ACTIVE PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing procedures for the KYMCO ACTIVE 50. ENGINE Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation. Section 2 is the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance. Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section. ELECTRICAL EQUIPMENT Sections 5 through 18 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment. GENERAL INFORMATION 1 INSPECTION/ADJUSTMENT 2 LUBRICATION SYSTEM 3 FUEL SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 ALTERANTOR/CAM CHAIN TENSIONER 8 CLUTCH/GEAR SHIFT MECHANISM 9 CHASSIS Sections 3 and 4 state the servicing procedures and cautions for the removal and installation of lubrication and fuel systems. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION 10 FRONT WHEEL/SUSPENSION/ STEERING 11 REAR WHEEL/BRAKE/SUSPENSION 12 HYDRAULIC BRAKE 13 FRAME COVER IGNITION SYSTEM 14 15 CHARGING SYSTEM 16 STARTING SYSTEM 17 (c) 4-Stroke.net Our company reserves right to make any alteration in the The information and design. contents included in this manual may be different from the motorcycle in case specifications are changed. KWANG YANG MOTOR CO., LTD. OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION 50 LIGHTS/INSTRUMENTS/SWITCHES/ 18 HORN/FUEL UNIT 1. GENERAL INFORMATION ACTIVE 50 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER ---------------------------------------------SPECIFICATIONS ---------------------------------------------------------SERVICE PRECAUTIONS -----------------------------------------------TORQUE VALUES --------------------------------------------------------SPECIAL TOOLS ----------------------------------------------------------LUBRICATION POINTS -------------------------------------------------CABLE & HARNESS ROUTING ---------------------------------------WIRING DIAGRAM-------------------------------------------------------TROUBLESHOOTING----------------------------------------------------- (c) 4-Stroke.net 1- 1 1- 2 1- 3 1-11 1-12 1-13 1-14 1-18 1-19 1-0 1. GENERAL INFORMATION ACTIVE ENGINE SERIAL NUMBER Location of Engine Serial Number (c) 4-Stroke.net Location of Frame Serial Number SPECIFICATIONS 1-1 50 1. GENERAL INFORMATION Front wheel Rear wheel Ground clearance (mm) Braking distance (m) PerformMin. turning radius ance 2.5-17 2.75/17 120 7under 3800(R/L) Tires (mm) Starting system Moving Device 13 (c) 4-Stroke.net Lubrication System Lubrication type Oil pump type Oil filter type Oil capacity Cooling Type 1.8/7000kw(r/min) 2.6/4500kgm/rpm 0° 35° 30° 5° 0.02mm 0.02mm 1700rpm Forced pressure & wet sump Inner/Outer rotor Wire gauze filter 0.9 liter Air cooling SERVICE PRECAUTIONS Damping Device Engine Type Cylinder arrangement Combustion chamber type Valve arrangement Bore x stroke (mm) Compression ratio Compression pressure (kg/cm²) Max. output Max. torque Intake Open Close Port (1mm) timing Exhaust Open (1mm) Close Valve clearance Intake (cold) Exhaust Idle speed (rpm) Starting motor & kick starter OHC Single cylinder Semi-sphere Single cam, OHC φ52.4x 49.5 8 Transmission Gear 48.5 63.5 Power Drive System Front wheel Gross weight(kg) Rear wheel Air cleaner type Wet, single Fuel capacity 4liter Type PIF Piston dia. (mm) 14.9 Venturi dia.(mm) φ20equivalent Throttle type Plunger type Type CDI Ignition timing 15±2°/1700rpm Spark plug CHAMPION-P-PZ9HC Spark plug gap 0.6 0.7mm Battery Capacity 12V5AH Clutch Type Wet multi-disc clutch Type Permanent gear meshing Operating method Foot operated Type Cycle type 1st gear 2.92 2nd gear 1.67 Reduction 3rd gear 1.17 ratio 4th gear 0.92 5th gear ------Front Caster angle 27° Axle Wheel base 1305 Front 1.75 Tire pressure (kg/cm²)(2 riders) Rear 2.25 Left 45° Turning angle Right 45° Front Disk brake Brake system type Rear Drum brake Ignition System 46.5 58 Electrical Equipment nonleaded gasoline 50 Carburetor LCA7 ACTIVE 50 1995 680 1090 1275 4∞ 49 S y Motorcycle name & Model No. Motorcycle name Overall length (mm) Overall width (mm) Overall height (mm) Wheel base (mm) Engine type Displacement (cc) Fuel type Front wheel Dry weight (kg) Rear wheel ACTIVE Shock absorber type Frame type Front Telescope Rear Mono Shock Back bone „ Make sure to install new gaskets, O-rings, 1-2 1. GENERAL INFORMATION ACTIVE 50 circlips, cotter pins, etc. when reassembling. „ When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. „ Use genuine parts and lubricants. „ When servicing the motorcycle, be sure to use special tools for removal and installation. (c) 4-Stroke.net „ After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly. „ Apply or add designated greases and lubricants to the specified lubrication points. 1-3 1. GENERAL INFORMATION ACTIVE 50 „ After reassembly, check all parts for proper tightening and operation. „ When two persons work together, pay attention to the mutual working safety. „ Disconnect the battery negative (-) terminal before operation. „ When using a spanner or other tools, make sure not to damage the motorcycle surface. (c) 4-Stroke.net „ After operation, check all connecting points, fasteners, and lines for proper connection and installation. „ When connecting the battery, the positive (+) terminal must be connected first. „ After connection, apply grease to the battery terminals. „ Terminal caps shall be installed securely. „ If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. 1-4 1. GENERAL INFORMATION ACTIVE „ After operation, terminal caps shall be installed securely. „ When taking out the connector, the lock on the connector shall be released before operation. „ Hold the connector body when connecting or disconnecting it. „ Do not pull the connector wire. „ Check if any connector terminal is bending, protruding or loose. (c) 4-Stroke.net Confirm Capacity 1-5 „ The connector shall be inserted completely. „ If the double connector has a lock, 50 1. GENERAL INFORMATION ACTIVE 50 lock it at the correct position. „ Check if there is any loose wire. „ Before connecting a terminal, check for damaged terminal cover or loose negative terminal. „ Check the double connector cover for proper coverage and installation. „ Insert the terminal completely. „ Check the terminal cover for proper coverage. „ Do not make the terminal cover opening face up. (c) 4-Stroke.net „ Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. „ After clamping, check each wire to make sure it is secure. Snapping! 1-6 1. GENERAL INFORMATION ACTIVE 50 „ Do not squeeze wires against the weld or its clamp. „ After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. „ When fixing the wire harnesses, do not make it contact the parts which will generate high heat. No Contact ! (c) 4-Stroke.net „ Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. „ Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws. „ Route harnesses so they are neither pulled tight nor have excessive slack. 1-7 1. GENERAL INFORMATION ACTIVE 50 „ Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. „ When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. „ Do not break the sheath of wire. „ If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it. (c) 4-Stroke.net „ When installing other parts, do not press or squeeze the wires. Do not pull too tight! Do not press or squeeze the wire. „ After routing, check that the wire 1-8 1. GENERAL INFORMATION ACTIVE harnesses are not twisted or kinked. „ Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. „ When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. Do you understand the instrument? Is the instrument set correctly? „ Be careful not to drop any parts. „ When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. Remove Rust ! (c) 4-Stroke.net „ Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. „ Symbols: 1-9 50 1. GENERAL INFORMATION ACTIVE 50 The following symbols represent the servicing methods and cautions included in this service manual. Engine Oil : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. Grease Special : Use special tool. : Caution : Warning (c) 4-Stroke.net 1-10 1. GENERAL INFORMATION ACTIVE TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut Torque (kg-m) 0.45 0.6 0.8 1.2 1.8 2.0 3.0 4.0 5.0 6.0 Item 5mm screw 6mm nut, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut Torque (kg-m) 0.35 0.5 0.7 1.1 1.0 1.4 2.0 3.0 3.5 4.5 Torque specifications listed below are for important fasteners. ENGINE Item Kick plate bolt R/L case bolt Stopper shift bolt Cam gear shift bolt Pin guide bolt Oil pump bolt Clutch nut Rotor oil nut Rotor oil cover bolt Motor bolt Head stud bolt Cam sprocket bolt Head cover cap nut Pivot cam chain bolt Tensioner bolt Cylinder head bolt Hole TP cap nut Plate L case screw Sprocket drive bolt Fly wheel nut L cover bolt Head side cover L bolt Inlet pipe bolt Carburetor bolt Head stud bolt Head side cover R bolt R cover oil bolt Filter hole cap Outer starting Quantity Thread 2 8 1 1 1 3 1 1 3 3 4 3 4 1 1 2 2 2 2 1 9 2 2 2 2 2 1 1 3 6 6 6 6 8 6 10 10 6 6 7 5 7 8 14 6 30.8 6 6 10 6 6 6 6 8 6 14 30.8 6 Torque (kg-m) 0.8 0.8 0.8 1.0 0.8 0.8 3.8 3.8 0.45 0.8 0.7 0.7 1.2 1.3 1.5 0.6 1.0 0.8 1.0 3.2 0.8 0.8 0.8 0.8 0.7 0.8 2.0 1.0 1.0 1.2 1.2 1.2 1.4 1.2 1.2 4.5 4.5 0.6 1.2 1.1 1.1 1.6 1.8 2.5 0.9 2.0 1.2 1.6 4.0 1.2 1.2 1.2 1.2 1.1 1.2 3.0 2.0 1.5 (c) 4-Stroke.net 1-11 Remarks 50 1. GENERAL INFORMATION ACTIVE 50 FRAME Item Steering stem lock nut Steering top cone race Front axle nut Rear axle nut Rear shock absorber upper mount bolt Rear shock absorber lower mount bolt Rear fork pivot nut Handlebar lock nut Rear driven gear bolt Rear brake panel nut Intake pipe mounting bolt Engine hanger upper nut Engine hanger lower nut Quantity Thread 1 1 1 1 1 1 1 1 4 1 2 1 1 25.4 25.4 14 16 10 10 12 10 8 8 6 1 1 Torque (kg-m) 6.0 0.5 5.5 6.0 3.0 3.0 5.5 6.0 1.8 1.8 1.8 1.8 1.8 Remarks 9.0 1.3 7.0 8.0 4.0 4.0 7.0 9.0 2.0 2.5 2.5 2.5 2.5 SPECIAL TOOLS Tool Name Flywheel puller Bearing puller 18mm Lock nut socket wrench Tappet adjuster Oil seat & bearing install Bearing puller 15mm Bearing puller 12mm Flywheel holder Tool No. Ref. Page Remarks 8-4 E003 10-10 E008 F007 E010 E049 9-5 11-16 11-18 2-5 E012 10-11 11-9 E014 10-10 E018 10-10 E020 8-3 8-7 9-6 E021 (c) 4-Stroke.net Bearing puller 10mm E031 10-10 Clutch holder E039 9-5 Gear holder E038 9-9 Bearing driver handle & Bearing installer E014 11-9 11-17 Race cone install F005 1-12 1. GENERAL INFORMATION ACTIVE 50 LUBRICATION POINTS or CABLE LUBRICANT SPEEDOMETER, THROTTLE, BRAKE CABLE CHAIN LUBRICANT DRIVE CHAIN THROTTLE GRIP STEERING HEAD BEARINGS SWING ARM PIVOT VUSHINGS BRAKE CAM (c) 4-Stroke.net ENGINE ENGINE CENTER & SIDE STAND PIVOTS WHEEL BEARINGS BRAKE PEDAL PIVOT SPEEDOMETER GEAR WHEEL BEARINGS 1-13 1. GENERAL INFORMATION ACTIVE 50 CABLE & HARNESS ROUTING Throttle Cable Front brake hose Ignition Switch Horn (c) 4-Stroke.net 1-14 1. GENERAL INFORMATION Winker Relay Regulator/ Rectifier ACTIVE Wire Harness 50 Horn Front Brake Hose Ignition Coil (c) 4-Stroke.net Starter Motor 1-15 Ignition Coil Wire Choke Cable 1. GENERAL INFORMATION ACTIVE 50 WIRING DIAGRAM (c) 4-Stroke.net 1-16 1. GENERAL INFORMATION ACTIVE 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Symptom Inspection/Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Fuel reaches carburetor Fuel does not reach carburetor Empty fuel tank Clogged carburetor fuel inlet tube, vacuum tube or fuel tube Clogged float oil passage Clogged fuel filter Clogged charcoal canister Clogged auto fuel valve strainer Faulty valve passage Faulty fuel pump Weak or no spark Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Faulty exciter coil Faulty ignition switch Broken or shorted ignition coil wire Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps Test cylinder compression Normal compression Low or no compression Faulty or slipping clutch Valve clearance too small Valve stuck open Worn cylinder and piston rings Leaking cylinder head gasket (c) 4-Stroke.net Start engine by follow-ing normal starting procedure Engine does not fire Engine fires but does not start Dry spark plug Wet spark plug Faulty choke control system Leaking intake manifold Incorrect ignition timing Incorrectly adjusted air screw Remove spark plug and inspect again 1-17 Flooded carburetor Throttle valve excessively open Clogged air cleaner 1. GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Probable Cause Symptom Check ignition timing Correct Incorrect Correctly adjusted Incorrectly adjusted Faulty CDI unit Faulty pulser coil Check carburetor air screw adjustment Mixture too lean (turn screw in) Mixture too rich (turn screw out) Check carburetor gasket for air leaks No air leak Air leaks Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Faulty intake manifold gasket Carburetor not securely tightened Damaged insulator rubber Broken vacuum tube (c) 4-Stroke.net Good spark Weak or intermittent spark Faulty or fouled spark plug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Faulty ignition switch Check A.C. generator Good Faulty Faulty A.C. generator Damaged vacuum tube Clogged air vent hole 1-18 1. GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE (ENGINE LACKS POWER) Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Engine speed increases Engine speed does not increase sufficiently Check ignition timing using a timing light Correct Incorrect Correct Incorrect Normal compression Abnormal compression Not clogged Clogged Clogged air cleaner Poor fuel flow (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Carburetor fuel level too low Clogged carburetor high speed fuel passage Faulty CDI unit Faulty pulser coil Check valve clearance Test cylinder compression Improper valve clearance adjustment Excessively worn valve seat (protruded valve stem) Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Check carburetor for clogging Clean and unclog Remove spark plug and inspect Plug not fouled or discolored Plug fouled or discolored Fouled spark plug Incorrect heat range plug Check crankcase for oil level and condition (c) 4-Stroke.net Correct and not contaminated Incorrect or contaminated Oil level too high Oil level too low Oil not changed Remove cylinder head oil pipe bolt and inspect Valve train lubricated properly Valve train not lubricated properly Clogged oil cooler Clogged oil line Faulty oil pump Check for engine overheating Engine does not overheats Engine overheats Rapidly accelerate or run at high speed Engine does not knock 1-19 Engine knocks Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too advanced Excessive carbon build-up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too advanced 1. GENERAL INFORMATION ACTIVE 50 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Probable Cause Symptom Check ignition timing Correct Incorrect Faulty CDI unit Faulty pulser coil Correct Incorrect Improperly adjusted valve clearance Worn valve seat Fuel flows freely Fuel flow restricted Not clogged Clogged Clean and unclog Correct Incorrect Cam timing gear aligning marks not aligned Not weakened Weak spring Check valve clearance Check fuel filter for fuel supply Check carburetor for clogged jets Empty fuel tank Clogged fuel filter or tube Clogged fuel tank cap breather hole Cracked fuel pump vacuum tube (c) 4-Stroke.net Check valve timing Check valve spring tension Faulty spring 1-20 1. GENERAL INFORMATION ACTIVE 50 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Normal voltage Voltage does not increase Dead battery Faulty battery Measure resistance between AC generator coil terminals Faulty coil Broken pink and yellow wires Shorted pink and yellow wires Normal Resistance too high Normal voltage No voltage Broken red wire Normal Abnormal Faulty regulator/rectifier Poorly connected coupler Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage Check regulator/rectifier coupler for loose connection Faulty A.C. generator Overcharging (c) 4-Stroke.net Inspection/Adjustment Connect battery (+) wire to regulator/rectifier coupler black wire and battery (-) wire to engine ground and test voltage Symptom Probable Cause Battery has voltage with ignition switch “ON” Battery has no voltage with ignition switch “ON” Normal Abnormal Broken black wire Check regulator/rectifier coupler for loose connection Poorly connected coupler Faulty regulator/rectifier 1-21 1. GENERAL INFORMATION ACTIVE 50 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Weak or no spark Good spark Faulty old spark plug Not loose Loose Loose spark plug cap Normal Abnormal Normal Abnormal Check spark plug cap and ignition coil wire for looseness Check CDI unit coupler for looseness Poorly connected coupler Measure resistance between CDI unit coupler wire terminals Check related parts (c) 4-Stroke.net Abnormal Normal Faulty ignition switch Faulty exciter coil Faulty pulser coil Faulty ignition coil Broken wire harness Poorly connected coupler Check CDI unit with a CDI unit tester Abnormal Normal Faulty CDI unit Check ignition coil with a CDI unit tester Abnormal Faulty ignition coil 1-22 2. INSPECTION/ADJUSTMENT ACTIVE 50 2 __________________________________________________________________________________ 2 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------MAINTENANCE SCHEDULE-------------------------------------------FUEL LINE/FILTER-------------------------------------------------------THROTTLE OPERATION/CHOKE-------------------------------------AIR CLEANER -------------------------------------------------------------SPARK PLUG---------------------------------------------------------------VALVE CLEARANCE ----------------------------------------------------CARBURETOR IDLE SPEED -------------------------------------------IGNITION TIMING--------------------------------------------------------CYLINDER COMPRESSION --------------------------------------------ENGINE OIL ----------------------------------------------------------------DRIVE CHAIN -------------------------------------------------------------CLUTCH---------------------------------------------------------------------BRAKE SHOE --------------------------------------------------------------BRAKE FLUID -------------------------------------------------------------SUSPENSION---------------------------------------------------------------NUTS/BOLTS/FASTENERS ---------------------------------------------WHEELS/TIRES -----------------------------------------------------------STEERING HANDLEBAR ------------------------------------------------ (c) 4-Stroke.net 2- 1 2- 2 2- 3 2- 3 2- 4 2- 4 2- 5 2- 5 2- 6 2- 6 2- 7 2- 7 2- 8 2- 8 2- 8 2- 9 2- 9 2- 9 2-10 2-0 2. INSPECTION/ADJUSTMENT ACTIVE 50 SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area. SPECIFICATIONS ENGINE Throttle grip free play : 2 6mm Spark plug gap : 0.6 0.7mm Spark plug specification : NGK–DR8EA Valve clearance : IN: 0.02mm EX: 0.02mm Cylinder compression : 13±2kg/cm² Ignition timing : 15±2°/1700rpm Idle speed : 1700±100rpm Engine oil capacity: At disassembly : 1.0 liter At change : 0.9 liter CHASSIS Front brake free play : 10 20mm Rear brake free play : 20 30mm Brake fluid : DOT-4 (c) 4-Stroke.net TIRE PRESSURE 1 Rider 2 Riders Front 1.75kg/cm² 2.0kg/cm² Rear 2.25kg/cm² 2.25kg/cm² TIRE SIZE: Front : 2.5-17 Rear : 2.75-17 TORQUE VALUES Front axle nut 5.5 7.0kg-m Rear axle nut 6.0 8.0kg-m 2-1 2. INSPECTION/ADJUSTMENT ACTIVE 50 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate, Refill, Repair or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten Regular Service Mileage (km) Whichever Frequency comes first Ö Ø Item 1000 Engine oil R Engine oil filter screen C 200 300 400 500 600 700 800 900 1000 1100 1200 0 0 0 0 0 0 0 0 0 0 0 R R R R C R R R R R C Replace at every 5000km Valve clearance Inspect at every 3000km and adjust if necessary I Air Cleaner Note 2,3 Spark plug I I I C C C Clean at every 2000km and replace at every 5000km Brake system I I I I I I Drive chain A A A A A A Suspension I I I (c) 4-Stroke.net Nuts, bolts, fasteners Tire R C Fuel filter screen Carburetor R Steering head bearing I Inspect at every 8000km I I I I I I I I • In the interest of safety, we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas. 3. Service more frequently when riding for long distance, in rain or at full throttle. 2-2 2. INSPECTION/ADJUSTMENT ACTIVE 50 Fuel Filter FUEL LINE/FILTER Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. Do not smoke or allow flames or sparks in your working area. THROTTLE OPERATION Check for smooth throttle grip movement in all steering positions. Measure the throttle grip free play. Free Play: 2 6mm Adjust the throttle grip free play by turning the adjusting nut on the throttle cable. Slide the dust boot out and adjust by loosening the lock nut and turning the adjusting nut. (c) 4-Stroke.net Dust Boot CHOKE Check choke lever operation. If the choke lever moves stiffly, clean and lubricate the pivot. After cleaning, recheck the lever movement. 2-3 Adjusting Nut Lock Nut 2. INSPECTION/ADJUSTMENT ACTIVE 50 Measure the spark plug gap. Spark Plug Gap: 0.6 0.7mm When installing, first screw in the spark plug by hand and then tighten it with a spark plug wrench. Choke Lever AIR CLEANER Air Cleaner Case Air Cleaner Case Cover AIR CLEANER REPLACEMENT Remove the right center cover. (page 14-3) Remove the air cleaner case. (page 4-5) Remove the air cleaner case cover screws and the cover. (page 4-5) Remove the air cleaner screen and element. Check the element and replace it with a new one if it is excessively dirty or damaged. CHANGE INTERVAL Wash the air cleaner element in detergent oil, squeeze out and allow to dry. Never use gasoline or organic vaporable oil with acid or alkali for washing. (c) 4-Stroke.net After washing, soak the element in clean engine oil SAE 15W-40# and squeeze out excess oil. Reinstall the element. Wash Squeeze out and dry Engine Squeeze out oil and dry SPARK PLUG Remove the spark plug. Check the spark plug for wear, damage and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: CHAMPION-P-PZ9HC Spark Plug Gap, Wear, and Fouling Deposits 2-4 2. INSPECTION/ADJUSTMENT ACTIVE 50 CARBURETOR IDLE SPEED 0.6 0.7mm The engine must be warm for accurate idle speed inspection and adjustment. Turn the throttle stop screw to obtain the specified idle speed. Idle Speed: 1700±100rpm When the engine misses or run erratic, adjust the air screw. Washer Deformation Cracks Damage VALVE CLEARANCE When adjusting the carburetor, make sure to use a E/M tester. Cylinder Head Cover Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the cylinder head cover. Bolts Rotate the generator flywheel to locate the camshaft on the top dead center (TDC) and align the “T” mark on the flywheel with the mark on the left crankcase cover. “T” Mark (c) 4-Stroke.net After adjustment, rotate the crankshaft several turns to make sure that the valve clearance is correct. Inspect and adjust the valve clearance. Valve Clearance: IN : 0.02mm EX: 0.02mm Loosen the lock nut and adjust by turning the adjusting bolt. Special Tappet adjuster E012 Check the valve clearance again after the lock nut is tightened. 2-5 2. INSPECTION/ADJUSTMENT ACTIVE 50 If the compression is low, check for the following: Leaky valves Valve clearance to small Leaking cylinder head gasket Worn piston rings Worn piston/cylinder If the compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and the piston head. Air Screw Throttle Stop Screw IGNITION TIMING • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system. Remove the ignition timing eye hole cap on the left crankcase cover. Eye Hole Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the index mark on the left crankcase cover aligns with the “F” mark on the flywheel. (c) 4-Stroke.net Timing Light “F” Mark CYLINDER COMPRESSION Warm up the engine before compression test. Stop the engine, then remove the spark plug and insert a compression gauge. Open the throttle valve fully and crank the engine with the starter motor or kick lever. Measure the compression. Compression: 13±2kg/cm² 2-6 2. INSPECTION/ADJUSTMENT Compression Gauge ACTIVE 50 3. Turn the rear wheel to see if the drive chain slack is within the specified range. 4. Tighten the rear axle nut. After drive chain adjustment, check the rear brake pedal free play and adjust if necessary. ENGINE OIL Upper Limit Lower Limit When checking the oil level, place the motorcycle on its main stand on level ground for oil level check. After the engine is stopped for 10 minutes, check if the oil level is between the upper and lower limits. If the oil level is low, add the recommended oil to the proper level. Recommended Oil: SAE15W40# API: SG After oil change, be sure to tighten the drain bolt securely. Check the drain bolt washer for damage. Oil Capacity: At disassembly : 1.0 liter At change : 0.9 liter (c) 4-Stroke.net Drain Bolt DRIVE CHAIN Check the drive chain slack. Specified Slack: 1 2cm Drive Chain Adjustment: 1. Loosen the rear axle nut. 2. Adjust the right and left adjusting nuts to align the right punch mark with the left punch mark. 2-7 2. INSPECTION/ADJUSTMENT Punch Mark Adjusting Nut ACTIVE 50 BRAKE FLUID Turn the steering handlebar upright and check if the brake fluid level is between the upper and lower limits. Specified Brake Fluid: DOT-4 BRAKE SHOE Inspect the front brake linings for wear. BRAKE LEVER/PEDAL Measure the rear brake pedal free play. Free Play: 20 30mm (c) 4-Stroke.net Lock Nut Adjusting Bolt CLUTCH Stop the engine. Loosen the lock nut. Slowly turn the adjusting bolt counterclockwise and stop when resistance is felt, From this point, turn the adjusting bolt clockwise 1/8 turn and tighten the lock nut, Check that the clutch is not slipping and is properly disengaging. 2-8 2. INSPECTION/ADJUSTMENT ACTIVE Rear 1.75kg/cm² Lower Limit TIRE SIZE Front: 2.5-17 Rear: 2.75-17 SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. REAR Check the action of the rear shock absorber by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn. NUTS/BOLTS/FASTENERS (c) 4-Stroke.net Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded objects or other damages. Check the tire pressure. Tire pressure should be checked when tires are cold. TIRE PRESSURE Front 2-9 1 Rider 2 Riders 1.75kg/cm² 1.75kg/cm² 50 2.25kg/cm² 2. INSPECTION/ADJUSTMENT ACTIVE 50 Tire Pressure Gauge Check the front and rear axle nuts for looseness. If the axle nuts are loose, tighten them to the specified torques. Torques: Front : 5.5 7.0kg-m Rear : 6.0 8.0kg-m Front Axle Nut STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. (c) 4-Stroke.net 2-10 3. LUBRICATION SYSTEM ACTIVE 50 3 __________________________________________________________________________________ __________________________________________________________________________________ 3 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------ENGINE OIL/OIL FILTER -----------------------------------------------OIL PUMP/OIL FILTER ROTOR ---------------------------------------- 3- 2 3- 2 3- 3 3- 4 (c) 4-Stroke.net 3-0 3. LUBRICATION SYSTEM ACTIVE (c) 4-Stroke.net 3-1 50 3. LUBRICATION SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The service and maintenance of this section can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line. • The oil pump must be replaced as a set when it reaches its service life. • After the oil pump is installed, check each part for oil leaks and improper lubrication. • When removing and installing the oil cooler, be careful not to bend or deform the oil pipe. SPECIFICATIONS Item Tip clearance Oil pump Body clearance End clearance Standard (mm) Service Limit (mm) ─ 0.20 ─ 0.20 0.10 0.15 0.15 TROUBLESHOOTING Oil level too low • External oil leak • Worn valve guide or seal • Worn piston rings Engine burns • Oil not changed often enough • Head gasket faulty • Worn piston rings (c) 4-Stroke.net 3-2 3. LUBRICATION SYSTEM ACTIVE Upper Limit ENGINE OIL/OIL FILTER OIL LEVEL • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes. Check the oil level. If the level is near the lower limit, fill to the upper limit with the specified engine oil. Lower Limit OIL CHANGE The engine oil will drain more easily while the engine is warm. Remove the drain bolt to drain the engine oil thoroughly. Check the drain bolt washer for damage or deformation and replace with a new one if necessary. Drain Bolt ENGINE OIL FILTER Remove the right crankcase cover attaching bolts and right crankcase cover. Remove the dowel pins and gasket. Clean oil filter screen. (c) 4-Stroke.net Bolts Specified Oil: SAE15W40 API service classification: SG Oil Capacity: At disassembly : 1.0 liter At change : 0.9 liter Check for oil leaks and then start the engine and let it idle for few minutes. Stop the engine and recheck the oil level. Oil Filter Screen Cap 3-3 50 3. LUBRICATION SYSTEM ACTIVE 50 OIL PUMP/OIL FILTER ROTOR REMOVAL Remove the right crankcase cover (page 9-3) When installing, make sure to use a new right crankcase cover gasket. Right Crankcase Cover Gasget Oil Filter Rotor Cover OIL FILTER ROTOR Remove the filter rotor cover and gasket (pqge 9-3). Clean the oil filter rotor cover and rotor. Install the oil filter rotor cover (page 9-9). Install the right crankcase cover (page 9-11). Oil Filter Rotor Oil Pump Mounting Bolts OIL PUMP The oil pump can be removed with the engine mounted in the frame. Remove the oil drain bolt and drain the oil from the engine (page 3-3). Remove the right crankcase cover (page 9-3). Remove the clutch drum (page 9-3) Remove the three oil pump mounting bolts and oil pump. (c) 4-Stroke.net Screws DISASSEMBLY Remove the three cover screws and cover. Remove the rotor shaft. Remove the inner and outer rotors from the pump body. Clean the disassembled parts in non-flammable or high flash-point solvent. Check all parts for damage or wear. Pump Cover 3-4 3. LUBRICATION SYSTEM ACTIVE 50 INSPECTION Install the drive shaft and rotors. Measure the rotor tip clearance. Service limit: 0.2mm Measure the pump body clearance. Service limit: 0.2mm Install the gasket and measure the rotor end clearance. Service limit: 0.15mm (c) 4-Stroke.net Pump Body Align Flats Drive Shaft OIL PUMP ASSEMBLY Install the outer and inner rotors. Insert the drive shaft and align the flat on the shaft with the flat in the inner rotor, Inner Rotor 3-5 Outor Rotor 3. LUBRICATION SYSTEM ACTIVE 50 Install a new pump body cover gasket and the cover. Make sure that the pump rotates freely without binding. Gasket Gasket INSTALLATION Install the oil pump with a new gasket under it by aligning the slot if the drive shaft with the cam chain guide spindle. Cam Chain Guide Spindle Drive Shaft Oil Pump Mounting Bolts Tighten the oil pump mounting bolts securely. Check the cover screws for loose, retighten if necessary. Install the right crankcase cover, kick starter pedal. Fill the crankcase with the recommended engine oil. (c) 4-Stroke.net Cover Screws Pump Cover 3-6 4. FUEL SYSTEM ACTIVE 50 4 _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ 4 _____________________________________________________________________________________________ _____________________________________________________________________________________________ FUEL SYSTEM _____________________________________________________________________________________________ SERVICE INFORMATION -----------------------------------------------TROUBLESHOOTING----------------------------------------------------AIR CLEANER REMOVAL ----------------------------------------------THROTTLE VALVE DISASSEMBLY ----------------------------------THROTTLE VALVE INSTALLATION ---------------------------------CARBURETOR REMOVAL----------------------------------------------- (c) 4-Stroke.net 4-0 4- 2 4- 3 4-4 4- 5 4- 6 4- 7 4. FUEL SYSTEM ACTIVE (c) 4-Stroke.net 4-1 50 4. FUEL SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. work in a well-ventilated area. Be sure to • Do not bend or twist control cables. Damaged control cables will not operate smoothly. • When disassembling fuel system parts, note the locations of O-rings. Replace them with new ones during reassembly. • Before float chamber disassembly, loosen the drain screw to drain the residual gasoline into a clean container. • After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent foreign matters from entering. • The carburetor air jets and fuel jets must be cleaned with compressed air. • When the motorcycle is not used for over one month, drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel. SPECIFICATIONS Item Standard Carburetor type PIF Venturi dia. φ11 Piston dia φ13.5 Main jet 77.5# Idle speed Throttle grip free play 1700±100rpm 2 6mm (c) 4-Stroke.net Air screw opening SPECIAL TOOL Float level gauge 4-2 1¾±½ 4. FUEL SYSTEM ACTIVE TROUBLESHOOTING Engine cranks but won’t start Engine lacks power • No fuel in tank • Clogged air cleaner • No fuel to carburetor • Faulty carburetor • Cylinder flooded with fuel • Faulty ignition system • No spark at plug • Faulty fuel pump • Clogged air cleaner Lean mixture • Intake air leak • Clogged carburetor fuel jets • Improper throttle operation • Float level too low • Intake air leak Engine idles roughly, stalls or runs poorly • Faulty charcoal canister • Faulty charcoal canister • Restricted fuel line • Ignition malfunction • Faulty carburetor Rich mixture • Poor quality fuel • Float level too low • Lean or rich mixture • Clogged air jets • Clogged air cleaner • Clogged air cleaner • Incorrect idle speed • Worn throttle needle Misfiring during acceleration • Faulty ignition system • Faulty carburetor • Faulty accelerating pump • Faulty charcoal canister (c) 4-Stroke.net Backfiring at deceleration • Float level too low • Incorrectly adjusted carburetor • Faulty exhaust muffler 4-3 50 4. FUEL SYSTEM ACTIVE 50 Bolt AIR CLEANER REMOVAL Remove the front cover (page 14-3). Remove the screw attaching the carburetor. Remove the air cleaner case by removing the attaching bolts. Screw Element Screw . Remove the four screws with the air cleaner case cover. Element Holder Remove the element and the element holder from the air cleaner case. Air Cleaner Case Cover (c) 4-Stroke.net INSTALLATION Install the air cleaner case in the reverse order of removal. 4-4 4. FUEL SYSTEM ACTIVE 50 THROTTLE VALVE DISASSEMBLY Remove the front cover (page 14-3). Loosen the carburetor cap and remove the throttle valve. Carburetor Cap Throttle Valve Disconnect the throttle cable from the throttle valve. Throttle Cable Throttle Valve Remove the throttle valve, spring and carburetor top. The carburetor top is an integral part of the throttle cable assembly. The top can not be separated from the assembly without causing damage to the cable. (c) 4-Stroke.net Needle Clip Throttle Valve Remove the jet needle by removing the needle clip. Check the jet needle and throttle valve for wear or damage. Spring 4-5 Jet Needle 4. FUEL SYSTEM THROTTLE VALVE INSTALLATION ACTIVE Throttle Cable Throttle Valve Set the needle clip on the jet needle clip. Standard podition: 3rd groove from the top Install the jet needle on the throttle valve. Install the retainer on the throttle valve and secure the jet needle. Carburetor Top Install the throttle cable to the throttle valve while depressing the throttle valve spring. Throttle Valve Spring Insert the throttle valve into the carburetor, aligning the throttle valve groove with the throttle stop screw. (c) 4-Stroke.net Groove Carburetor Top Install the carburetor top onto the carburetor. After installing the carburetor and throttle valve, perform the following adjustments: -Throttle grip free play (page 2-3). -Carburetor air screw adjustment if the carburetor was overhauled or cleaned. 4-6 50 4. FUEL SYSTEM ACTIVE 50 CARBURETOR REMOVAL Remove the front cover (page 14-3). Loosen the air cleaner connecting tube band. Remove the carburetor top (page 4-6). Carburetor top Choke Cable Remove the fuel tube from the carburetor. Remove the choke cable. Remove the carburetor mounting bolts. Remove the insulator, O-ring and carburetor. (c) 4-Stroke.net Bolts Fuel Tube CARBURETOR DISASSEMBLY Loosen the drain screw to drain the gasoline from the float chamber. • Keep sparks and flames away from the work area. • Drain gasoline into a clean container. Drain Screw 4-7 4. FUEL SYSTEM ACTIVE 50 Float/Float Valve Disassembly Remove the four float chamber attaching screws and remove the float chamber. Screws Remove the float pin, float and float valve. Float FLOAT/FLOAT VALVE INSPECTION Inspect the float valve seat for wear or damage. Inspect the float for damage or fuel level inside the float chamber. (c) 4-Stroke.net Float Valve Seat MAIN JET/SLOW JETS/AIR STOP SCREW SCREW/THROTTLE REMOVAL Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Needle Jet Holder Slow Jet 4-8 Float Pin Needle Jet Main Jet 4. FUEL SYSTEM ACTIVE Remove the air screw and throttle stop screw. 50 Throttle Stop Screw CAUTIONS ! • Be careful not to damage the jets and jet holder when removing them. • Before removing, turn the throttle stop screw and air screw in and carefully count the number of turns until they seat lightly and then make a note of this. • Do not force the screw against its seat to avoid seat damage. • Be sure to install the O-ring in the reverse order of removal. Air Screw Carburetor Cleaning Blow compressed air through all passages of the carburetor body. Slow Jet/Main Jet Installation Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and air screw. Needle Jet Holder Needle Jet Air Screw • When installing the air screw, return it to the original position as noted during removal • After the carburetor is installed, be sure to perform the Exhaust Emission Test. (c) 4-Stroke.net Install the float valve, float and float pin. Slow Jet Main Jet Throttle Stop Screw Float 4-9 Float Pin 4. FUEL SYSTEM ACTIVE 50 FLOAT LEVEL INSPECTION Turn the carburetor upside down so that the float will go down to make the float valve contact the float valve seat. Then slowly tilt the carburetor and measure the float level with the float level gauge while the float pin just contacts with float valve. Float Level: 20mm When adjusting, carefully bend the float pin. Check the float for proper operation and then install the float chamber. Float Level Gauge Choke Cable CARBURETOR INSTALLATION Install the carburetor onto the intake manifold and tighten the two mounting bolts. Install the fuel tube and the choke cable.. Torque: 0.8 1.2kg-m Install the air cleaner connector and tighten the band screw. Bolt Fuel Tube (c) 4-Stroke.net Carburetor Top Assemble the carburetor top and throttle valve spring. Connect the throttle cable to the throttle valve. 4-10 4. FUEL SYSTEM ACTIVE 50 Fuel Unit Wire FUEL TANK FUEL TANK REMOVAL Warning • Keep sparks and flames away from the work area. • Wipe off any spilled gasoline. Turn the fuel valve to “OFF”. Remove the three bolts attaching the rear carrier. Remove the four seat lock nuts. Remove the tool box mounting bolt and tool box. Disconnect the fuel strainer and remove the nuts on the end of the fuel tank. Disconnect the fuel unit wire connector and fuel gauge wire. Remove the fuel tank. Screw Fuel Strainer FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank. INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air. • When removing the fuel strainer, do not allow flames or sparks near the working area and drain the residual gasoline into a container. (c) 4-Stroke.net INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump. Fuel Unit Wire FUEL TANK INSTALLATION Install the fuel tank in the reverse order of removal. Check that there is no fuel leakage. Check the wire connectors for proper connection. Screw 4-11 Fuel Strainer 5. ENGINE REMOVAL/INSTALLATION ACTIVE 50 5. __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 5 __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5- 1 ENGINE REMOVAL ------------------------------------------------------- 5- 2 ENGINE INSTALLATION ------------------------------------------------ 5- 3 (c) 4-Stroke.net 5-0 5. ENGINE REMOVAL/INSTALLATION ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • A engine stand or floor jack is required to support and maneuver the engine. • The following parts can be serviced with the engine installed in the frame: ⎯ Cylinder head/valves (Section 6) ⎯ Cylinder/piston (Section 7) ⎯ Alterantor/cam chain tensioner (Section 8) ⎯ Clutch/gear shift mechanism (Section 9) • When removing and installing the engine, do not use a hammer or screw driver to strike or pry the engine. • Do not damage the crankcase mating surfaces and clean off all gasket materials from the mating surfaces. • After crankcase assembly, check that the transmission system operates smoothly. • After engine installation, start the engine and check that the lubrication system is normal. Engine oil capacity: At disassembly : 1.0 liter At change : 0.9 liter TORQUE VALUES Engine bracket bolt Drive gear lock bolt Exhaust muffler hanger lock bolt Rear fork pivot nut Exhaust muffler joint lock nut 2.0 0.8 2.4 5.5 0.8 2.5kg-m 1.2kg-m 3.0kg-m 6.5kg-m 1.2kg-m (c) 4-Stroke.net 5-1 5. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ACTIVE Carburetor 50 Bolt Remove the right and left decorative covers under the seat. Remove the carburetor (page 4-5). Screw Exhaust Muffler Remove the two exhaust muffler joint lock nuts. Remove the exhaust muffler hanger lock bolt and exhaust muffler. • Drain the engine oil before engine removal. • The exhaust muffler temperature is extremely high. Remove it when the engine is cold. Screw A.C. Generator Wire Bolt Remove the spark plug cap. Disconnect the A.C. generator wire connector. (c) 4-Stroke.net Spark Plug Cap Loosen the rear axle nut and adjust the drive chain slack (page 2-7). 5-2 5. ENGINE REMOVAL/INSTALLATION ACTIVE 50 Bolts Gearshift Pedal Remove the gear shift lever bolt and gear shift lever. Remove the two bolts attaching the left rear crankcase cover and remove the rear crankcase cover. Rear Crankcase Cover Drive Chain Bolts Drive Gear Remove the two bolts attaching the drive gear set plate and the set plate. Remove the drive gear and chain. Remove the engine hanger nuts and pull out the engine hanger bolts. Remove the engine. Engine Hanger Bolt/Nut ENGINE INSTALLATION Install the engine in the reverse order of removal. Install the engine to its original position with a jack or other adjustable support. (c) 4-Stroke.net • When installing the engine, do not damage the bolt thread and route the wires and cables properly. • Install the gear shift lever by align the punch mark on the lever with that on the spindle. • Fill the crankcase to the proper level with recommended engine oil. • After installation, perform the following inspections and adjustments: 1. Throttle operation 2. Drive chain adjustment 5-3 Set Plate 6. CYLINDER HEAD/VALVES ACTIVE 50 6. __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 6 CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------CYLINDER HEAD REMOVAL -----------------------------------------CYLINDER HEAD DISASSEMBLY -----------------------------------CYLINDER HEAD ASSEMBLY ----------------------------------------CYLINDER HEAD INSTALLATION ----------------------------------- (c) 4-Stroke.net 6- 1 6- 2 6- 3 6- 4 6- 5 6- 8 6-10 6-0 6. CYLINDER HEAD/VALVES ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 6-1 50 6. CYLINDER HEAD/VALVES ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication. • The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head. • After disassembly, clean the removed parts and dry them with compressed air before inspection. • After removal, mark and arrange the removed parts in order. When assembling, install them in the reverse order of removal. Item Valve clearance (cold) IN EX Cylinder head compression pressure Cylinder head warpage IN Camshaft cam height EX IN Valve rocker arm I.D. EX Valve rocker arm shaft IN O.D. EX IN Valve stem O.D. EX IN Valve guide I.D. EX Valve stem-to-guide IN clearance EX TORQUE VALUES Cylinder head cap nut Valve clearance adjusting nut Cylinder head cover nut Standard (mm) 0.02 0.02 13kg/cm² ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ ⎯ 4.92 4.970 4.90 4.950 ⎯ ⎯ ⎯ ⎯ Service Limit (mm) 0.04 0.04 0.05 25.8 25.6 10. 10. 9.78 9.78 4.9 4.9 5. 5. 0.1 0.1 1.0 2.0kg-m 0.9kg-m 1.2 1.6kg-m (c) 4-Stroke.net SPECIAL TOOLS Valve spring compressor 6-2 6. CYLINDER HEAD/VALVES ACTIVE 50 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed • Compression too low Compression too low • Incorrect valve clearance adjustment • Burned or bend valves • Incorrect valve timing • Broken valve spring • Poor valve and seat contact • Leaking cylinder head gasket • Warped or cracked cylinder head • Poorly installed spark plug White smoke from exhaust muffler • Worn valve stem or valve guide • Damaged valve stem oil seal Abnormal noise • Incorrect valve clearance adjustment • Sticking valve or broken valve spring • Damaged or worn camshaft • Worn cam chain tensioner • Worn camshaft and rocker arm Compression too high • Excessive carbon build-up in combustion chamber (c) 4-Stroke.net 6-3 6. CYLINDER HEAD/VALVES ACTIVE 50 CYLINDER HEAD REMOVAL Remove the left crankcase cover bolt. Remove the left crankcase cover. Remove the crankshaft hole cap and timing hole cap. Remove the left side cover and gasket. Remove the cam chain tensioner sealing bolt, washer, spring and tensioner shaft.(See the diagramp6-4-4) Remove the valve inspection hole caps. Align Bolt Turn the crankshaft counterclockwise until the “o” mark on the cam sprocket aligns with the index mark on the cylinder head. Make sure there slight clearances between the valve stems and rocker arms by moving the rocker arms up and down. If the rocker arms are tight, turn the crankshaft counterclockwise one full turn and realign the “o” mark with the index mark. Remove the cam sprocket bolts and cam sprocket. • Suspend the cam chain with a wire or cord to prevent it from falling into the cylinder. Loosen the cylinder bolts. Remove the bolt attaching the cylinder head to the cylinder, Remove the four nuts holding the cylinder head cover, Remove the cylinder head cover. Cam Sprocket Cylinder Bolt Cylinder Head Cover (c) 4-Stroke.net Nuts And Washers Gasket Cylinder Head Bolt Inspection Hole Caps Remove the cylinder head cover gasket. Remove the cylinder head. Remove the cylinder head gasket and dowel pins. Tensioner Sealing Bolt Bolt Left Side Cover 6-4 6. CYLINDER HEAD/VALVES ACTIVE 50 CYLINDER HEAD DISASSEMBLY Remove the two bolts and the right side cover. Bolts Screw a 8mm bolt into the rocker arm shaft, and pull it out of the cylinder head. Rocker Arm Shaft Rocker Arms Remove the rocker arms and camshaft from the cylinder head. (c) 4-Stroke.net Camshaft While compressing the valve spring with a valve spring compressor, remove the valve cotters. Loosen the valve spring compressor and remove the valve retainers, valve springs, spring seats, stem seals and valves. Valve Spring Compressor • To prevent loss of tension, do not compress the valve springs more than necessary to remove the valve spring cotters. • Mark all parts to insure original assembly. Remove carbon deposits from the combustion chamber. Right Side Cover 6-5 6. CYLINDER HEAD/VALVES ACTIVE 50 Clean any gasket material from the cylinder head mating surface. Be careful not to damage the cylinder head mating surface and valve seat. CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if over CAMSHAFT INSPECTION Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. (c) 4-Stroke.net Camshaft Bearing Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: IN: 25.8mm replace if below EX:25.6mm replace if below ROCKER ARM INSPECTION 6-6 6. CYLINDER HEAD/VALVES ACTIVE Measure the I.D. of each valve rocker arm. Service Limits: IN: 10. mm replace if over EX: 10. mm replace if over ROCKER ARM SHAFT INSPECTION Measure each rocker arm shaft O.D. Service Limits: IN: 9.78mm replace if below EX: 9.88mm replace if below VALVE SPRING INSPECTION Measure the free length of the inner and outer valve springs. Service Limits: Inner (IN, EX) : 32.41mm replace if below Outer (IN, EX): 35.25mm replace if below (c) 4-Stroke.net VALVE /VALVE GUIDE INSPECTION Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: IN: 4.90mm replace if below EX: 4.90mm replace if below 6-7 50 6. CYLINDER HEAD/VALVES ACTIVE 50 Measure each valve guide I.D. Service Limits: IN: 5.00mm replace if over EX: 5.00mm replace if over Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. Service Limits: IN: 0.10mm replace if over EX: 0.10mm replace if over If the stem-to-guide clearance exceeds the service limits, replace the guides as necessary. Reface the valve seats whenever the valve guides are replaced. CYLINDER HEAD ASSEMBLY Valve Outer Spring Inner Spring Stem Seal Retainer Valve Cotters Install new valve stem seals when assembling. Lubricate each valve stem with oil. Insert the valves into the valve guides. Install the valve spring seats and valve stem seals. (c) 4-Stroke.net Be sure to install new valve stem seals. Apply engine oil to the inside of the valve stem seals and insert the valves into the valve guides. Install the valve springs and retainers. Compress the valve springs using the valve spring compressor, then install the valve cotters. • When assembling, a valve spring compressor must be used. • Install the cotters with the pointed ends facing down from the upper side of the cylinder head. Special Tool Valve Spring Compressor Tap the valve stems gently with a plastic 6-8 6. CYLINDER HEAD/VALVES ACTIVE 50 hammer to firmly seat the cotters. Be careful not to damage the valves. Camshaft Rocker Arms Coat the camshaft, camshaft bearings and automatic decompressor cam with clean engine oil. Install the camshaft into the cylinder head with the cam lobes facing the piston. Install the rocker arms as shown. Coat the rocker arm shafts with clean engine oil. Install the rocker arm shafts by screwing an 8 mm bolt into the thread end as shown. (c) 4-Stroke.net Rocker Arm Shafts Install a new Gasket on the right side cover. Install the right side cover. Gasket CYLINDER HEAD INSTALLATION Clean the cylinder head gasket surface of any gasket material. 6-9 6. CYLINDER HEAD/VALVES ACTIVE 50 Be careful not to enter dust and dirt into the cylinder. Install the dowel pins and a new cylinder head gasket. Gasket Inspection Hole Caps Gasket Install the cylinder head. Install the new cylinder head cover gasket. Install the cylinder head cover with its arrow mark facing the inlet side. Install one copper washer and three washers. Install the four cylinder head cover cap nuts, cylinder head bolt and cylinder bolt. Tighten the four cap nuts in a crisscross pattern in 2-3 steps first, then tighten the cylinder head bolt and cylinder bolt. TORQUE Cylinder head cover cap nut: 1.2 1.6kg-m Cylinder head bolt: 0.6 0.9kg-m Cylinder bolt: 0.6 0.9kg-m Caps Nuts And Washers Cap Nut And Copper Washer Align Cylinder Bolt Arrow Cylinder Head Bolt (c) 4-Stroke.net Bolt Rotate the flywheel counterclockwise to align the “T” mark on the cylinder head. Install the cam chain over the cam sprocket, and install the cam sprocket on the camshaft. Install and tighten the cam sprocket bolts. TORQUE: 0.7 1.1 kg-m Cam Chain Dowel Pins Cam Sprocket Install the left side cover Gasket on the left side cover. Install the left side cover. 6-10 6. CYLINDER HEAD/VALVES ACTIVE Adjust the valve clearance. Gasket (c) 4-Stroke.net Left Side 6-11 50 7. CYLINDER/PISTON ACTIVE 50 7 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING -------------------------------------------------SERVICE INFORMATION -----------------------------------------------TROUBLESHOOTING----------------------------------------------------CYLINDER REMOVAL---------------------------------------------------PISTON REMOVAL -------------------------------------------------------PISTON INSTALLATION ------------------------------------------------CYLINDER INSTALLATION--------------------------------------------- (c) 4-Stroke.net 7- 1 7- 2 7- 2 7- 3 7- 4 7- 6 7- 6 7 7-0 7. CYLINDER/PISTON ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 7-1 50 7. CYLINDER/PISTON ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed. • After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Item Cylinder Piston, piston ring . I.D. Warpage Cylindricity True roundness Ring-to-groove clearance Ring end gap top Second top Second Oil side rail Standard Limit (mm) Service Limit (mm) ⎯ 52.4 ⎯ 0.05 ⎯ 0.05 ⎯ 0.05 ⎯ 0.12 ⎯ 0.12 0.1 0.25 0.5 0.1 0.25 0.5 0.5 0.1 0.25 55.58 55.95 Piston O.D. 5mm from bottom of Piston O.D. measuring position skirt 0.005 0.014 Piston-to-piston pin clearance 0.01 0.35 Piston pin hole I.D. Piston pin O.D Connecting rod small end I.D. bore 51.6 5mm from bottom of skirt 0.1 13.00 12.994 13.000 12.944 13.016 13.034 13.08 (c) 4-Stroke.net TROUBLESHOOTING • When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven compression • Worn or damaged cylinder and piston rings • Worn, stuck or broken piston rings Compression too high • Excessive carbon build-up in combustion chamber or on piston head Excessive smoke from exhaust muffler • Worn or damaged piston rings • Worn or damaged cylinder and piston Abnormal noisy piston • Worn cylinder, piston and piston rings • Worn piston pin hole and piston pin • Incorrectly installed piston 7-2 7. CYLINDER/PISTON ACTIVE 50 Guide Roller Bolt CYLINDER REMOVAL Remove the cylinder head. Remove the cam chain guide roller. Remove the cylinder by removing the cylinder bolt. Remove all gasket material from the cylinder surface. Guide Roller Dowel Pins Remove the gasket and dowel pins. CYLINDER INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. at three levels of top, middle and bottom at 90° to the piston pin (in both X and Y directions). Service Limit: 52.4mm repair or replace if over (c) 4-Stroke.net 52.4mm repair or replace if below Measure the cylinder-to-piston clearance. Service Limit: 0.35mm repair or replace if over The true roundness is the difference between the values measured in X and Y directions. The cylindricity (difference between the values measured at the three levels) is subject to the maximum value calculated. Service Limits: True Roundness: 0.05mm repair or replace if over Cylindricity: 0.05mm repair or replace if over 7-3 Top Middle Bottom Cylinder Bolt Gasket 7. CYLINDER/PISTON ACTIVE 50 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Piston Clip PISTON REMOVAL Remove the piston pin clip. Press the piston pin out of the piston. Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase. Piston Pin Install the piston rings onto the piston and measure the piston ring-to-groove clearance. Service Limits: Top: 0.12mm replace if over 2nd: 0.12mm replace if over (c) 4-Stroke.net Remove the piston rings and insert each piston ring into the cylinder bottom. • Use the piston head to push each piston ring into the cylinder. Measure the piston ring end gap. Service Limit: 0.5mm replace if over 7-4 7. CYLINDER/PISTON ACTIVE Measure the piston O.D. • Take measurement at 5mm from the bottom and 90° to the piston pin hole. Service Limit: 51.6mm replace if below Measure the piston-to-piston pin clearance. Service Limit: 0.10mm replace if over Measure the piston pin hole I.D. Service Limit: 13.06mm replace if over Measure the piston pin O.D. Service Limit: 12.944mm replace if below (c) 4-Stroke.net Measure the connecting rod small end I.D. Service Limit: 13.016mm replace if over 7-5 50 7. CYLINDER/PISTON ACTIVE PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring. 50 Top Second • Be careful not to damage the piston and piston rings during assembly. • All rings should be installed with the markings facing up. • After installing the rings, they should rotate freely without sticking. • Stagger the ring end gaps as the figure shown. Top Second Side Rail Oil Ring Side Rail Install the piston, piston pin and a new piston pin clip. “IN” Mark Piston Pin Clip • Position the piston “IN” mark on the intake valve side. • Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase. (c) 4-Stroke.net Piston Piston Pin Dowel Pins CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase. Gasket 7-6 7. CYLINDER/PISTON ACTIVE Coat the cylinder bore, piston and piston rings with clean engine oil. Carefully lower the cylinder over the piston by compressing the piston rings. • Be careful not to damage or break the piston rings. • The piston ring end gaps should not be parallel with or at 90° to the piston pin. Roller Bolt Install the cam chain guide roller and tighten the roller bolt. Guide Roller Temporarily install the cylinder bolts. Install the cylinder head (page 6-10). Tighten the cylinder bolt to the specified torque. TORQUE: 0.6 0.9kg-m (c) 4-Stroke.net Bolt 7-7 50 8. ALTERNATOR/STARTER CLUTCH/ 9. CAM CHAIN TENSIONER ACTIVE 50 8 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ALTERNATOR/STARTER CLUTCH/ CAM CHAIN TENSIONER __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------ALTERNATOR REMOVAL ---------------------------------------------STARTER CLUTCH REMOVAL ---------------------------------------CAM CHAIN TRNSIONER --------------------------------------------TENSIONER SPRING AND PUSH ROD ------------------------------STARTER CLUTCH INSTALLATION --------------------------------- (c) 4-Stroke.net 8-2 8-2 8-3 8-4 8-5 8-5 8-6 8 8-0 8. ALTERNATOR/STATER CLUTCH/ CAM CHAIN TENSIONER ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 8-1 50 8. ALTERNATOR/STARTER CLUTCH/ 9. CAM CHAIN TENSIONER ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The starter motor, generator, left crankcase and starter clutch can be serviced in the frame. • Do not install the starter clutch forcedly. • Install the generator by aligning the groove in the flywheel with the key on the crankshaft. • Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove. SPECIFICATIONS Standard (mm) 11.985 12.00 37.87 37.90 19.01 19.02 110 107 Item Push rod O.D. Driven sprocket O.D. Driven sprocket I.D. Tensioner spring free length TORQUE VALUES Flywheel lock nut Service Limit (mm) 11.945 37.60 19.041 90 3.2 4.0kg-m SPECIAL TOOLS Flywheel holder Flywheel puller E021 E003 TROUBLESHOOTING Hard starting and poor performance at high speed • Improperly tightened flywheel lock bolt Starter clutch slips • Worn starter clutch roller • Faulty starter clutch roller or spring • Worn starter gear shaft O.D. Starting noise • Worn reduction gear • Worn starter gear • Worn starter clutch roller • Faulty reduction gear shaft bearing (c) 4-Stroke.net 8-2 8. ALTERNATOR/STATER CLUTCH/ CAM CHAIN TENSIONER ACTIVE 50 Bolts ALTERNATOR REMOVAL Remove the four bolts. Remove the left crankcase cover. Gasket Remove the gasket and dowel pins. Dowel Pins Flywheel Holder Remove the flywheel nut and washer while holding the flywheel with a flywheel holder. Special Flywheel holder (c) 4-Stroke.net Flywheel Puller Remove the flywheel using a flywheel puller as shown. Special Flywheel puller 8-3 8. ALTERNATOR/STARTER CLUTCH/ 9. CAM CHAIN TENSIONER Remove the clamp. Remove the five bolts and alternator stator base from the crankcase cover. ACTIVE Clamp 50 Bolts • Do not disassemble the stator and pulse generator coils. Stator Base STARTER CLUTCH REMOVAL REMOVAL Drain the engine oil (page 3-3) Remove the alternator (page 8-3) Remove the stopper plate and chain sliders. Remove the snap ring. Remove the chain, starter drive sprocket and driven sprocket as an assembly. Snap Ring Drive Sprocket Stopper Plate Driven Sprocket Chain Sliders Remove the two screws, base plate and three O-rings. (c) 4-Stroke.net Screws INSPECTION Inspect the chain sliders for wear or damage. Replace them if necessary. Base Plate Chain Sliders 8-4 8. ALTERNATOR/STATER CLUTCH/ CAM CHAIN TENSIONER ACTIVE 50 INSPECTION Measure the driven sprocket O.D. Service Limit:37.83mm replace if over Measure the driven sprocket I.D. Service Limit:19.06mm replace if over Check the one-way clutch rollers, spring caps and springs for wear or damage. Spring CAM CHAIN TENSIONER Spring Cap Cam Chain Tensioner Roller Tensioner Rod REMOVAL Drain the engine oil (page 3-3) Remove the alternator (page 8-3) Remove the starter clutch (page 8-4) Remove the tensioner sealing bolt, washer, spring and tensioner rod. Remove the pivot bolt and cam chain tensioner. (c) 4-Stroke.net Spring TENSIONER SPRING AND PUSH ROD INSPECTION Measure the tensioner spring free length. Service limit: 90mm 8-5 Washer And Bolt 8. ALTERNATOR/STARTER CLUTCH/ 9. CAM CHAIN TENSIONER ACTIVE 50 Check the push rod valve for clogged Check the push rod for wear or scraches. Measure the push rod O.D. Service limit: 11.945 mm One Way Valve INSTALLATION Install the cam chain tensioner and secure it with the pivot bolt. Install the tensioner rod, spring, sealing washer bolt. Tighten the tensioner sealing bolt. TORUQE: 1.5 2.5 kg-m Tensioner Tensioner Rod Spring Sealing Washer And Bolt Install the tensioner spring with its small coil end up. Install the starter clutch and alternator (page 8-6) (c) 4-Stroke.net Base Plate STARTER CLUTCH INSTALLATION Install the new O-rings onto the left crankcase and base plate, Install the base plate, being careful not to damage the O-ring. Tighten the base plate screws. O-rings 8-6 8. ALTERNATOR/STATER CLUTCH/ CAM CHAIN TENSIONER ACTIVE 50 Install the chain, drive sprocket and driven sprocket as an assembly. Chain Install the following components: -snap ring. -stopper plate. -chain sliders. Snap Ring Chain Sliders Clamp Grommet Stopper Plate Bolts Install the alternator stator base and secure it with the two bolts. Install the grommet into the grove of the left crankcase cover. Install the wire clamp. (c) 4-Stroke.net Install the woodruff key on the crankshaft, Wipe all oil lff the inside of the flywheel amd crankshaft, and install the flywheel aligning its groove with the woodruff key. Install the flywheel, turning it counterclockwise. Install and tighten the flywheel nut while holding the flywheel with a flywheel holder. TORQUE: 3.2 4.0 kg-m Flywheel Holder Special Flywheel Holder 8-7 Drive Sprocket Stator Base Nut 8. ALTERNATOR/STARTER CLUTCH/ 9. CAM CHAIN TENSIONER ACTIVE 50 Gasket Install the dowel pins and a new gasket. Dowel Pins Bols Install the left crankcase cover and tighten the four bolts. Torque: 0.8 1.2kg-m (c) 4-Stroke.net 8-8 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CLUTCH/GEAR SHIFT MECHANISM __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------RIGHT CRANKCASE COVER REMOVAL --------------------------CENTRIFUGAL CLUTCH/MANUAL CLUTCH REMOVAL -----CENTRIFUGAL CLUTCH/MANUAL CLUTCH INSTALLATION GEAR SHIFT MECHANISM---------------------------------------------RIGHT CRANKCASE COVER INSTALLAION ---------------------- (c) 4-Stroke.net 9 -2 9 -3 9 -4 9 -4 9 -8 9-11 9-12 9-0 9 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE (c) 4-Stroke.net 9-1 50 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The clutch and gear shift mechanism can be serviced in the frame. • Install the clutch plates in the same chamfer direction. • Install the thrust washer with the chamfer facing up and the flat facing down. SPECIFICATIONS mm ITEM Clutch outer. I.D. Driven gear outer.O.D Gear primary drive.O.D. Center clutch. O.D. Guide clutch center.O.D Spring clutch damper Centrifugal clutch Spring clutch Spring clutch free Disc A clutch friction thickness Disc B clutch friction thickness STANDARD 110mm 46.0mm 34.25mm 68.00mm 21.00 11.3mm 17.5mm 21mm 2.7~2.73mm SERVICE LIMIT 110.4mm 45.80mm 34.15 67.7mm 20.97~20.93 3.7~3.73mm 3.5~3.53mm 2.5~2.53 TORQUE VALUES Centrifugal clutch lock nut Manual clutch lock nut Drum stopper bolt 3.8 4.5kg-m 3.8 4.5kg-m 0.8 1.2kg-m (c) 4-Stroke.net SPECIAL TOOLS Clutch holder Lock nut wrench 18mm Gear holder Lock nut wrench 20mm Flywheel holder E017 E010 E009 E021 TROUBLESHOOTING 9-2 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE Faulty clutch operation can usually be corrected by adjusting the clutch. Clutch slips when accelerating • Faulty clutch lifter mechanism • Discs worn • Weak spring • Incorrect clutch adjustment Clutch will not disengage • Faulty clutch lifter • Incorrect clutch adjustment • Plates warped ATC creeps with engine idling • Faulty centrifugal clutch Clutch operation feels rough • Rough manual clutch outer slots • Worn or damaged centrifugal clutch shoes or drum Gearshift pedal will not return • Weak or broken gearshift spindle return spring • Binding gearshift spindle Hard to shift • Gearshift spindle damaged • Stopper plate and pin damaged • Stopper plate bolt loosened • Clutch adjustment incorrect Transmission jumps out of gear • Stopper arm damaged • Stopper plate damaged • Stopper plate bolt loosen (c) 4-Stroke.net 9-3 50 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 Bolts RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-3). Remove the kickstarter pedal. Remove the right crankcase cover attaching bolts and right crankcase cover. Remove the dowel pins and gasket. Nut Clutch Lifter CLUTCH LIFTER REMOVAL/INSPECTION Remove the lock nut, and O-ring. Remove the clutch adjusting bolt and clutch lifter. Check the removed parts for wear or damage and replace them if necessary. O-Ring Adjusting Bolt Lifter Cam Bolts CENTRIFUGAL CLUTCH/MANUAL CLUTCH REMOVAL REMOVEAL Remove the clutch lifter lever and clutch lifter cam. Remove the four bolts, oil filter rotor cover and gasket. (c) 4-Stroke.net Lifter Lever Bearing Rotor Cover And Gasket Rotor Cover And Gasket Remove the clutch lifter bearing. 9-4 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 Clutch Holder Install the clutch holder and secure it with the bolts. Remove the lock nut and plane washer using a lock nut wrench. Remove the clutch. Special Clutch holder Lock nut wrench Lock Nut Wrench Washer Remove the clutch square nut. Remove the washer and clutch square nut lock nuts. Remove the clutch. Clutch Square Nut Lock Nuts Circlip Remove the clutch circlip. Remove the gear primarv driven. (c) 4-Stroke.net Gear Primary Driven 9-5 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 Washer Remove the follows: - Gear primary drive. -Guide clutch center. - Washer Gear primary drive MANUAL CLUTCH DISASSEMBLY Remove the set ring(101.5mm) Set Ring(101.5mm) Remove the four bolts(5*10mm) (c) 4-Stroke.net Bolts(5*10mm) Plate Drive Center Clutch Driven Gear Outer Set Ring Plate A Clutch Disk Clutch Friction Guide Clutch Center Plate A Clutch 9-6 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE Measure the O.D. of the crankshaft at the primary drive gear. SERVICE LIMIT: 17.00mm INSPECTION CLUTCH GEAR O.D/I.D Inspect the clutch outer groove for scratches caused by the friction disks. Measure the clutch outer I.D. Service Limit: 110mm Measure the driven gear outer O.D. Service Limits: 46mm Measure the gear primary drive O.D. Service Limits:34.25 mm Measure the center clutch O.D. Service Limits: 68mm Measure the center clutch O.D Service Limits:21 mm INSPECTION CLUTCH TENSION SPRING Measure each spring clutch damper. Service Limit:11.3 mm Measure each spring clutch. Service Limit: 17.5mm Measure each spring clutch free Service Limit: 21mm Replace the spring with a new one if it is shorter than the service limit. 50 crankshaft Clutch Outer Driven Gear Outer Center Clutch Spring Clutch Damper Gear Primary Drive Guide Clutch Center Spring Clutch (c) 4-Stroke.net Spring Clutch Free CLUTCH FRICTION DISK Measure each disk B clutch friction thickness. Service Limit:3.7 mm Measure each disk A clutch friction thickness. Service Limit:2.7 mm Disk B Clutch Friction 9-7 Disk A Clutch Friction 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 CLUTCH A PLATE/ CLUTCH A PLATE Measure each clutch plate bending using a feeler gauge. Service Limit: 0.20mm Plate Drive Center Clutch CENTRIFUGAL CLUTCH/MANUAL CLUTCH INSTALLATION Driven Gear Outer Set Ring MANUAL CLUTCH ASSEMBLY Coat the clutch discs and plates with clean engine oil. Assemble the clutch plate drive, driven gear outer, center clutch, plate A clutch, disk clutch friction, plate B clutch and set ring. Plate A Clutch Disk Clutch Friction Plate B Clutch Outer Clutch Outer Clutch Set Ring Install the clutch four bolts. Install the four spring clutch damper Install the clutch Set Ring. (c) 4-Stroke.net Spring Clutch Damper Collapsible Guide Clutch Center INSTALLATION Install the collapsible. Install the guide clutch center Spline Washer 9-8 9. CLUTCH/GEAR SHIFT MECHANISMGuide Clutch ACTIVE Center 50 Washer Install the clutch outer guide onto the main shaft. Install the washer over the crankshaft. Gear Primary Driver Install the clutch drum and manual clutch assembly. Gear primary drive Manual Clutch Assembly Clutch Drum Washer Lock Washer Install the washer with the “OUT SIDE” mark facing out. (c) 4-Stroke.net “OUT SIDE” Mark Install the plane washer and centrifugal clutch lock nut. Install the clutch holder and secure it with two bolts. Tighten the lock nut to the specified torque. TORQUE: 3.8 4.5kg-m Special Clutch holder Lock nut wrench 9-9 Lock Nut Wrench Gear Holder 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE Gasket 50 Cover Install the oil filter rotor cover and a new gasket. Secure the oil filter rotor with the three bolts. Bearing 6000 Install the clutch Bearing. Clutch Lifter Cam Punch Mark And Notch Mark Install the clutch lifter bearing and clutch lifter Cam.(page9-10-4) Install the clutch lifter lever onto the Gearshift spindle,aligning its punch mark with The notch mark on the spindle. Install the right crankcase cover(page9-12). (c) 4-Stroke.net Clutch Lifter Lever Install the clutch lift comp. Install the through oil through and through oil. Install the spring cam plate sid.e Install the Retainer Clutch Bot. Retainer Clutch Bot Clutch Lift Comp Through Oil Through Spring Cam Plate Side Through Oil 9-10 9. CLUTCH/GEAR SHIFT MECHANISM GEAR SHIFT MECHANISM Drum stopper ACTIVE 50 gear shift pedal r warcher Remove the cenrifugal clutch and manual clutch (page 9-3) Remove the warcher. Remove the gear shift spindle and washer. Remove the gear shift pedal. Gear Shift Spindle Remove the bolt, drum stopper and spring. Remove the gearshift stopper plate bolt and the plate. Gearshift Stopper Plate Bolt Spring Bolt INSTALL Install the pin in the holes. Install the warcher Install the stopper plate, aligning the holes in the stopper plate with the dowel pin. Tighten the stopper plate bolt security. Warcher Drum Stopper Dowel Pin Holes (c) 4-Stroke.net Pin Stopper Plate Gear Shift Cam Stopper Install the gear shift cam stopper and spring. Tighten the 6mm lock bolt. Torque: 0.8~1.2kg-m Spring 9-11 9. CLUTCH/GEAR SHIFT MECHANISM ACTIVE 50 Install the gear shift spindle and washer. During installation, make sure that the return spring aligns with the crankcase tab. Spring Lock Nut Adjusting Bolt RIGHT CRANKCASE COVER INSTALLATION Install the new O-ring and lock nut. O-ring Dowel Pins Install the dowel pin and a new gasket. (c) 4-Stroke.net Gasket Bolts Install the right crankcase cover and tighten the cover bolts. Install the kickstarter pedal. Adjust the clutch (page 2-8). Gear Shift Spindle 9-12 10. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION ACTIVE 50 10 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/GRANKSHAFT/TRANS-MI SSION SYSTEM/STARTER SPINDLE __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------CRANKCASE REMOVAL -----------------------------------------------CRANKSHAFT/KICK STARTER---------------------------------------TRANSMISSION-----------------------------------------------------------CRANKCASE BEARING REPLACEMENT --------------------------CRANKCASE INSTALLATION ----------------------------------------- (c) 4-Stroke.net 10- 2 10- 3 10- 4 10- 5 10- 7 10-10 10-12 10 10-0 10. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION ACTIVE (c) 4-Stroke.net 10-1 50 10. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • During crankcase separation, do not separate the crankcase halves with an iron hammer to avoid crankcase deformation or damage. • After separation, be careful not to damage the right and left crankcase mating surfaces to avoid oil leakage. • Replace the gasket with a new one during reassembly of the crankcase halves. • After transmission system disassembly, make sure that the gear shifting operation is normal before reassembly of the remaining parts. • Apply engine oil to the transmission system and crankshaft before reassembly. SPECIFICATIONS Item Transmission Claw thickness fork Shaft hole I.D. Transmission fork shaft O.D. Transmission Left drum O.D. Right Main shaft 2nd gear Main shaft 3rd gear Main shaft 4th gear Gear I.D. Countershaft 1st gear Countershaft 2nd gear Countershaft 3rd gear Countershaft 4th gear Transmission Left crankcase side gear Main Shaft Starter gear O.D. 2nd /3rd/4th gear Right crankcase Left crankcase Countershaft 1st gear O.D. 2nd gear 3rd/4th gear Connecting rod big end side clearance Crankshaft Connecting rod big end radial clearance Runout Standard (mm) 4.93 5.0 34.02 34.05 33.90 33.96 13 13.02 16.10 16.12 17.0 17.018 17.0 17.018 17.016 17.034 23.020 23.041 20.0 20.021 23.020 23.041 20.0 20.021 11.978 11.9899 25.30 25.50 16.966 16.984 11.978 11.989 16.978 16.989 16.978 16.989 18.80 19.0 19.959 19.98 0.05 0.3 0 0.05 0.03 Service Limit (mm) 4.43 34.05 33.96 13 16.04 17.058 17.058 17.074 23.081 22.061 23.081 22.061 11.938 25.20 16.926 11.938 16.938 16.938 18.760 19.919 0.8 0.05 0.1 (c) 4-Stroke.net 10-2 10. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION ACTIVE SPECIAL TOOLS Bearing remover Bearing remover block Universal bearing puller Bearing driver handle Pilot, 15mm Pilot, 17mm Pilot, 20mm Pilot, 22mm Inner bearing driver handle Bearing outer driver TROUBLESHOOTING Excessive engine noise • Worn main shaft journal bearing • Worn crankshaft pin bearing • Worn transmission bearings Transmission gear tripping • Worn gear teeth • Bent transmission fork • Bent transmission fork shaft • Damaged gear shift cam stopper (c) 4-Stroke.net Hard shifting • Improperly adjusted clutch • Bent or damaged transmission fork • Bent transmission fork shaft • Bent gear shift spindle • Damaged transmission drum grooves 10-3 50 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION CRANKCASE REMOVAL 50 Bolts The following parts must be removed before removing the crankcase: • Cylinder head (Refer to Section 6.) • Cylinder/piston (Refer to Section 7.) • Alterantor/cam chain tensioner (Refer to Section 8.) • Clutch/gear shift mechanism (Refer to Section 9.) Turn the engine so that the left crankcase is facing up. Remove the eight crankcase attaching bolts. Spring Lay the crankcase on the right side. Remove the snap ring on the kick starter spindle. Remove the spring retainer and spring. Spring Retainer Lay the crankcase on the left side. Separate the right and the left crankcase halves. Snap Ring Right Crankcase (c) 4-Stroke.net Left Crankcase Remove the gasket and dowel pins. Dowel Pins Gasket 10-4 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION CRANKSHAFT/KICK STARTER Kick starter spindle 50 Crankshaft REMOVAL Remove the crankshaft. Remove the kick starter spindle. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.80mm replace if over Measure the connecting rod big end radial clearance at two points at right angles to the shaft. Service Limit: 0.05mm replace if over (c) 4-Stroke.net Measure the crankshaft runout. Service Limit: 0.1mm replace if over A 10-5 B 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION 50 Turn the outer races of the crankshaft bearings with your fingers. The bearings should turn smoothly and quietly. Also check that the inner races of the bearings fit tightly on the crankshaft. Check the timing sprocket for wear or damage. Timing Sprocket Bearing Spring Snap Ring KICK STARTER DISASSEMBLY Remove the Snap Ring. Remove the circlip. Remove the Starter ratchet Starter ratchet Circlip And Trust Washer Starter Ratchet Remove the starter ratchet and spring. Pry out the circlip and thrust washer. Removethe kick starter pinion. (c) 4-Stroke.net Kick Starter Spindle Circlips KICK STARTER ASSEMBLY Assemble the kick starter spindle in the reverse order of disassembly. INSTALLATION Install the crankshaft and kick starter to the left crankcase. Align the punch mark of the kick starter spindle with the punch mark on the starter driven ratchet. Pinion Gear Starter Driven Ratchet Spring 10-6 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION 50 Kick Starter Spindle TRANSMISSION DISASSEMBLY Remove the kick starter spindle from the left crankcase. Main Shaft Countershaft . Remove the transmission main shaft and countershaft and transmission drum and transmission forks from the left crankcase. When removing, the transmission gears must be removed as a set. Transmission Drum INSPECTION Inspect each gear for wear or damage and replace if necessary. Check the gear teeth and engagement dogs for wear or damage. Check the mainshaft and countershaft splines and sliding surfaces for wear or damage. (c) 4-Stroke.net Measure the I.D, of each spinning gear. Service limit: M2: M4: C1: C3: 17.058mm 17.074mm 23.081mm 20.081mm Measure the I.D. and O.D. of C1 bushing. Service limit: I.D.: O.D.: 10-7 20.08mm 22.75mm Transmission Forks 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION Measure the O.D. of the mainshaft and countershaft in the locations as shown. Service limit: M2, M4: C3, C4: M4 50 M2 16.926mm 19.919mm C4 C3 Measure each transmission fork shaft hole I.D. Service Limit: 34.05mm replace if over Check the transmission fork shaft for bending or damage. Measure the transmission fork shaft O.D. Service Limit: 33.96mm replace if below (c) 4-Stroke.net TRANSMISSION FORK/DRUM INSPECTION Inspect each transmission fork for bending or damage. Measure each transmission fork claw thickness. Service Limit: 5mm replace if below Inspect the transmission drum for scratches or poor lubrication. 10-8 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION 50 Check the transmission drum grooves for damage. Check the bearing for excessive free play. Measure the transmission drum O.D. Service Limits: Left : 13.05mm replace if below Right : 16.10mm replace if below Check the transmission drum and transmission fork shaft holes in the left and right crankcase halves for wear or damage. TRANSMISSION BEARING INSPECTION Turn the inner races of the bearings with your finger. The bearings should turn smoothly and quietly. Also check that the outer races of the bearings fit tightly in the crankcase. Replace the bearings if they are abnormal (page 10-10) ASSEMBLY Apply clean engine oil to the sliding and rotating surfaces of the gears, bushings and shafts. Assemble the main shaft and countershaft. Install the snap rings aligning their end gaps between the shaft teeth as shown. Make sure the snap rings are seated securely in the grooves of the shafts. (c) 4-Stroke.net Main Shaft M4 (24T) M3 (21T) M2 (17T) Spline Washer Snap Ring C4 (23T) Cam locating plate Right 10-9 Left Spring Spline Washer C1 Bushing C2 (30T) C3 (26T) M1 (12T) C1 (34T) Countershaft Install the main shaft, countershaft and shift drum as an assembly. Install the kick starter spindle (page 10-6) 10. CRANKCASE/CRANKSHAFT/KICK STARTER/TRANSMISSION ACTIVE 50 CRANKCASE BEARING REPLACEMENT Remove the oil pump drive shaft and drive sprocket. LEFT CRANKCASE Remove the countershaft oil seal. Drive the countershaft bearing out of the left crankcase. Bearing Oil Seal (c) 4-Stroke.net BEARING REPLACEMENT Remove the main shaft and countershaft bearings from the left and right crankcase halves using the following tools. Bearings Bearing Remover Special Bearing Remover Bearing Remover Block Bearing Remover Block Drive in new bearings using a bearing installer. 10-10 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION 50 • Apply engine oil to the bearings before installation. • Drive in bearings squarely. Special Bearing installer Countershaft Oil Seal Install a new left countershaft oil seal in the left crankcase and grease the oil seal lip. RIGHT CRANKCASE Drive the mainshaft and countershaft bearings out of the right crankcase. Main shaft Bearing Counter Bearing (c) 4-Stroke.net Counter Bearing Main shaft Bearing Drive in new bearings using a bearing installer. • Apply engine oil to the bearings before installation. • Drive in bearings squarely. Special Bearing Driver Main shaft Bearing Counter Bearing CRANKCASE INSTALLATION Install the dowel pins and a new gasket onto the left crankcase. 10-11 10. CRANKCASE/CRANKSHAFT/KICK ACTIVE STARTER/TRANSMISSION 50 Dowel Pins Bolts Install the right crankcase over the left crankcase. Make sure that the gasket stays in place. Install and tighten the crankcase bolts securely in a crisscross pattern in 2-3 steps. Spring Install the return spring and spring retainer onto the kick starter spindle. Install the snap ring. Refer to the sections on page 10-4 for installation of the removed parts. (c) 4-Stroke.net Retainer Snap Ring Gasket 10-12 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 11 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRONT WHEEL/SUSPENSION/STEERING __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------HANDLEBAR --------------------------------------------------------------FRONT WHEEL------------------------------------------------------------FRONT SHOCK ABSORBER--------------------------------------------STEERING STEM----------------------------------------------------------- (c) 4-Stroke.net 11- 2 11- 3 11- 4 11- 7 11-11 11-16 11 11-0 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 SCHEMATIC DRAWING (c) 4-Stroke.net 11-1 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS SPECIFICATIONS Item Front axle shaft runout Axial Radial Front wheel rim runout Front fork spring free length Front fork tube runout Front fork oil capacity TORQUE VALUES Steering stem lock nut Steering top cone race Master cylinder holder bolt Front brake disk nut 6.0 8.0kg-m 0.15 0.25kg-m 1.8 2.5kg-m 1.8 2.5kg-m Standard (mm) ⎯ 1 1 328.2 ⎯ 50 Service Limit (mm) 0.2 2.0 2.0 ⎯ 0.2 ⎯ Front axle nut Front fork mount bolt 5.0 6.0kg-m 1.8 2.5kg-m SPECIAL TOOLS Lock nut wrench Lock nut socket wrench Outer driver, 28×30mm Rear shock absorber remover Rear shock absorber compfressor Ball race remover Driver handle A Outer driver, 37×40mm Pilot, 10mm Bearing puller Snap ring pliers(close) Damper compressor (c) 4-Stroke.net 11-2 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 TROUBLESHOOTING Hard steering • Insufficient tire pressure • Excessively tightened steering stem nut • Damaged steering stem bearings • Damaged steering bearing races Steers to one side or does not track straight • Uneven front shock absorbers • Bent front fork • Bent front axle or uneven tire Front wheel wobbling • Improperly tightened axle nut • Bent rim • Worn front wheel bearing • Faulty tire Soft suspension • Weak fork springs • Insufficient front fork oil Hard suspension • Incorrect front fork oil level • Bent front fork tube • Clogged front fork oil passages Front suspension noise • Slider bending • Loose front fork fasteners • Insufficient front fork oil • Worn front fork bearing • Insufficient speedometer gear grease (c) 4-Stroke.net 11-3 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 cover FR handle cover top throttle HANDLEBAR REMOVAL Remove the cover RR handle. Remove the cover FR handle. Remove the throttle pipe holder screws. Remove the cover top throttle. Remove the cover up throttle. Cover up theottle Disconnect the throttle cable from the throttle grip and then remove the throttle pipe from the handlebar. Master Cylinder cover RR handle screws Throttle Pipe Throttle Cable Remove the two master cylinder holder bolts and the master cylinder. Holder (c) 4-Stroke.net Bolts Remove the handlebar lock nut to remove the handlebar. 11-4 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Handlebar Tab/Groove INSTALLATION Install the handlebar, aligning the tabs of the handlebar with the grooves in the steering stem. Install and tighten the handlebar lock nut. Torque: 4.5~5.0kg-m Hole When installing the right and left handlebar switch housings, align the pin on the housing with the hole in the handlebar. Tighten the two switch housing screws. (c) 4-Stroke.net Bolts When installing the master cylinder align the tab on the holder with the hole in the handlebar with the holder “UP” mark facing up. First tighten the upper bolt and then the lower bolt. Torque: 1.0 1.4kg-m Pin Hole “UP” Mark Nut Bolt THROTTLE PIPE INSTALLATION 11-5 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Clean the handlebar surface and install the throttle pipe. Check the throttle grip for proper operation. Throttle Pipe Hole Connect the throttle cable to the throttle grip. Apply grease to the throttle cable. Install the throttle cover by aligning the pin on the cover with the hole in the handlebar and then tighten the one screws. Pin Throttle Cable (c) 4-Stroke.net FRONT WHEEL REMOVAL 11-6 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Place a jack or other adjustable support under the engine to raise the front wheel off the ground. Remove the front axle nut and pull out the axle. Remove the front wheel. Axle Nut INSPECTION Set the axle in V blocks and measure the runout using a dial gauge. Service Limit: 0.2mm replace if over WHEEL RIM INSPECTION Place the front wheel in a turning stand. Spin the wheel by hand and measure the rim runout using a dial gauge. Service Limits: Axial: 2.0mm adjust if over Radial: 2.0mm adjust if over Check the wheel spoke wires for looseness. If the wheel rim is made of aluminum alloy, replace with a new one if necessary. (c) 4-Stroke.net Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand. Replace the bearings if they are noisy or have excessive play. Radial Axial DISASSEMBLY Remove the speedometer gearbox and dust 11-7 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 seal from the left side of the wheel. Dust Seal Remove the axle collar from the right side of the wheel. Axle Collar Nuts Remove the dust seal. Remove the five nuts and the brake disk. (c) 4-Stroke.net Dust Seal Drive out the wheel bearings and distance collar. Bearing Remover Shaft Speedometer Gearbox Tabs ASSEMBLY Pack all bearing cavities with grease. First 11-8 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 drive in the right bearing and then install the distance collar. Finally, drive in the left bearing. Special Bearing driver handle Bearing installer Attachment, 37x40mm Apply grease to the dust seal and install the dust seal. Install the brake disk and tighten the five nuts. Dust Seal Tabs Install the speedometer gearbox by aligning the tabs with the grooves. (c) 4-Stroke.net Groove Speedometer Gearbox Apply grease to the speedometer gearbox and dust seal, then install them to the wheel from the left side. Dust Seal Bearing Driver Handle Install the axle collar to the right side of the wheel. 11-9 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Groove INSTALLATION Install the front wheel onto the front fork, aligning the tab on the front fork with the groove in the speedometer gearbox. Tab Insert the axle shaft and tighten the axle nut. Torque: 5.5 7.0kg-m Install the speedometer cable by aligning the groove with the tab. (c) 4-Stroke.net Front Axle Nut Axle Collar FRONT SHOCK ABSORBER 11-10 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 REMOVAL Remove the front wheel. (Refer to 11-7.) Remove the fender FR bolts. Remove the fender FR. Remove the four front fender. Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers. Fender FR Bolts Remove the dust boot. Remove the circlip. Dust Boot Circlip Front Shock Absorber Use a vise to hold the front shock absorber and remove the shock absorber tube, hex bolt and copper washer from the front shock absorber. (c) 4-Stroke.net Bolt/Washer Fender FR r 11-11 Upper Fork Bridge Bolts Use a vise to hold the front shock absorber tube and remove the damper from the shock absorber tube. 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 When holding the shock absorber tube, place a shop towel under it and do not apply too much force. Front Fork Spring Use a vise to hold the front fork bottom tube and place shop towels under the bottom tube. Remove the socket head bolt. • When using the vise, do not tighten the front fork bottom tube excessively. • If it is difficult to remove the socket head bolt, temporarily install the front fork spring and front fork bolt. Remove the front fork piston and return spring. Remove the front fork bottom tube and the oil stopper. (c) 4-Stroke.net 6mm Socket Spanner Remove the dust seal and snap ring. Take out the oil seal and circlip. Oil Seal Snap Ring • Do not damage the bottom tube when taking out the oil seal and circlip. • Be sure to replace the removed oil seal and circlip with new ones during assembly. INSPECTION Measure the front fork spring free length. 11-12 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Service Limit: 328.2mm replace if below Replace the spring with a new one if it exceeds the service limit. Set the front fork tube in V blocks and measure the tube runout. Service Limit: 0.2mm replace if over Check the front fork tube, bottom tube and piston for abnormal wear or damage and replace if necessary. Check the front fork piston ring for wear. Check the return spring for weakness or damage. Piston Ring Front Fork Tube (c) 4-Stroke.net Front Fork Bottom Tube ASSEMBLY 11-13 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Before assembly, clean the removed parts with high flash or non-flammable solvent. (c) 4-Stroke.net Install the return spring and piston into the front fork tube and then install oil stopper to the piston end. Install the front fork tube into the bottom tube. Piston Return Spring Front Fork Tube Place shop towels under the bottom tube and set it in a vise. Apply locking agent to the socket head bolt and then install it into the piston. Tighten the socket head bolt using the socket spanner. When tightening the socket head bolt, temporarily install the front fork spring and front fork tube. 11-14 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Torque: 1.5 2.5kg-m Apply engine oil to a new oil seal and install the oil seal using the fork seal driver. Then, install the snap ring and dust seal. Fully compress the front fork and fill SAE8# engine oil into the front fork tube. Do not fill too much engine oil. Specified Capacity: 50cc Damper Nut Install the damping spring to the damper and then install them into the front shock absorber tube. Install the front shock absorber spring and tighten the damper mut. Torque: 1.5 3.0kg-m (c) 4-Stroke.net Install the front shock absorber spring with the loosely wound coils facing up 6mm Socket Spanner INSTALLATION Install the front shock absorbers onto the steering stem. Tighten the lower mount bolts. Install the front fender. Install the front wheel. STEERING STEM REMOVAL Remove the steering handlebar. Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper. 11-15 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Remove the front wheel. Hold the steering stem top cone race and remove the steering stem lock nut. Special Lock nut socket wrench Lock Nut Socket Wrench Remove the top cone race and remove the steering stem. Be careful not to lose the steel balls (26 on top race and 19 on bottom race). Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Lock Nut Wrench Top Cone Race (c) 4-Stroke.net Bolts BALL RACE REPLACEMENT Remove the top and bottom ball races. 11-16 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 Ball Race Remover Bearing Driver Handle Drive the top and bottom ball races into the steering head using a bearing driver. Special Bearing driver handle Bearing installer Attachment, 37x40mm BOTTOM CONE RACE REPLACEMENT Drive out the bottom cone race. Install a new washer and dust seal onto the steering stem and then drive in a new bottom cone race onto the steering stem. (c) 4-Stroke.net STEERING STEM INSTALLATION Apply grease to the top and bottom ball races and steel balls. Install 23 steel balls each on the top and 29 steel balls on the bottom ball races. Apply grease to the ball races again and then install 11-17 11. FRONT WHEEL/SUSPENSION/ STEERING ACTIVE 50 the steering stem. Steel balls: 6mm Lock nut wrench Apply grease to the top cone race and install it. Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely. Check that the steering stem rotates freely and that there is no vertical play. Lock Nut Socket Wrench Install the steering stem lock nut and tighten it while holding the top cone race. Torque: 6.0 8.0kg-m Install the handlebar. Install the speedometer cable. Special (c) 4-Stroke.net Lock nut socket wrench Lock Nut Wrench Steel Balls 11-18 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 12 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/BRAKE/SUSPENSION __________________________________________________________________________________ SERVICE INFORMATION ................................................................ 12- 2 (c) 4-Stroke.net TROUBLESHOOTING ....................................................................... 12- 3 REAR WHEEL..................................................................................... 12- 4 REAR BRAKE ..................................................................................... 12- 7 REAR SHOCK ABSORBER............................................................... 12-10 REAR FORK........................................................................................ 12-11 12 12-0 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 12-1 50 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • When installing the drive chain joint clip, the cutout of the clip should be opposite to the rotating direction. • After the drive chain is adjusted, make sure that the rear brake pedal free play is normal and adjust it if necessary. SPECIFICATIONS Item Rear axle shaft runout Rear rim runout Axial Radial Rear brake drum I.D. Rear brake lining thickness Rear shock absorber spring free length TORQUE VALUES Rear shock absorber upper mount nut Rear shock absorber lower mount nut Rear axle nut Rear fork pivot nut Rear shock absorber damper nut 3.0 3.0 8.0 6.0 1.0 Standard (mm) ⎯ 0.5 0.5 140 4.5 266 Service Limit (mm) 0.2 2.0 2.0 141 2.0 266 4.0kg-m 4.0kg-m 10.0kg-m 8.0kg-m 1.4kg-m SPECIAL TOOLS Bearing remover set Pivot set Remover handle Block Rear shock absorber attachment A Rear shock absorber attachment Bearing outer driver Pilot Rear shock absorber compressor Bearing remover shaft Bearing remover head (c) 4-Stroke.net 12-2 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 TROUBLESHOOTING Rear wheel wobbling • Bent rim • Worn rear wheel bearing • Loose or broken wheel spoke wires • Faulty tire • Improperly tightened axle nut • Loose rear fork pivot nut Soft suspension • Weak shock absorber spring • Improperly adjusted shock absorber • Damper oil leaks Poor brake performance • Improperly adjusted brake • Worn brake linings • Contaminated or damaged brake linings • Worn brake cam • Worn brake drum • Improperly installed brake linings • Worn brake shoes at cam contacting area • Worn camshaft Hard suspension • Improperly adjusted shock absorber Rear suspension noise • Bent rear shock absorber • Loose shock absorber fasteners • Insufficient damper oil (c) 4-Stroke.net 12-3 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 REAR WHEEL REMOVAL Remove the rear axle nut. Remove the rear brake adjusting nut. Remove the pin, nut and rear panel fixing arm bolt. Rear Brake Adjusting Nut Pin, Nut and Bolt Drive Chain Rear Brake Panel Remove the rear brake panel. Remove the drive chain. Remove the rear wheel. (c) 4-Stroke.net INSPECTION Set the rear axle in V blocks and measure the runout with a dial gauge. Service Limit: 0.2mm Rear Axle Nut Place the rear wheel in a turning stand and 12-4 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 measure the rim runout. Service Limits: Axial: 2.0mm Radial: 2.0mm Check the wheel spoke wires for looseness. Check the wheel bearing play by placing the wheel in a turning stand and spinning the wheel by hand. Axial Radial (c) 4-Stroke.net Check the drive chain gear teeth for wear or damage. Replace the drive chain gear if necessary. Good If the drive chain gear teeth are worn or damaged, also check the drive chain and replace if necessary. DISASSEMBLY 12-5 Replace 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 Remove the side collar and dust seal from the left side of the rear wheel. First tap the safety piece flat and then remove the four drive chain gear lock nuts. Remove the safety piece and drive chain gear. Remove the snap ring and gear gasket. Check the damping bushings for damage. Collar RR dist Lock Nuts Collar RR dist Remove the Collar RR dist. Drive out the wheel bearings and remove the distance collar. Bearing Remover ASSEMBLY Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. (c) 4-Stroke.net • Drive in the bearings squarely. • Install the bearings with the sealed end facing out. Bearing Outer Driver Dust Seal Install the drive chain gear and secure it with Gear Gasket 12-6 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE the snap ring. Apply grease to the dust seal and install it to the bearing. Install the side collar. INSTALLATION Install the rear wheel in the reverse order of removal. Drive Chain Slack: 1 2cm After rear wheel installation, be sure to adjust the drive chain slack and rear brake pedal free play. Torque: 8.0 10.0kg-m (c) 4-Stroke.net REAR BRAKE REMOVAL Remove the rear wheel and rear brake panel. INSPECTION Measure the rear brake lining thickness. Service Limit: 2.0mm replace if below Side Collar Measure the brake drum I.D. 12-7 50 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 Service Limit: 141mm replace if over Brake Shoes DISASSEMBLY Remove the springs and brake shoes. Springs (c) 4-Stroke.net Brake Cam Brake Arm Remove the brake arm bolt to remove the brake arm. Remove the oil seal. Remove the brake cam. ASSEMBLY 12-8 • Keep grease off the linings because contaminated brake linings reduce stopping power. • During installation, wipe any excess grease off the brake cam. 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 Springs Grease Brake Lining Apply grease to the brake cam and anchor pin, then install the brake cam to the brake panel. Brake Cam (c) 4-Stroke.net Apply engine oil to the oil seal and install it to the brake cam. Grease Brake Cam 12-9 Install the brake arm onto the brake cam, 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 aligning the punch mark on the cam with the scribed line on the arm. Install and tighten the brake arm bolt. Torque: 0.8 1.2kg-m INSTALLATION Install the brake panel and rear wheel in the reverse order of removal. After the rear wheel installation, check the drive chain slack and rear brake pedal free play. (c) 4-Stroke.net REAR FORK REMOVAL 12-10 12. REAR WHEEL/BRAKE/SUSPENSION ACTIVE 50 Remove the rear wheel. Remove the rear shock absorbers. Remove the cover the rear fork pivot nut to remove the pivot and rear fork. Rear Fork Pivot Nut (c) 4-Stroke.net Remove the drive chain slider and check for wear or damage. 12-11 When replacing the rear fork pivot bushings, press in the new bushings to make them flush with the rear fork. 12. REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the rear fork in the reverse order of removal. Tighten the rear fork pivot nut. Torque: 5.5 7.0kg-m After the rear fork is installed, install the following parts: Rear shock absorbers Rear wheel Drive chain cover Rear brake adjustment ACTIVE Rear Fork Pivot 50 Rear Fork (c) 4-Stroke.net Pivot Bushing 12-12 13. HYDRAULIC BRAKE ACTIVE 50 13 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HYDRAULIC BRAKE __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------BRAKE FLUID CHANGE/AIR BLEED--------------------------------BRAKE PAD/DISK --------------------------------------------------------BRAKE MASTER CYLINDER ------------------------------------------BRAKE CALIPER ---------------------------------------------------------- (c) 4-Stroke.net 13- 2 13- 3 13- 4 13- 5 13- 6 13- 9 13 13-0 13. HYDRAULIC BRAKE ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 2.5 3.5kg-m 2.4 3.0kg-m 13-1 50 13. HYDRAULIC BRAKE ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Drain the brake fluid from the hydraulic brake system before disassembly. • Do not allow any foreign matters entering the brake reservoir when filling the brake reservoir with brake fluid. • Be careful not to splash brake fluid on any coated surfaces and instrument covers to avoid damage. • Inspect the brake operation before riding. • Brake fluid will damage painted, coated surfaces and plastic parts. When working with brake fluid, use shop towels to cover and protect painted, rubber and plastic parts. Wipe off any splash of brake fluid with a clean towel. Do not wipe the motorcycle with a towel contaminated by brake fluid. • Make sure to use recommended brake fluid. Use of other unspecified brake fluids may cause brake failure. SPECIFICATIONS Item Brake disk thickness Brake disk runout Brake master cylinder I.D. Brake master cylinder piston O.D. Brake caliper piston O.D. Brake caliper cylinder I.D. TORQUE VALUES Caliper holder bolt Pad pin bolt Brake fluid tube bolt Caliper bleed valve Master cylinder holder bolt Standard Limit (mm) 4 0.15 12.7 12.743 12.657 12.684 25.4 25.45 25.335 25.368 Service Limit (mm) 3.0 ⎯ 12.75 12.64 25.50 25.30 2.40 3.0kg-m 1.5 2.0kg-m 2.5 3.5kg-m 0.4 0.7kg-m 1.0 1.4kg-m (c) 4-Stroke.net SPECIAL TOOL Snap ring pliers 13-2 13. HYDRAULIC BRAKE ACTIVE TROUBLESHOOTING Loose brake lever • Air in hydraulic brake system • Brake fluid level too low • Hydraulic brake system leakage Tight brake lever • Seized piston • Clogged hydraulic brake system • Smooth or worn brake pad Hard braking • Seized hydraulic brake system • Seized piston Poor brake performance • Contaminated brake pad surface • Brake disk or wheel not aligned Brake noise • Contaminated brake pad surface • Excessive brake disk runout • Incorrectly installed caliper • Brake disk or wheel not aligned (c) 4-Stroke.net 13-3 50 13. HYDRAULIC BRAKE ACTIVE 50 Screws BRAKE FLUID CHANGE/AIR BLEED Place the motorcycle on its main stand on level ground and set the handlebar upright. Remove the two screws attaching the brake fluid reservoir cap. Use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid. Connect a transparent hose to the brake caliper bleed valve and then loosen the bleed valve nut. Use a syringe to draw the brake fluid out through the hose. BRAKE FLUID REFILLING Connect a transparent hose and syringe to the brake caliper bleed valve and then loosen the bleed valve nut. Fill the brake reservoir with brake fluid and use the syringe to draw brake fluid into it until there is no air bubbles in the hose. Then, tighten the bleed valve nut. Bleed Valve Brake Reservoir (c) 4-Stroke.net • When drawing brake fluid with the syringe, the brake fluid level should be kept over 1/2 of the brake reservoir height. • Use only the recommended brake fluid. Bleed Valve Recommended Brake Fluid: DOT-4 Brake Lever BRAKE SYSTEM BLEEDING Connect a transparent hose to the bleed valve and fully apply the brake lever after continuously pull it several times. Then, loosen the bleed valve nut to bleed air from the brake system. Repeat these steps until the brake system is free of air. When bleeding air from the brake system, the brake fluid level should be kept over 1/2 of the brake reservoir height. Bleed Valve 13-4 13. HYDRAULIC BRAKE ACTIVE 50 Bolts BRAKE PAD/DISK BRAKE PAD REPLACEMENT Remove the two bolts attaching the brake caliper holder. The brake pads can be replaced without removing the brake fluid tube. Remove the brake caliper. Pin Bolts Remove the pad pin bolts and brake pads. Pad Spring Remove the pad springs. (c) 4-Stroke.net ASSEMBLY Assemble the brake pads in the reverse order of removal. Tighten the pad pin bolts. Torque: 1.2 2.0kg-m Tighten the pad pin bolt caps. Do not tighten the pad pin bolt caps excessively. Torque: 0.2 0.4kg-m 13-5 Pin Bolts 13. HYDRAULIC BRAKE ACTIVE 50 BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0mm Measure the brake disk runout. Service Limit: 0.3mm Fluid Tube Bolt BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic brake system. Do not splash brake fluid onto any rubber, plastic and coated parts. When working with brake fluid, use shop towels to cover these parts. Remove the two master cylinder holder bolts and remove the master cylinder. Bolt Fluid Tube When removing the brake fluid tube bolt, be sure to place towels under the tube and plug the tube end to avoid brake fluid leakage and contamination. (c) 4-Stroke.net 13-6 13. HYDRAULIC BRAKE ACTIVE 50 DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Pliers Master Cylinder Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Spring Main Piston INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm replace if over (c) 4-Stroke.net Measure the brake master cylinder piston O.D. Service Limit: 12.64mm replace if below 13-7 Snap Ring 13. HYDRAULIC BRAKE ACTIVE 50 ASSEMBLY Before assembly, apply brake fluid to all removed parts. Install the spring together with the 1st rubber cup. • During assembly, the master cylinder, main piston and spring must be installed as a unit without exchange. • When assembling the piston, soak the cups in brake fluid for a while. Fluid Tube Bolt Install the main piston and snap ring. Install the rubber cover. Install the brake lever. Place the brake master cylinder on the handlebar and install the master cylinder holder with the “UP” mark facing up, aligning the tab on the holder with the hole in the handlebar. First tighten the upper bolt and then tighten the lower bolt. Torque: 1.0 1.4kg-m (c) 4-Stroke.net “UP” Mark Sealing Washer Bolt Install the brake fluid tube with the bolt and two sealing washers. Then, install the rearview mirror. Fill the brake reservoir with recommended brake fluid to the upper level. Bleed air from the hydraulic brake system. (Refer to 13-4.) 13-8 13. HYDRAULIC BRAKE ACTIVE 50 BRAKE CALIPER REMOVAL Remove the brake caliper and brake pad springs. Place a clean container under the brake caliper and disconnect the brake fluid tube from the brake caliper. Be careful not to splash brake fluid on any coated surfaces. Caliper Seat Caliper Seat DISASSEMBLY Remove the brake caliper seat from the brake caliper. Compressed Air Remove the pistons from the brake caliper. Use compressed air to press out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons. (c) 4-Stroke.net Push the piston oil seals inward to remove them. Clean each oil seal groove with brake fluid. Be careful not to damage the piston surface. 13-9 Piston Oil Seals 13. HYDRAULIC BRAKE ACTIVE 50 INSPECTION Check each piston for scratches or wear. Measure each piston O.D. with a micrometer gauge. Service Limit: 25.45mm replace if below Check each caliper and caliper cylinder for scratches or wear and measure the caliper cylinder I.D. Service Limit: 25.30 mm replace if over ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the oil seals and then install the brake caliper pistons with the grooved side facing out. (c) 4-Stroke.net Install the piston with its outer end protruding 3 5mm beyond the brake caliper. Wipe off excessive brake fluid with a clean shop towel. Apply silicon grease to the brake caliper seat pin and caliper inside. Install the brake caliper seat. 13-10 13. HYDRAULIC BRAKE ACTIVE INSTALLATION Install the brake caliper onto the right front fork and tighten the bolts. Torque: 2.4 3.0kg-m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 2.4 3.0kg-m Add the recommended brake fluid into the brake reservoir and bleed air from the brake system. (Refer to 13-4.) (c) 4-Stroke.net 13-11 50 14. FRAME COVER ACTIVE 50 14 14 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVER __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14- 2 FRAME COVER------------------------------------------------------------- 14- 3 (c) 4-Stroke.net 14-0 14. FRAME COVER ACTIVE SCHEMATIC DRAWING (c) 4-Stroke.net 14-1 50 14. FRAME COVER ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The exhaust muffler must be removed when it is cold to avoid burns. • When installing the exhaust muffler, first tighten the exhaust muffler joint lock nuts and then tighten the exhaust muffler hanger lock bolt. TORQUE VALUES Rear carrier lock bolt Exhaust muffler joint lock nut 3.0 4.0kg-m 0.8 1.2kg-m (c) 4-Stroke.net 14-2 14. FRAME COVER FRAME COVER ACTIVE Back Cover 50 Key Molding BACK COVER REMOVAL Remove the key molding. Remove the two screws attaching the back cover. Remove the back cover. The installation sequence is the reverse of removal. Bolt MET-IN BOX REMOVAL Open seat with key and remove five screws of the rear hand grip cover. Remove the rear hand grip. Remove the met-in box. The installation sequence is the reverse of removal. Met-in Box FRAME BODY COVER REMOVAL Screw seat cable Open the seat. Remove the back cover (page 14-3). Disconnect the seat cable. Remove the met-in box (page 14-3). Remove the two screws from right side and left side of the frame body cover. Remove the frame body cover. The installation sequence is the reverse of removal. (c) 4-Stroke.net Side Cover R/L SIDE COVER REMOVAL Remove the three screws attaching the side cover. Remove the side cover. The installation sequence is the reverse of removal. Screws 14-3 14. FRAME COVER ACTIVE 50 Screws FRONT COVER REMOVAL Remove the R/L side cover (page 14-3). Remove the six screws from right side and left side of the front cover. Remove the screw from front side of the front cover. Remove the front cover. The installation sequence is the reverse of removal. Screws Conter covers CETER COVER REMOVAL Remove the back cover(page 14-3) Remove the met-in box(page 14-3). Remove the center cover. The installation sequence is the reverse of removal. Screw REAR LIGHT SET REMOVAL Open the seat. Remove the R/L side cover (page 14-3). Remove the rear carrier (page 14-3). Remove the frame body cover (page 14-4). Remove the two screws from right side and left side of the rear light set. Disconnect the wire connector of rear light set. Remove the rear light set. The installation sequence is the reverse of removal. Wire connector (c) 4-Stroke.net Rear light set 14-4 14. FRAME COVER REAR FRENDER REMOVAL Open the seat. Remove the R/L side cover (page 14-3). Remove the frame body cover (page 14-4). Remove the rear light set (page 14-4). Remove the two screws from right side and left side of the rear frender. Remove the rear frender. The installation sequence is the reverse of removal. ACTIVE Screw Rear Cover 50 Screw Screw HANDLEBAR FRONT/REAR COVER REMOVAL Remove the three screws attaching the handlebar rear cover. Disconnect the handlebar rear cover. Remove the handlebar front cover. Disconnect the headlight and the signal wire connector. The installation sequence is the reverse of removal. Front Cover The Headlight And The Signal Wire (c) 4-Stroke.net Screw 14-5 14. FRAME COVER ACTIVE 50 Horn Wire Disconnect the instrument light and the horn wire connector. Instrument Light Wire Rear Cover Disconnect the speedometer cable. Remove the handlebar rear cover. The installation sequence is the reverse of removal. Speedometer Cable EXHAUST MUFFLER REMOVAL The exhaust muffler must be removed when it is cold to avoid burns. Remove the two exhaust muffler joint lock nuts. Remove the exhaust muffler lock nut. Remove the exhaust muffler. (c) 4-Stroke.net INSPECTION Inspect the exhaust muffler joint and gasket for damage, deformation or leakage. Replace if necessary. I NSTALLATION Install the exhaust muffler joint and gasket and then install the exhaust muffler. First tighten the two exhaust muffler joint lock nuts and then tighten the exhaust muffler lock nut. Torques: Exhaust muffler joint lock nut: 0.8 1.2kg-m Exhaust muffler hanger lock bolt: 2.4 3.0kg-m Nuts Nut 14-6 15. IGNITION SYSTEM ACTIVE 50 15 __________________________________________________________________________________ 15 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------IGNITION COIL------------------------------------------------------------CDI UNIT--------------------------------------------------------------------PULSER COIL/EXCITER COIL------------------------------------------ (c) 4-Stroke.net 15- 2 15- 3 15- 4 15- 5 15- 6 15-0 15. IGNITION SYSTEM CDI Unit Pulser Coil ACTIVE Wire Harness A.C. Generator Wire Connector (c) 4-Stroke.net 15-1 50 Ignition Switch Ignition Coil 15. IGNITION SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • Inspect the ignition system according to the sequence specified in the Troubleshooting 15-2. • The ignition system has an electrical auto aligner in the CDI unit, so the ignition timing is not adjustable. • Do not drop or impact the CDI unit with strong force to avoid damage. Be careful when removing it. • Loose connector and poor wire connection are the main causes of faulty ignition system. Check each connector before operation. • Check the spark plug heat range. Use of spark plug with improper heat range is the main cause of poor engine performance or burned engine. • Perform inspections according to the servicing procedures specified in each section. SPECIFICATIONS Item Standard type Standard CHAMPION-P-RZ9HC Spark plug Spark plug gap 0.6 0.7mm Ignition timing Ignition coil resistance (20 ) “F” mark:15±2°/1,700rpm Primary coil Secondary with plug cap coil without plug cap Pulser coil resistance (20 ) Exciter coil resistance (20 ) Ignition coil primary side max. voltage Pulser coil max. voltage Exciter coil max. voltage ⎯ 0.2 0.3Ω 7.2 8.2KΩ 4.2 5.2KΩ 80 160Ω 550 650Ω 140V min. 1.5V/300rpm min. 350 1000rpm 400V max. (c) 4-Stroke.net TESTING INSTRUMENT Electric Tester Timing light Tachometer 15-2 15. IGNITION SYSTEM ACTIVE TROUBLESHOOTING Engine stalls immediately after it starts • Weak spark • Improper ignition timing • Faulty CDI unit No spark at plug • Faulty ignition switch • Poorly connected, broken or shorted wire −Between pulser coil, CDI unit and ignition coil −Between exciter coil and CDI unit −Between CDI unit and ignition coil −Between CDI unit and ignition switch −Between ignition coil and spark plug Engine starts but runs poorly • Faulty ignition coil • Poorly connected wire • Faulty spark plug • Spark plug cap electricity leakage • Faulty A.C. generator • Stator not installed properly (Loose) • Faulty CDI unit (c) 4-Stroke.net 15-3 50 15. IGNITION SYSTEM ACTIVE 50 IGNITION COIL CONTINUITY TEST This test is to inspect the continuity of ignition coil. Remove the right decorative cover. Measure the resistance between the ignition coil primary coil terminals. Resistance(20 ): 0.2 0.3Ω Ignition Coil Measure the secondary coil resistance between the spark plrg cap and the primary coil terminal as Figure A shown. Resistance(20 )(with plug cap): 7.2 8.2KΩ Figure A Figure B Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown. Resistance(20 ) (without plug cap): 4.2 5.2KΩ (c) 4-Stroke.net 15-4 15. IGNITION SYSTEM ACTIVE 50 CDI Coupler CDI UNIT REMOVAL Remove the left side cover (page 14-3). Disconnect the CDI coupler and remove the CDI unit. CDI Unit INSPECTION Measure the resistance between the CDI unit terminals. Replace the CDI unit if the readings are not within the specifications in the table below. • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester or measurements in an improper range may give false readings. • Use a Sanwa Electric Tester or Kowa Electric Tester TH-5H for testing • In this table, “Needle swings then returns” indicates that there is a charging current applied to a condenser. The needle will then remain at “∞” unless the condenser is discharged. Black/Yellow Black/Red Blue/Yellow Testing Range Use the xKΩ range for the Sanwa Tester. Use the x100Ω range for the Kowa Tester. Green (c) 4-Stroke.net Unit: KΩ (+)Probe Black/ Yellow (-)Probe Black/ Yellow Black/ Red Black/ White ∞ Blue/Yell ow Green ∞ ∞ ∞ 0.1-10 ∞ ∞ ∞ ∞ Black/ Red ∞ Black/ White ∞ ∞ Blue/Yell ow ∞ 0.5-50 0.5-200 Green ∞ 0.1-10 0.2-30 15-5 1-50 1-100 Black/White 15. IGNITION SYSTEM ACTIVE 50 Black/Yellow EXCITER COIL/PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the met-im box. Disconnect the A.C. generator wire connector. Measure the pulser coil resistance between the blue/yellow wire and ground. Resistance: 80 160Ω Black/Red EXCITER COIL INSPECTION Disconnect the exciter coil wire coupler and measure the resistance between the black/red wire terminal and ground. Resistance: 550 650Ω (c) 4-Stroke.net 15-6 16. CHARGING SYSTEM ACTIVE 50 16 __________________________________________________________________________________ __________________________________________________________________________________ 16 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CHARGING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------BATTERY -------------------------------------------------------------------PERFORMANCE TEST---------------------------------------------------A.C. GENERATOR --------------------------------------------------------REGULATOR/RECTIFIER------------------------------------------------ (c) 4-Stroke.net 16- 2 16- 3 16- 4 16- 5 16- 5 16- 6 16-0 16. CHARGING SYSTEM ACTIVE Battery Positive Cable Regulator/Rectifier Starter Relay Battery (c) 4-Stroke.net 16-1 Fuse 50 16. CHARGING SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The battery is a MF battery which needs no refilling of distilled water. • Do not quick charge the battery. Be sure to use a MF battery charger and the battery temperature should not exceed 45 . • Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, keep sparks and flames away from a charging battery. • When inspecting the A.C. generator, use an electric tester. • Route the charging system wires properly to avoid shorted wire due to wires being twisted or kinked. SPECIFICATIONS Battery capacity Electrolyte specific gravity Charging current Charging rpm A.C. generator Capacity Regulator/Rectifier Charging coil resistance 12V5AH 1.260 1.280 20 10A max. 2,500 rpm (min.) 1.3A min./6,000 rpm No contact point type 0.2 0.3Ω TORQUE VALUES A.C. generator stator bolt A.C. generator rotor bolt (c) 4-Stroke.net SPECIAL TOOLS Flywheel holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester 16-2 16. CHARGING SYSTEM ACTIVE TROUBLESHOOTING No power • Dead battery • Fuse burned out • Disconnected battery cable • Faulty ignition switch Low power • Weak battery • Loose battery connection (terminal) • Charging system failure • Faulty regulator/rectifier Intermittent power • Loose battery cable connection • Loose charging system connection • Loose lighting system connection Charging system failure • Loose, broken or shorted wire or connector • Faulty regulator/rectifier • Faulty A.C. generator (c) 4-Stroke.net 16-3 50 16. CHARGING SYSTEM ACTIVE Terminal (+) BATTERY 50 Battery REMOVAL Open the seat and battery cover. First disconnect the battery negative cable and then the positive cable. Remove the battery. When disconnecting the battery positive (+) cable, do not touch the frame with tool; otherwise it will cause short circuit and sparks to damage the battery and ignite the gasoline. The installation sequence is the reverse of removal. First connect the positive (+) cable and then the negative (-) cable to avoid short circuit. BATTERY VOLTAGE (OPEN CIRCUIT VOLTAGE) INSPECTION Remove the left side cover. Disconnect the battery cables. Measure the voltage between the battery terminals. Fully charged : 13.1V Undercharged : 12.3V Battery charging inspection must be performed with a voltmeter. CHARGING Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. (c) 4-Stroke.net • Keep flames and sparks away from a charging battery. • Turn power ON/OFF at the charger, not at the battery terminals to prevent sparks near the battery to avoid explosion. • Charge the battery according to the current specified on the battery. • Quick charging should only be done in an emergency. • Measure the voltage 30 minutes after the battery is charged. Charging current : Standard : 0.5A Charging time : Standard : 5 10 hours After charging: Open circuit voltage: 12.8V min. 16-4 16. CHARGING SYSTEM PERFORMANCE TEST ACTIVE Positive Probe Perform this test with a fully charged battery. Start and warm up the engine for 10 minutes. Connect the battery positive cable to the ammeter positive probe and the battery negative cable to the ammeter negative probe. Negative Probe. Then connect the voltmeter across the battery terminals to test the charging voltage. CHARGING PERFORMANCE: Headlight Charging Switch rpm 3000 rpm 8000 rpm Position rpm 4A 16V 6.3A 16.7V OFF (Day) 2150 max. rpm 1.1A 14V 2.1A 14V ON (Night) 2150 max. (1.0A min.) (3.7A min.) Limit Voltage Test: Start the engine and gradually increase the engine speed to measure the limit voltage. Limit Voltage: 14.5±0.5V Note: Test when the battery is fully charged. When testing the limit voltage, use a tachometer for operation. (c) 4-Stroke.net A.C. GENERATOR INSPECTION Disconnect the A.C. generator pink and yellow wires and measure the resistance between the pin and yellow wires. Resistance: 0.3 1.5Ω Do not connect the A.C. generator pink and yellow wires to ground wire. 16-5 50 16. CHARGING SYSTEM ACTIVE 50 REGULATOR/RECTIFIER REMOVAL Remove the front cover(page 14-4). Remove the regulator/rectifier lock nut and disconnect the regulator/rectifier wire coupler. Measure the resistances between the regulator/rectifier wire terminals. Replace the regulator/rectifier if the readings are not within the specifications in the table below. Regulator/Rectifier • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester or measurements in an improper range may give false readings. Use a Sanwa Electric Tester or Kowa Electric Tester for testing. (+)Probe Testing Range Range for the Sanwa Tester: xKΩ Range for the Kowa Tester: x100Ω (-)Probe A (Red) A (Red) B C ∞ ∞ ∞ ∞ 5K-100 K (c) 4-Stroke.net B (Yellow) D (Yellow) (White) (green) ∞ C (White) 3-50 ∞ D (green) ∞ 5-100K ∞ ∞ Note: The readings in this table are taken with a Sanwa Tester. 16-6 17. STARTING SYSTEM ACTIVE 50 17 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 17 __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM DIAGRAM --------------------------------------SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------STARTER MOTOR --------------------------------------------------------STARTER RELAY---------------------------------------------------------- (c) 4-Stroke.net 17- 1 17- 2 17- 2 17- 3 17- 5 17-0 17. STARTING SYSTEM ACTIVE STARTING SYSTEM DIAGRAM Battery Starter Motor Starter Relay 7A (c) 4-Stroke.net R/W 12V5AH 17-1 50 17. STARTING SYSTEM ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed in the frame. • Refer to Section 8-3 for the removal of starter clutch. • When connecting the starting system wires, connect them securely to avoid hard starting due to poor connection. SPECIFICATIONS Item Standard Limit (mm) Service Limit (mm) ─ 8.5 Starter motor brush length TORQUE VALUES Starter motor bolt Starter clutch lock nut SPECIAL TOOLS 0.8 1.2kg-m 3.2 4.0kg-m TROUBLESHOOTING Starter motor won‘t turn • Fuse burned out • Weak battery • Faulty ignition switch • Faulty starter clutch • Faulty starter relay • Poorly connected, broken or shorted wire • Faulty starter motor Lack of power • Weak battery • Loose wire or connection • Foreign matter stuck in starter motor or gear Starter motor rotates but engine does not start • Faulty starter clutch • Reverse rotation of starter motor • Weak battery (c) 4-Stroke.net 17-2 17. STARTING SYSTEM ACTIVE 50 STARTER MOTOR REMOVAL Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly. Disconnect the starter motor wire. Remove the three starter motor mounting bolts and the motor. Mounting Bolts Starter Gear Case O-Ring DISASSEMBLY Remove the four starter motor case mounting screws, and disassemble them. Gasket INSPECTION Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils. Turn the outer race of the bearing with your fingers. The bearing should turn smoothly and quietly. Also check that the inner race of the bearing fits tightly on the armature shaft. Gear Cover Bearing Commutator (c) 4-Stroke.net Check for continuity between pairs of commutator bars. Also, make a resistance check between individual commutator bars and the armature shaft. There should be no continuity. Commutator bar pairs Continuity: normal Commutator bars and armature shaft No continuity: normal 17-3 Continuity No Continuity 17. STARTING SYSTEM ACTIVE 50 Continuity Check for continuity from the cable terminal to the brush holder and from the cable terminal to the brush. Cable terminal and brush holder No continuity: normal Cable terminal and brush Continuity: normal No Continuity Inspect the brushes for wear or damage. Measure the brush length. Service limit: 8.5mm Inspect the brush springs for wear or fatigue. Brush Springs INSDTALLATION Install a new O-ring and apply oil to it. Install the starter motor and tighten the three mounting bolts securely. (c) 4-Stroke.net Install the ground terminal properly as shown with starter motor mounting bolt. Connect the starter motor connector. Install the starter clutch (page ?) Install the front cover. Mounting Bolts 17-4 17. STARTING SYSTEM STARTER RELAY ACTIVE Starter Relay INSPECTION Remove the left side cover. Disconnect the starter relay coupler and then remove the starter relay. Connect the starter relay yellow/red terminal to the 12V battery positive (+) terminal and the relay green terminal to the battery negative (-) terminal. Check for continuity between the starter relay red and red/white terminals. The relay is normal if there is continuity. (c) 4-Stroke.net 17-5 50 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 18 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 18 __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT __________________________________________________________________________________ SERVICE INFORMATION-----------------------------------------------TROUBLESHOOTING----------------------------------------------------HEADLIGHT/INSTRUMENT -------------------------------------------TURN SIGNAL LIGHT ---------------------------------------------------STOP LIGHT/TAIL LIGHT ----------------------------------------------IGNITION SWITCH -------------------------------------------------------STARTER BUTTON/HORN BUTTON---------------------------------HANDLEBAR SWITCHES-----------------------------------------------DIMMER SWITCH/GEARSHIFT DISPLAYER ----------------------FUEL UNIT ------------------------------------------------------------------ (c) 4-Stroke.net 18- 1 18- 1 18- 2 18- 3 18- 3 18- 3 18- 4 18- 5 18- 6 18- 7 18-0 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 SERVICE INFORMATION GENERAL INSTRUCTIONS • All plastic plugs have locking tabs that must be released before disconnecting. • An electric tester must be used for checking the continuity between two points. The electric tester also contains a voltmeter which can be used to measure voltage. • Different bulbs have different specifications. When replacing, use a new bulb of the same specifications to avoid damage of the electrical equipment. • The continuity check of switches can be made without removing the switches from the motorcycle. SPECIFICATIONS Headlight Stoplight/Taillight Turn signal light Turn signal indicator light Instrument light High beam indicator light Fuse 12V 35/35W 12V 21/5W 12V 10Wx4 12V 3.4W x2 12V 1.7Wx2 12V 1.7W 10A TROUBLESHOOTING Light does not come on when ignition switch is “ON” • Burned bulb • Faulty ignition or light switch • Fuse burned out • Dead battery or loose battery wire Headlight beam does not change when dimmer switch is operated • Faulty or burned bulb • Faulty dimmer switch • Loose wire connection (c) 4-Stroke.net Light comes on but dims • Weak battery • Wire or switch resistance too high • Aged bulb or faulty lighting circuit 18-1 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 HEADLIGHT REMOVAL Remove the handlebar front cover (page 14-5). Remove the headlight unit and disconnect the headlight wire coupler. Remove the headlight bulb and bulb socket. Check the bulb for damage and replace with a new one if necessary. INSTALLATION Install the headlight in the reverse order of removal. After installation, adjust the headlight beam. Turn signal Bulbs INSTRUMENT INSTRUMENT BULBS REPLACEMENT Remove the handlebar rear cover (page 14-5). Remove the bulbs and replace with new ones. (c) 4-Stroke.net Nighttime light SPEEDOMETER REMOVAL Disconnect the speedometer cable. Disconnect the speedometer wire connector. Remove the three screws attaching the speedometer seat. Remove the speedometer. INSTALLATION The installation sequence is the reverse of removal. Screws 18-2 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 TURN SIGNAL LIGHT Remove the cover FR handle. Remove the two turn signal light bulb. The installation sequence is the reverse of removal. Light Shell Bulb Light Shell STOP LIGHT/TAILLIGHT Remove the two taillight shell screws and the shell. Remove the bulb and check the bulb for damage. Replace with a new one if necessary. Bulb Specification: 12V.21/5W The installation sequence is the reverse of removal. Screws IGNITION SWITCH Disconnect the ignition switch wire coupler. Remove the two bolts attaching the ignition switch. Remove the ignition switch. (c) 4-Stroke.net Bolts INSPECTION Check for continuity between the wires indicated below. Color Black Position Red OFF ON 18-3 ○ ○ Black/ White ○ Green ○ 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 STARTER BUTTON Disconnect the right switch wire coupler. Check for continuity between the black and yellow/red wires. Color Position Black Yellow/Red ○ ○ FREE PUSH Starter Button HORN BUTTON Remove the decorative covers under the fuel tank. Disconnect the left switch wire coupler. Check for continuity between the black and light green wires. Color Position Black Light Green ○ ○ FREE PUSH Horn Button Light Green Black HORN Remove the steering head decorative cover. Disconnect the horn wire coupler. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals. Replace the horn if it does not sound. (c) 4-Stroke.net 18-4 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 HANDLEBAR SWITCHES FRONT STOP SWITCH Disconnect the front stop switch wire coupler. Check for continuity between the front stop switch wires. Brake lever applied: There is continuity. Brake lever released: There is no continuity. Front Stop Switch REAR STOP SWITCH Remove the right side cover. Disconnect the rear stop switch wire coupler. Check for continuity between the rear stop switch wires. Brake pedal depressed: There is continuity. Brake pedal released: There is no continuity. TURN SIGNAL SWITCH Disconnect the turn signal switch wire coupler. Check for continuity between the turn signal switch wires. Color Position (c) 4-Stroke.net Orange Gray Light Blue ○ ○ R ○ L ○ Turn Signal Switch Headlight Switch HEADLIGHT SWITCH Disconnect the headlight switch wire coupler. Check for continuity between the headlight switch wires. Color Position B Br Br/W ○ ○ ○ 18-5 ○ ○ B W/L ○ ○ 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE Passing Switch DIMMER SWITCH 50 Dimmer Switch Disconnect the dimmer switch wire coupler. Check for continuity between the dimmer switch wires. Color Position White/Blue White ○ ○ LO ○ N ○ ○ HI Blue ○ ○ PASSING SWITCH Position Color Blue White ○ ○ FREE PUSH GEARSHIFT DISPLAYER 1.Disconnect the gearshift displayer wire coupler. 2.Check if all the gearshift displayer wire connect correctly or not. (c) 4-Stroke.net G/R L/R B/L W/L R/W N ○ 1 2 3 4 ○ B ○ ○ ○ ○ gearshift displayer wire ○ ○ ○ ○ 18-6 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 FUEL UNIT No Smoking REMOVAL Remove the seat.(Refer to 4-10.) Disconnect the fuel unit wire connectors. Do not damage the fuel unit wire. Remove the fuel unit. Be careful not to bend or damage the fuel unit float arm. Fuel Unit Wire L/W Y/W INSPECTION Remove the fuel unit. Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions. Wire Terminals G~Y/W G~L/W Y/W~L/W Upper 36Ω 550Ω 600Ω Lower 700Ω 160Ω 600Ω G (c) 4-Stroke.net FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON” Before performing the following test, operate the turn signals to determine that the battery circuit is normal. Check the fuel gauge needle for correct indication by moving the fuel unit float up and down. Float Position Upper Lower Needle Position “F”(Full) “E”(Empty) Fuel Unit 18-7 18. LIGHTS/INSTRUMENTS/SWITCHES/HORN/ FUEL UNIT ACTIVE 50 INSTALLATION The installation sequence is the reverse of removal. Align the groove on the fuel unit with the flange on the fuel tank. (c) 4-Stroke.net Flange Groove 18-8