshift cam driven gear, the big shoulder Ⓐ A
A
face toward outside as shown in figure.
● Install the gearshift cam guide and lifter.
W hen installed, apply the THREAD LOCK to the
securing screw.
A
A
THREAD LOCK
■ GEARSHIFT SHAFT
When installing the gearshift, match the center teeth of
the gear on the gearshift shaft with the center teeth on
the gearshift cam driven gear as shown.
CAUTION 6th
After the gearshift cam driven gear, gearshift 5th

cam lifter, gearshift cam guide, gearshift shaft
4th
and neutral cam stopper have been fitted,
confirm that gear change is normal while turning 3rd
the countershaft and driveshaft. If gear change
is not obtained, it means that assembly of gears 2nd
or installation of gear shifting fork is incorrect. N
In this case, disassemble and trace the
mistake. 1st
◉ OIL PUMP
● Before installing the oil pump, apply the engine oil to
the contact face of case, outer rotor, inner rotor and
shaft.
oil pump securing screws.
THREAD LOCK
● Tighten the oil pump securing screws to the specified
torque.
Oil pump mounting screw
: 12 ~ 16 N·m (1.2 ~ 1.6 kgf·m)
ENGINE 3-46
● Put in the washer ①, oil pump idle gear ②, washer

③ and install the circlip ④.
②
①
④
CAUTION
When installing the oil pump to the crankcase,
turn the oil pump gear and check that rotation
is smooth by the hand.
● I nstall the pin ⑤ to the crankshaft and the key ⑥

to the balancer shaft.
⑤
⑥
● Install the crank balancer drive gear ⑦.
⑦
3-47 ENGINE
● Tighten the crank balancer drive gear nut ① by

using the special tool to the specified torque.
C
onrod holder : 09910-20115
Crank balancer socket wrench
①
: 09940HP7600
Crank balancer drive gear nut
: 100 ~ 120 N·m (10.0 ~ 12.0 kgf·m)
CAUTION
The crank balancer drive gear nut has left-hand
thread.
● Install the cam chain ② and key ③.

②
③
● Install the primary drive gear ④.
● Install the primary drive gear and NO.2 gear to the

crankshaft and put in the key to the key groove. Align the key groove
and mark.
CAUTION
When installing the NO.2 gear, install so that the
mark on the gear align the key groove as shown
in figure.
No.2 Gear
ENGINE 3-48
● Install the two washers ①, ②.
CAUTION
Pay attention to the two washers when assembling.
①,②
● Tighten the primary drive gear nut ③ by holding the

crankshaft immovable with the special tool to the
specified torque.
C
onrod holder : 09910-20115
Primary drive gear nut ③
: 40 ~ 60 N·m (4.0 ~ 6.0 kgf·m)
CAUTION
The primary drive gear nut has left-hand thread.
● Install the crank balancer driven gear ④.

● Install the spacer ⑤ and two washers ⑥, ⑦.
● Tighten the crank balancer driven gear nut ⑧ to
the specified torque.
④
Crank balancer driven gear nut
: 40 ~ 60 N·m (4.0 ~ 6.0 kgf·m)
⑤
⑥,⑦
NOTE
When installing the crank balancer driven gear, Ⓐ Ⓒ
put the three points Ⓐ, Ⓑ and Ⓒ on a straight Ⓑ
line.
3-49 ENGINE
● Install the spacer ① to the counter shaft ②.

①
②
◉ PRIMARY DIRVEN GEAR

③
NOTE
Apply the engine oil to the inside face of the
primary driven gear bearing.
● Install the primary driven gear assembly ③.
◉ CLUTCH ④
● Install the clutch sleeve hub ④ and lock washer ⑤. ⑤
● Install the clutch sleeve hub nut, and tighten it to the
specified torque by using the special tool.
Clutch sleeve hub holder

: 09920-53710
Clutch sleeve hub nut

: 30 ~ 50 N·m (3.0 ~ 5.0 kgf·m)
● Bend the lock washer securely.

ENGINE 3-50
● Install the clutch drive plates and driven plates.
● I nstall the clutch release rack ①, bearing ② and

washer ③.
① ② ③
● Install the clutch pressure plate ④, clutch springs

and clutch spring mounting bolts.
● Tighten the clutch spring mounting bolts diagonally
by holding the crankshaft immovable with the special
tool.
Conrod holder : 09910-20115 ④
NOTE
Make sure that the clutch pressure plate is
installed correctly.
3-51 ENGINE
■ CLUTCH COVER
● Install the two dowel pins ① and new gasket.
● Apply engine oil to each gears, bearings and clutch ①
plates.
● Install the clutch cover ② and tighten the clutch cover

bolts securely.
● Install the clutch release arm as following :

① Match the incision part Ⓐ of the clutch release arm
and the groove Ⓑ on the clutch release cam shaft. Ⓑ
② And then match the incision part Ⓒ of the clutch
release arm and the mark Ⓓ on the crankcase.
Ⓓ Ⓒ
◉ NEUTRAL CAM STOPPER

● Put in the neutral cam stopper, spring and washer,
and tighten the cam stopper plug to the specified
torque.
Neutral cam stopper plug
: 20 ~ 25 N·m (2.0 ~ 2.5 kgf·m)
◉ ENGINE OIL DRAIN PLUG

● Tighten the engine oil drain plug to the specified
torque.
Engine oil drain plug
: 35 ~ 45 N·m (3.5 ~ 4.5 kgf·m)
ENGINE 3-52
◉ STATOR
threaded parts of screws.
THREAD LOCK
◉ MAGNETO ROTOR
● Fit the key ① in the key slot on the crankshaft.
● Install the starter clutch on the crankshaft with the
magneto rotor.
threaded parts of the crankshaft.
THREAD LOCK
①
● T ighten the magneto rotor nut by holding the

crankshaft immovable with the special tool to the
specified torque.
Magneto rotor nut
: 50 ~ 60 N·m (5.0 ~ 6.0 kgf·m)
◉ STARTER IDLE GEAR ④

● Install the starter idle gear ②, starter idle shaft ③ and
②
spacer ④. ③
3-53 ENGINE
◉ MAGNETO COVER
● Install the new gasket and dowel pin ①.
①
● Apply oil to the each gear, bearing and starter clutch.
● I nstall the magneto cover ② and tighten the

magneto cover bolts.
Magneto cover bolt
: 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
◉ PISTON RING
● Install the oil ring first, the 2nd ring second, and the
1st ring last. ③
NOTE
❖ The 1st ③ and 2nd ④ piston rings differ in
shape.
❖ T he 1st and 2nd piston rings should be
installed with the mark facing up.
④
● When installing the oil ring, install the spacer ⑤ into

the oil ring groove first, and then install the two side
rails ⑥. The spacer and side rails do not have a
designated top and bottom.
They can be installed in any position. ⑥
CAUTION ⑤
When installing the spacer, be careful not to ⑥
allow its two ends to overlap in the groove.
ENGINE 3-54
INCORRECT
CORRECT
● To minimize compression and oil leaks, locate

each piston ring end gap in the position as shown
EX
in the right illustration.
Before inserting the piston into its cylinder, check ① ②
that the gaps are properly positioned.
① 2nd ring and lower side rail

② Upper side rail
③ 1st ring and spacer
③
IN
◉ PISTON
● Apply the MOLY PASTE on the piston pin and small
end of the conrod.
MOLY PASTE
● When installing the piston, turn the mark Ⓐ on the
piston head toward the exhaust side.
● After the piston pin has been inserted through the ④ Ⓐ
conrod, install the circlip ④.
CAUTION
Replace the circlip with a new one.
Place a piece of rag under the piston when
installing the circlip to prevent it from falling
into the crankcase.
3-55 ENGINE
◉ CYLINDER
● A pply the GASKET BOND to the parting line of
crankcase.
GASKET BOND
● P lace the dowel pin ① and new gasket on the
crankcase.
①
CAUTION
Make sure to replace the gasket with a new one.
● Apply the engine oil to the conrod big end, piston and
the piston rings.
● Coat the cylinder wall with oil.
● Tighten the cylinder base nuts ② to the specified
torque.
Cylinder base nut
: 7 ~ 11 N·m (0.7 ~ 1.1 kgf·m)
● Hold each piston ring with the piston ring sections

positioned correctly and put it into the cylinder.
Make sure that the piston rings are caught by the
cylinder skirt.
NOTE
When mounting the cylinder, after attaching the
cam chain, keep the cam chain taut.
The cam chain must not be caught between the
cam chain sprocket and crankcase when the
crankshaft is rotated.
◉ VALVE AND SPRING

● Install each valve spring seat ③.
● Apply the MOLY PASTE to each oil seal and press-fit
them into position.
MOLY PASTE
③
CAUTION
Do not reuse the oil seals.
ENGINE 3-56
● Apply the MOLY PASTE to the valve as shown, and

then insert them into the valve guides.
MOLY PASTE
CAUTION
When inserting each valve into the valve guides,
make sure not to damage the lip of the oil seal.
● Install the valve spring with the narrow pitch part Ⓐ

facing the cylinder head.
Broad pitch part
NOTE
he pitch of the spring's upper side and lower
T
side is different. Head direction
The pitch of the spring is decreased from the
upper side to the lower side. Ⓐ
Narrow pitch part
● Install the valve spring retainer by pressing down the

spring using the valve spring compressor. Fit the
cotter halves to the stem end and release the lifter to
allow the cotter ① to wedge between the retainer and
the valve stem. Make sure that the rounded lip ② of
the cotter fits snugly into the groove ③ in the stem
end. ③ ②
Valve spring compressor
: 09916-14510
Valve spring compressor attachment ①
: 09916H35C00
CAUTION
Be sure to install all of the parts in their original
positions.
3-57 ENGINE
◉ CYLINDER HEAD
● Install the cylinder head ①. ①
● With the cylinder head snugly seated on the cylinder,
secure it by tightening the bolts in diagonal stages.
Tighten the cylinder head bolts diagonally to the
specified torque.
Cylinder head bolt

: 38 ~ 42 N·m (3.8 ~ 4.2 kgf·m)
NOTE
❖ Apply engine oil to the threaded parts of the
cylinder head bolts and its washers.
❖ Be sure to install the washer with rounded side
facing up.
● A fter tightening the cylinder head bolts to the

specification, tighten the cylinder head base nuts ②
to the specified torque.
Cylinder head base nut ②
: 7 ~ 11 N·m (0.7 ~ 1.1 kgf·m)
● Install the tappet and shim.
CAUTION
After fitting the tappet, it should be replaced if Tappet
turn not smoothly by the hand.
Shim
CAUTION
The tappet and shim should be installed at the
original position when removed.
If otherwise, it is difficult to adjust the valve clear-
ance.
ENGINE 3-58
● Fit the cam chain guide No.1 ①.
◉ CAMSHAFT ASSEMBLY
● Distinguish the“EX”mark for the exhaust camshaft,
the“IN”mark for the intake camshaft.
Be distinguished always each camshaft what has
notch at the rightside end and leftside end of it.
EX IN
NOTE
Just before installing the camshaft into the
cylinder head, apply the MOLY PASTE to the
camshaft journals and cam faces.
Also, apply engine oil to the camshaft housing.
MOLY PASTE
3-59 ENGINE
● Rotate the magneto rotor counter-clockwise with a

socket wrench to set the piston at TDC of the
compression stroke.
With pulling up the camshaft drive chain, rotate the
magneto rotor until the “-” line on the magneto
rotor is aligned with the “ ” mark on the magneto
cover.
CAUTION
If the crankshaft is turned without drawing the
cam chain upward, the cam chain will catch
between crankcase and cam chain sprocket.
● Install the exhaust camshaft first, and then install the

intake camshaft.
● With the “-” line on the magneto rotor is aligned with the triangle mark on the magneto cover, hold the camshaft
steady and lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft
sprocket.
● The exhaust camshaft sprocket has an arrow marked “1” Ⓐ.
Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.
Engage the cam chain with the exhaust camshaft sprocket.
● The other arrow marked “2” Ⓑ should now be pointing straight up.
Starting from the roller pin that is directly above the arrow marked “2” Ⓑ, count out 16 roller pins (from the exhaust
camshaft side going towards the intake camshaft side).
Engage the 16th roller pin on the cam chain with the arrow marked “3” Ⓒ on the intake sprocket.
Refer to the following illustrations.
ENGINE 3-60
NOTE
The cam chain should now be on all three sprockets.
Be careful not to move the crankshaft until the camshaft housing and cam chain tensioner are secured.
Ⓑ
Ⓒ
Ⓐ
3-61 ENGINE
● Install the dowel pins ①.

● Place each camshaft housing and cam chain guide
into the correct position.
NOTE
Camshaft housing marked “EX” are for the
exhaust side and those marked “IN” are for the ①
intake side.
● Install the cam chain guide NO.2 ② and camshaft

housing ③.
● Tighten the camshaft housing bolts to the specified FW
D
torque.
Camshaft housing bolt
: 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m) ③
NOTE
When tightening the camshaft housing bolts, the
②
piston position must be at TDC of the
compression stroke.
◉ CAM CHAIN TENSION

ADJUSTER
● Apply the engine oil to the push rod.
● Unlock the ratchet mechanism and push the push rod
④ all the way. ④
● Install the new gasket and cam chain tension adjuster

to the cylinder.
● Tighten the cam chain tension adjuster mounting bolts
to the specified torque.
Cam chain tension adjuster mounting
bolt : 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
ENGINE 3-62
● Tighten the cam chain tension adjuster bolt ① to the

specified torque.
Cam chain tension adjuster bolt
: 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)
①
● Turn the crankshaft about 10 times counter-clock-

wise ( ) on the basis of the magneto rotor.
● I f the valve clearance is within standard after
measured the valve clearance, begin the next
operation.
If it is out of stanadard, adjust the valve clearance
within standard limit after disassembled the camshaft
and replaced the proper shim.
Valve clearance Standard

0.10 ~ 0.20 mm
IN. (0.004 ~ 0.008 in)
0.20 ~ 0.30 mm
EX. (0.008 ~ 0.012 in)
CAUTION
If you donʼt turn the crankshaft about 10 times
before measured the valve clearance, there is no
meaning in valve clearance.
◉ CYLINDER HEAD COVER

● Thoroughly wipe off oil from the fitting surfaces of
the cylinder head and cover.
● Apply the GASKET BOND to the end caps of the
cylinder head cover gasket as shown.
GASKET BOND
3-63 ENGINE
● Apply engine oil to both sides of the washer.

● L ightly tighten the cylinder head cover bolts in
diagonal stages, and then tighten them to the
specified torque.
Cylinder head cover bolt

: 12 ~ 16 N·m (1.2 ~ 1.6 kgf·m)
CAUTION
Use a new washers.
◉ SPARK PLUG
● Install the spark plug. (Refer to page 2-6)
◉ GEAR POSITION SWITCH

● Install the spring ① and contact ②.
● Apply the GREASE to the O-ring and install the gear
postion switch.
GREASE
①
◉ STARTER MOTOR
● Install the starter motor ③ by tightening the mounting
bolts to the specified torque.
Starter motor mounting bolt
: 8 ~ 12 N·m (0.8 ~ 1.2 kgf·m)

Manual de Taller GD250 Exiv (1) Mantenimiento y Motor

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Manual de Taller GD250 Exiv (1) Mantenimiento y Motor

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SERVICE MANUAL

This manual contains an introductory description on

Ⓒ COPYRIGHT S&T Motors Co., Ltd.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Apply GREASE. Measure in voltage range.

Apply SILICONE GREASE. Measure in resistance range.

Apply MOLY PASTE. Measure in current range.

Apply GASKET BOND. Measure in diode test range.

Use fork oil. Measure in continuity test range.

Use engine coolant. Use special tool.

B : Black Gr : Gray Sb : Light blue

BL : Black with Blue tracer BBr : Black with Brown tracer

BG : Black with Green tracer BO : Black with Orange tracer

BR : Black with Red tracer BW : Black with White tracer

BY : Black with Yellow tracer LB : Blue with Black tracer

LG : Blue with Green tracer LR : Blue with Red tracer

LW : Blue with White tracer LY : Blue with Yellow tracer

GB : Green with Black tracer GR : Green with Red tracer

GY : Green with Yellow tracer GrB : Gray with Black tracer

OB : Orange with Black tracer OL : Orange with Blue tracer

OG : Orange with Green tracer OR : Orange with Red tracer

OW : Orange with White tracer OY : Orange with Yellow tracer

RB : Red with Black tracer RW : Red with White tracer

WB : White with Black tracer WL : White with Blue tracer

WR : White with Red tracer YB : Yellow with Black tracer

YL : Yellow with Blue tracer YG : Yellow with Green tracer

YR : Yellow with Red tracer

SERIAL NUMBER LOCATION… ……………………………………… 1- 3

FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS… … 1- 4

FOUR SIDES OF EXTERIOR ILLUSTRATION…………………… 1- 7

WARNING / CAUTION / NOTE

SERIAL NUMBER LOCATION

⊙ frame serial number

⊙ engine serial number

FUEL, OIL AND ENGINE COOLANT RECOMMENDATIONS

℃ -30 -20 -10 0 10 20 30 40

⊙ FRONT FORK OIL

■ WATER FOR MIXING

■ LIQUID AMOUNT OF WATER/ENGINE COOLANT

The general rules are as follows :

(Turn signal lamp)

820  ᱥ॒᳑

900 (Turn signal lamp)

840 (License plate lamp)

(Turn signal lamp)

780 (Rear reflector)

(Turn signal lamp)

925 (Brake & Tail lamp)

⊙ DIMENSIONS AND DRY MASS

※ LED : Light Emitting Diode

LUBRICATION POINTS… ……………………………………………… 2- 2

MAINTENANCE PROCEDURES… ………………………………… 2- 3

EXHAUST PIPE NUTS AND MUFFLER MOUNTING BOLT… ……… 2- 7

ENGINE IDLE SPEED …………………………………………………… 2- 9

THROTTLE CABLE PLAY… …………………………………………… 2- 9

FUEL HOSE… …………………………………………………………… 2-10

CLUTCH… ………………………………………………………………… 2-10

ENGINE OIL AND ENGINE OIL FILTER… …………………………… 2-13

820 ᱥ॒᳑

● If the clearance is out of specification, first remove the

● Remove the two ECU mounting bolts.

● Disconnect the spark plug cap.

● Insert the spark plug and finger tighten it to the

● Tighten the exhaust pipe nuts ①, muffler plate

■ GEARSHIFT LEVER HEIGHT

ENGINE OIL AND

● Reinstall the gasket and engine oil drain plug ①.

● Loosen the engine oil filter ② counter-clockwise

● Install the engine oil filler plug ①.

■ ENGINE COOLANT LEVEL CHECK

● Remove the right side radiator cover ① by loosening

● R emove the coolant reserve tank filler cap ④ by

● Place a pan below the water pump, and then drain

● B leed the air from the engine coolant circuit as ⑤

■ AIR BLEEDING THE COOLING

● Start up the engine and bleed air from the radiator

■ INSPECTION OF DRIVE CHAIN ④

● C ount out 21 pins (20 pitches) on the chain and

■ ADJUSTMENT OF DRIVE CHAIN

● Loosen the axle nut ①.

● After adjusting the drive chain, tighten the axle nut

● R echeck the drive chain slack after tightening the