Tightening Torque - Engine - Team-BHP.com Bolt Caliper 2.2 ~ 2.8 Kg.m Pulsar DTS-i UG-III-180cc Training Notes Pulsar DTS-i UG-III-180cc Training Notes Tightening Torque - Frame Tightening
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Deale
r D
eve
lop
ment
Cente
r103
Deale
r D
eve
lop
ment
Cente
r104
Clu
tch
Nu
t (L
H T
hre
ad
s)
5.0
Kg
.m
Ca
msh
aft
Sp
roc
ke
t A
lle
n B
olt
1.4
Kg
.m (
Lo
cti
te 2
43)
4.5
Kg
.m
Ro
tor
Mo
un
tin
g B
olt
Sta
rte
r M
oto
r M
ou
nti
ng
Bo
lts
1.1
Kg
.m
Kic
k G
uid
e A
lle
n B
olt
s
1.2
Kg
.m
Dra
in B
olt
2.5
Kg
.m
Cylin
de
r H
ea
d C
ove
r B
olt
s
3.5
Kg
.m
Cylin
de
r H
ea
d C
ove
r N
uts
1.0
~ 1
.5 K
g.m
Sp
ark
Plu
gs (
2 N
os.)
1.4
Kg
.m
Fro
nt
Axle
Nu
t
4.0
~ 5
.0 K
g.m
Re
ar
Axle
Nu
t
8.0
~ 1
0.0
Kg
.m
To
rqu
e R
od
Nu
t
3.0
~ 4
.0 K
g.m
Sle
eve
Nu
t
7.0
~ 8
.0 K
g.m
Re
ar
Sp
roc
ke
t M
tg.
Nu
t
1.8
~ 2
.5 K
g.m
(L
octi
te 2
43)
Ha
nd
le B
ar
Ho
lde
r B
olt
s
2.0
~ 2
.2 K
g.m
Ste
eri
ng
To
p C
ap
Bo
lt
3.5
Kg
.m0.5
Kg
.m
Stg
. S
tem
Nu
t (s
lott
ed
)U
pp
er
Cla
mp
Alle
n B
olt
1.8
~ 2
.0 K
g.m
Lo
we
r C
lam
p B
olt
2.5
~ 3
.5 K
g.m
Sw
ing
Arm
Piv
ot
Nu
t
8.0
~ 1
0.0
Kg
.m
RS
A M
ou
nti
ng
Do
me
Nu
t
3.5
~ 4
.0 K
g.m
2.2
~ 2
.8 K
g.m
Ca
lip
er
Insta
ll B
olt
sB
rak
e D
isc
Alle
n B
olt
s
0.9
~ 1
.1 (
Lo
cti
te 2
43)
Ba
njo
Bo
lt C
alip
er
2.2
~ 2
.8 K
g.m
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Tig
hte
nin
g T
orq
ue -
Fra
me
Tig
hte
nin
g T
orq
ue -
Eng
ine
Deale
r D
eve
lop
ment
Cente
r105
Deale
r D
eve
lop
ment
Cente
r106
Fit
tin
g o
f O
il S
ea
ls a
nd
Be
ari
ng
s :
Cra
nk
ca
se
RH
(C
lutc
h S
ide
)
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•B
earin
g f
or
‘In
pu
t S
haft
Assem
bly
’
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•B
earin
g f
or
‘Ou
tpu
t S
haft
Assem
bly
’
Cra
nk
ca
se
LH
(M
ag
ne
to S
ide
)
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•B
earin
g f
or
‘Ou
tpu
t S
haft
’
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•B
earin
g f
or
‘In
pu
t S
haft
’
No
te :
Do
no
t use in
ner
guid
e w
hile
fitt
ing
th
e b
earing
fo
r ‘Inp
ut
Shaft
’ in
‘C
rankcase LH
’ as th
is w
ill d
am
ag
e th
e p
rotr
ud
ing
lu
g o
f cra
nkcase
casting
. S
hie
ld o
f b
rg.
must
be o
n c
rankcase s
ide/p
rotr
ud
ing
lug
sid
e.
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•B
earin
g f
or
‘Bo
dy B
ala
ncer
gear
Assem
bly
’
Use
Be
ari
ng
Dri
ve
r se
t (P
. N
o.
37
10
30
61
)
Fit
:
•O
il seal
on
‘G
uid
e S
tart
er
Assem
bly
’
•‘O
’ rin
g o
n ‘
Gu
ide S
tart
er
Assem
bly
’.
•D
am
per
Fit
:
•O
il seal
for
‘Ou
tpu
t S
haft
’
Fit
:
•O
il seal
for
‘Gear
Ch
an
ger
Lever’
Clu
tch
Co
ve
r
Fit
:
•O
il seal
for
‘Kic
k S
haft
Assem
bly
’
Fit
:
•O
il seal
for
‘Clu
tch
Lever’
on
‘C
lutc
h C
over’
Asse
mb
ly o
f S
ub
asse
mb
lie
s :
Ma
gn
eto
Co
ve
r
Fit
:
•‘H
arn
ess’
in t
he ‘
Co
ver’
•‘S
top
per’
an
d t
igh
ten
th
e ‘
Scre
w’
(Use L
octite
24
3)
•‘P
uls
ar
Co
il’ a
nd
tig
hte
n 2
‘S
cre
ws’
(Use L
octite
24
3)
•‘S
tato
r A
ssem
bly
’ an
d t
igh
ten
2 ‘
Bo
lts’
(Use L
octite
24
3)
•2
‘D
ow
el
Pin
s’
Ca
msh
aft
Asse
mb
ly
Fit
:
•P
ara
lle
l P
in (
A)
•D
e-c
om
pre
ssio
n M
ech
an
ism
(B
)
•‘W
ash
er’
(C
)
•W
ash
er
(D)
E
D
A
BC
F
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r108
Deale
r D
eve
lop
ment
Cente
r107
•U
sin
g A
rbo
ur
Pre
ss
Fit
:
•‘B
igg
er
Bearin
g’
(E)
•‘S
mall
Bearin
g’
(F)
Cylin
de
r H
ea
d
Fit
:
•V
alv
e s
team
seals
•S
lide t
he ‘
Valv
e’
fro
m b
elo
w.
•P
lac
e
the
‘V
alv
e
Sp
rin
gs’
(C&
D)
(In
ne
r a
nd
o
ute
r clo
sed
co
iled
en
ds
pla
ced
at
the b
ott
om
sid
e)
•V
alv
e S
prin
g R
eta
iner’
(B
)
Us
ing
th
e
sp
. to
ol
Va
lve
Sp
rin
g
Co
mp
re
ss
or
37
10
31
0
7
&
Ad
ap
tor
37
10
DJ
78
•P
ress t
he v
alv
e s
prin
gs
•F
it
the
co
tter
valv
es
(A)
&
rele
ase t
he s
pecia
l to
ol
He
ad
Co
ve
r
Fit
:
•R
olle
r ro
cker
arm
•T
ap
pet
Scre
w
•T
ap
pet
Nu
t
•2
0 R
olle
rs i
n c
ag
e o
ute
r
No
te :
•T
here
are
2 c
ag
es i
n r
olle
r ro
cker
arm
each c
ag
e h
old
s 2
0 r
olle
rs
•In
ner
cag
e i
n A
bsent
•M
ultip
urp
ose g
rease i
s t
o b
e a
pp
lied
in o
ute
r cag
e t
o h
old
the r
olle
r firm
ly w
hile
assem
blin
g
No
te
: A
pp
ly
thin
la
yer
of
oil
on
slid
ing
surf
aces
of
part
s
for
sm
oo
th
fitt
ing
.
No
te :
Rep
eat
the s
am
e p
roced
ure
fo
r fitm
ent
of
oth
er
rolle
r ro
cker
arm
Asse
mb
lin
g H
ea
d C
ove
r
Fit
:
•R
olle
r R
ocker
Arm
•S
et
of
Pla
n a
nd
Wave W
ash
er
•R
ocker
arm
sh
aft
•G
askets
•D
um
my P
lug
s
A
B
D
C
F
E
A
B
C
Sim
ilarly
carr
y
ou
t th
e
sam
e
pro
ced
ure
to
assem
ble
th
e
oth
er
‘Valv
e’
in t
he ‘
Cylin
der
Head
’.
No
te
: E
nsu
re
that
there
is
n
o
valv
e
leakag
e.
If
req
uired
p
ou
r th
e
petr
ol
in
inta
ke
an
d
Exh
au
st
man
ifo
ld
an
d
ob
serv
e
leakag
e
at
valv
e h
ead
.
No
te :
•E
nsure
co
ncentr
ity
of
‘Thru
st
Pla
te’
w.r
.to
‘C
lutc
h
Wheel’,
‘Clu
tch
Cente
r’,
‘Clu
tch H
ousin
g’. U
sin
g S
pecia
l T
oo
l -
•T
he
Sp
ecia
l T
oo
l can
als
o
help
s
in
pre
ven
tin
g
the
cra
ckin
g
/ B
end
ing
o
f ‘T
hru
st
Pla
te’
while
re
mo
vin
g
and
re
filli
ng
th
e
thru
st
pla
te.
Ch
ain
Te
nsio
ne
r A
sse
mb
ly
Fit
:
•‘O
’ rin
g (
F)
in t
he b
od
y (
I)
•‘T
hru
st
Wash
er’
(E
)
•‘S
prin
g’
(D)
•‘C
ap
’ (B
) alo
ng
w
ith
‘S
cre
w
Inte
rnal’
an
d
‘Scre
w
Exte
rnal’
(C)
(Keep
th
e ‘
Sp
rin
g’
an
d ‘
Scre
w T
erm
inal’ f
ully
co
mp
ressed
in
sid
e)
•‘C
irclip
’ (A
)
Clu
tch
Asse
mb
ly
Assem
ble
th
e
clu
tch
p
late
s
an
d
fric
tio
n
pla
tes
in
clu
tch
cen
ter
/ clu
tch
hu
b.
Fit
:
•‘P
lain
Wash
er’
in
‘C
lutc
h C
en
ter’
/ ‘
Clu
tch
Hu
b’
•‘B
elli
velli
Wash
er’
•‘C
lutc
h P
late
’(A
) 1
No
s
•‘P
ressu
re P
late
’ 5
No
s
•‘C
lutc
h P
late
’ (B
) 4
No
s
•‘C
lutc
h P
late
’ (C
) 1
No
s
•‘W
heel
Clu
tch
’
•‘S
prin
gs’
4 N
os.
•‘T
hru
st
Pla
te’
•‘B
olt’
Usin
g S
pe
cia
l T
oo
l T
10
11
16
8
Alig
n t
he c
lutc
h a
ssly
in
to t
he c
lutc
h h
ou
sin
g.
Fit
:
•‘S
pacer’
•‘C
lutc
h A
ssly
’
AB
E
D
C
HG
F
I
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
2
14
17
1
16
9
8
12
10
5
7
6
7
6
7
6
4
6
15
11
13
3
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r110
Deale
r D
eve
lop
ment
Cente
r109
BA C
Oil P
um
p
Fit
:
•‘O
’ rin
g (
A)
on
th
e ‘
Oil
Str
ain
er’
(B
)
•‘C
lip’
(C)
Kic
k S
ha
ft A
sse
mb
ly
Fit
:
•‘P
inio
n C
om
ple
te K
ick S
tart
er’
(I)
•‘W
ash
er’
(H
)
•‘C
irclip
’ (G
)
•‘R
atc
het
Kic
k S
tart
er’
(F
)
•‘S
prin
g K
ick S
tart
er
Ratc
het’
(E
)
•‘W
ash
er
Th
rust’
(D
)
•‘C
irclip
’ (C
)
•‘W
ash
er
Th
rust’
(B
)
•‘T
hru
st
Wash
er’
(A
)
No
te
: M
atc
h
the
do
t m
ark
o
f ‘R
atc
het
Kic
k
Sta
rt’
with
resp
ect
to
‘Sp
ind
le
Kic
k
Sta
rt
Assem
bly
’ and
th
en
slid
e
‘Ratc
het
Kic
k
Sta
rter’
(F
) o
n ‘
Sp
ind
le K
ick S
tart
’
Asse
mb
ly B
ala
nc
er
Idle
r G
ea
r B
ea
rin
g
Usin
g B
ea
rin
g D
rive
r se
t (P
. N
o.:
37
10
30
61
)
Fit
:
•N
eed
le r
olle
r b
earin
gs i
n c
ran
kcase R
H a
nd
Co
ver
No
te
: A
pp
ly
oil
on
bearing
O
D
befo
re
pre
ssin
g
bearing
s
for
sm
oo
th
bearing
No
te :
En
su
re th
at
on
e sp
rin
g en
d b
utt
s ag
ain
st
sp
rin
g d
ow
el
in
‘Bala
ncer
Idle
r G
ear’
&
th
e
oth
er
en
d
of
sp
rin
g
sh
ou
ld
bu
tt
ag
ain
st
the l
ug
on
‘S
cis
so
r G
ear’
Fit
:
•‘S
prin
gs’
(D)
•‘S
cis
so
r G
ears
’ (C
)
•‘C
irclip
’ (B
)
•T
hru
st
wash
er
Sim
ilarly
carr
y
ou
t th
e
sam
e
pro
ced
ure
o
n
oth
er
sid
e
of
the
gear
to a
ssem
ble
th
e ‘
Bala
ncer
Idle
r G
ear’
co
mp
lete
ly.
C
E
F
G
H
I
BA
D
AC
BD
EC
BA
D
No
te :
Keep
this
Assem
bly
bala
ncer
idle
r g
ear
in
load
ed
co
nd
itio
n w
ith
sp
ecia
l to
ol.
Ge
ar
Co
mp
lete
Sta
rte
r C
ou
nte
r A
sse
mb
ly
Usin
g A
rbo
ur
Pre
ss
Fit
:
•‘N
eed
le R
olle
r B
earin
g’
Cra
nk
ca
se
LH
(M
ag
ne
to S
ide
)
Fit
:
•‘G
uid
e S
tart
er
Assem
bly
’
•3
‘S
cre
ws’
(A)
(Use l
octite
24
3)
Clu
tch
Co
ve
r
Fit
:
•K
ick s
haft
oil
seal
(H)
•O
il in
sp
ectio
n w
ind
ow
•W
ire c
lip (
I)
•S
et
dam
pers
(K
)
•S
et
of
pla
tes (
L)
•B
olts (
J)
•‘R
ack’
(C)
•‘S
haft
Clu
tch
Rele
ase’
(B)
in ‘
Clu
tch
Co
ver’
by r
ota
tin
g i
t slig
htly
to m
atc
h t
he t
eeth
.
•‘P
ara
llel
Pin
’ (A
) to
lo
ck t
he ‘
Sh
aft
Clu
tch
Rele
ase’
•W
ash
er
Lo
ad
ing
th
e
asse
mb
ly
Ba
lan
ce
r
Idle
r G
ea
r
Usin
g
Sp
ec
ial
To
ol
- B
ala
nc
er
Ge
ar
Ho
lde
r 3
7 1
0D
J 6
3
•S
lid
e
the
‘A
sse
mb
ly
Ba
lan
ce
r Id
ler
Gear’
in
sp
ecia
l to
ol
(A)
•R
ota
te
the
‘S
cis
so
r G
ea
r’
an
ticlo
ckw
ise t
ill t
he lu
g c
on
tacts
the t
ors
ion
sp
rin
g.
•U
sin
g
a
mark
er,
m
ark
th
e
‘Bala
ncer
Idle
r G
ear’
an
d
‘Scis
so
r G
ear
To
oth
’
Usin
g S
pe
cia
l T
oo
l
•T
urn
th
e ‘
Scis
so
r G
ear’
an
ticlo
ckw
ise s
uch
th
at
2 t
eeth
pre
-lo
ad
is
ach
ieved
. T
his
can
b
e
co
nfirm
ed
b
y
the
mark
ing
s
do
ne
pre
vio
usly
.
•H
old
ing
th
e
‘Scis
so
r G
ear’
p
re-l
oad
ed
in
th
e
ab
ove
po
sitio
n
slid
e t
he ‘
Scis
so
r G
ear’
in
to t
he s
pecia
l to
ol
co
mp
lete
ly.
Rep
eat
the s
am
e p
roced
ure
fo
r lo
ad
ing
th
e o
ther
‘Scis
so
r G
ear’
.
A
BG
FE
D
A
H
J
L
K
C
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r112
Deale
r D
eve
lop
ment
Cente
r111
•‘S
prin
g’
tors
ion
clu
tch
lever
•E
xte
rnal
lever
•‘B
olt’
•S
prin
g j
oin
t ‘A
’ (F
)
•‘P
lun
ger
Pla
te’
(E)
•‘P
lun
ger
oil
(D)
•2
‘D
ow
el
Pin
s’
•‘G
rom
met
(M)
•O
il fe
ele
r p
lug
(G
)
Ap
ply
lo
cti
te 2
43
to
all d
am
pe
r fi
tme
nt
bo
lts.
No
te
: E
nsure
fitm
ent
of
set
of
dam
pers
and
p
late
b
efo
re
fitt
ing
th
e
ab
ove.
Inp
ut
Sh
aft
Asse
mb
ly
Fit
: F
rom
LH
sid
e o
f sh
aft
(A
)
•T
hru
st
wash
er
(K)
•G
ear
4th
(J
)
•S
plin
ed
wash
er
(I)
•C
irclip
(H
)
•G
ear
3rd
drive (
G)
•C
irclip
(F
)
•S
plin
ed
wash
er
(E)
•G
ear
5th
drive (
D)
•G
ear
2n
d d
rive (
C)
•T
hru
st
wash
er
(B)
Ou
tpu
t S
ha
ft A
sse
mb
ly
Fit
: f
rom
LH
sid
e o
f sh
aft
•G
ear
5th
driven
(M
)
•B
ush
(N
) w
ith
sh
ou
lder
rin
gnd
•G
ear
2 d
riven
(L
)
•w
ash
er
(K)
•C
irclip
(J
)
Fit
: f
rom
RH
sid
e o
f sh
aft
rd•
Th
rust
wash
er
(H)
beh
ind
th
e 3
gear
on
ou
tpu
t sh
aft
rd
•
Gear
3d
riven
(G
)
•S
plin
e w
ash
er
(F).
•C
irclip
(E
)
•G
ear
4th
driven
(D
)
•S
teel b
ush
(C
) w
ith
sh
ou
lder
rin
g
•G
ear1
st
driven
(B
)
•T
hru
st
wash
er
(A)
BC
D
EF
GH
J
IK
A
AB
C
D
EF
G
H
IJ
KLM
N
Clu
tch
Sid
e
Fit
:
•‘P
ara
llel
Pin
’.
•‘S
pro
cket
Cam
Drive’
•‘C
am
Ch
ain
’
En
gin
e A
sse
mb
lin
g
En
gin
e C
en
tra
l P
art
Fit
: (
In M
ag
ne
to s
ide
Cra
nkc
ase
)
•‘In
pu
t an
d O
utp
ut
Sh
aft
Assem
bly
’ sim
ultan
eo
usly
.
•‘F
ork
sh
ifts
’ alo
ng
w
ith
ro
llers
o
n
‘In
pu
t an
d
Ou
tpu
t S
haft
A
ssem
bly
’ (2
big
ger
fork
sh
ifts
on
ou
tpu
t sh
aft
an
d 1
sm
alle
r o
n
inp
ut
sh
aft
).
Ca
uti
on
:
Use
a
sharp
b
lad
e
or
knife
to
cut
off
any
pro
trud
ing
‘G
asket’
. T
his
is
very
im
po
rtant
for
pre
venting
any
oil
leakag
e
fro
m
‘Cra
nkcase’
and
‘C
ylin
der
Blo
ck
Jo
int’
. D
on't
ap
ply
g
rease
/ any
ad
hesiv
e
to
‘Cra
nkcase
Gasket’
as
these
‘Gasket’
w
hen
co
mes
in
co
nta
ct
with o
il exp
and
s a
nd
seals
hid
den c
avitie
s.
No
te
: F
or
ease
of
assem
bly
o
f g
ears
, re
mo
ve
gear
1st
driven
and
in
sert
b
oth
th
e in
put
and
o
utp
ut
shaft
assem
blie
s w
ith g
ears
in
m
esh
into
th
eir re
sp
ective b
earing
s.
The g
ear
bo
x sho
uld
b
e in
neutr
al
gear
befo
re ‘
RH
Cra
nkcase’
is a
ssem
ble
d o
n t
o ‘
LH
Cra
nkcase’.
Fit
:
•C
ran
kcase R
H
•B
olts (
LH
& R
H S
ide)
Ca
uti
on
:
C
heck o
il sup
ply
to
b
ig end
b
earing
b
y p
um
pin
g o
il in
th
e
clu
tch
sid
e
end
o
f cra
nkshaft
and
le
ts
oil
drib
ble
o
ut
of
co
n-r
od
b
ig
end
sid
es.
Fit
:
•C
ran
ksh
aft
No
te
: H
old
th
e
cam
chain
up
rig
ht
usin
g
a
so
ft
co
pp
er
wire
or
a
thre
ad
.
Fit
:
•‘D
rum
Ch
an
ge’
•‘S
haft
Gear
Sh
ift’
•‘K
ick S
prin
g’
(A)
•2
Do
wels
•‘G
asket’
A
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r114
Deale
r D
eve
lop
ment
Cente
r113
Fit
:
•‘G
ear
kic
k I
dle
r’
•S
top
per
•S
top
per
bo
lt (
A)
(Use l
octite
24
3)
No
te :
a.
Ap
ply
Lo
ctite
638 a
t ‘B
olt S
hift
Chang
e’
(B)
if r
em
oved
.
b.
Ensure
fr
ee
mo
vem
ent
on
‘Sto
pp
er
Gear
Shift’
in
‘B
olt
Shift
Chang
e’.
No
te :
Ensure
fitm
ent
of
2 ‘P
lain
W
ashers
’ o
n either
sid
e o
f ‘K
ick S
haft
A
ssem
bly
’.
Fit
:
•‘S
qu
are
Key
•‘P
rim
ary
Gear’
.
Fit
:
•‘B
od
y B
ala
ncer
Gear’
.
•‘L
ock’.
•‘B
olt’
(A)
(Use L
octite
24
3)
Fit
:
•‘P
ara
llel
Pin
’.
•‘S
pacer’
•‘G
uid
e g
ear
sh
ifte
r’
•‘A
llen
Bo
lt’
(A)
Fit
:
•‘S
prin
g’
(A)
Fit
:
•‘G
ear
ch
an
ge l
ever
assly
’
A
A
A
B
A
No
te :
Ensure
lo
ctite
638 o
n ‘
Kic
k G
uid
e’
alle
n b
olts,
if r
em
oved
No
te :
1.
Ensure
fitm
ent
of
2
‘Pla
in
Washers
’ o
n
either
sid
e
of
‘Kic
k
Shaft
A
ssem
bly
’
2.
Refe
r S
kill
tip
fo
r fitm
ent
pro
ced
ure
on p
ag
e n
o....
Fit
:
•‘T
hru
st
Wash
er’
•‘A
ssly
Bala
ncer
Idle
r G
ear’
with
Sp
ecia
l T
oo
l
•T
hru
st
wash
er
Fit
:
•W
ash
er
•‘K
ick S
haft
Assem
bly
’
•W
ash
er
Fit
:
•C
lutc
h h
ou
sin
g
No
te :
1.
Ensure
p
erf
ect
matc
hin
g
of
gear
alig
nm
ent
mark
s
w.r
.to
cra
nkcase
mark
s.
2.
Refe
r th
e
skill
tip
s
sectio
n
for
und
ers
tand
ing
p
roced
ure
fo
r g
ear
alig
nm
ent
mark
s g
iven o
n p
ag
e n
o 5
2.
Fit
:
•2
‘D
ow
els
’
•‘A
ssly
Bala
ncer
Idle
r G
ear
Co
ver’
•3
‘B
olt’
Usin
g
Sp
ec
ial
To
ol
- P
rim
ary
ge
ar
ho
lde
r 3
7
10
DJ
28
&
Sp
ec
ial
Nu
t 3
7 1
0D
J 4
3
Fit
:
•‘S
pacer’
.
•‘C
lutc
h A
ssem
bly
Co
mp
lete
’
•'W
ash
er’
•‘S
pecia
l N
ut’
Fit
: Alig
n g
ear
tim
ing
mark
s o
f ..
•P
rim
ary
g
ea
r m
ark
w
.r.t
cra
nkcase m
ark
•B
od
y
bala
ncer
assly
m
ark
w
.r.t
cra
nkcase m
ark
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r116
Deale
r D
eve
lop
ment
Cente
r115
No
te :
Sp
ecia
l nut
for
inp
ut
shaft
has L
H t
hre
ad
s.
Fit
:
•‘B
earin
g w
ith
plu
ng
er’
.
Usin
g
Sp
ec
ial
too
l :
Pri
ma
ry
ge
ar
ho
lde
r 3
7 1
0D
J 2
8
Fit
:
•‘G
asket’
•3
scre
ws
•C
over
Usin
g
Sp
ec
ial
To
ol
: P
rim
ary
Ge
ar
Ho
lde
r -
37
10
DJ
28
Usin
g
Sp
. T
oo
l :
Ce
ntr
ifu
ga
l
Oil F
ilte
r N
ut
- 3
7 1
0D
J 4
3
Fit
:
•‘C
en
trifu
gal
Oil
Filt
er’
.
•W
ash
er
•‘S
pecia
l N
ut’
.
Fit
:
•2
Do
wels
•‘O
il P
um
p A
ssem
bly
’
•3
‘B
olts’
Fit
:
•‘S
tart
er
Mo
tor’
•C
lutc
h c
over
gasket’
•‘2
Do
wels
’
No
te
: D
o
no
t ap
ply
an
y
gre
ase
to
stick
‘Gaskets
’ to
th
e
‘Clu
tch
C
over
/ M
ag
neto
C
over’
o
r ‘C
ran
kcase’.
A
s
gre
ase
de
teri
ora
tes
th
e
ga
sk
et
ma
teri
al
an
d
red
uc
es
s
ea
lin
g
eff
ecie
ncy.
Fit
:
•‘C
lutc
h C
over’
•1
0 ‘
Bo
lts’
•‘B
racket
clu
tch
cab
le’
•‘S
tart
er
Mo
tor
Cap
’
•‘S
cre
w’
•‘K
ick s
tart
er
lever’
Ma
gn
eto
Sid
e
Fit
:
•‘S
haft
Sta
rter
Co
un
ter’
.
•‘G
ear
co
mp
lete
sta
rter
co
un
ter
assly
’.
•‘C
olla
r’
Fit
:
•‘W
oo
dru
ff k
ey’
•‘M
ag
net
alo
ng
with
gear
sta
rter
clu
tch
’.
No
te :
Alw
ays a
pp
ly a
thin
layer
of
gre
ase o
n t
o t
he r
olle
r b
earing
of
sta
rter
co
unte
r g
ear.
No
te :
•
A
lways ap
ply
a th
in la
yer
of
gre
ase
to th
e ro
ller
bearing
o
f g
ear
sta
rter
clu
tch.
• A
dd
few
dro
ps o
f o
il o
n O
D o
f g
ear
sta
rter
clu
tch f
or
lub
ricatio
n.
Fit
:
•‘P
late
sta
rter
clu
tch
retu
rn (
A)
•‘B
olt’
(Use l
octite
24
3)
(B)
No
te :
Wh
en
assem
blin
g th
e ‘C
lutc
h C
over’
alw
ays re
mem
ber
that
the e
ntr
y o
f ‘K
ick S
haft
’ in
to t
he ‘
Clu
tch
Co
ver’
is t
he t
igh
test
as t
he t
ole
ran
ces a
re t
igh
tly c
on
tro
lled
. O
ne s
ho
uld
co
ncen
trate
o
n a
lign
ing
th
e k
ick s
haft
bo
re a
nd
kic
k s
haft
first,
rath
er
than
co
ncen
tratin
g o
n t
he p
ossib
ility
of
the p
lun
ger
falli
ng
do
wn
. W
hen
w
ork
ing
o
n
veh
icle
It
is
ad
vis
ab
le
to
loo
sen
th
e
‘RH
R
ider
Fo
otr
est’
wh
ich
help
s i
n t
he a
bo
ve a
nd
help
s a
lso
in
lo
osen
ing
an
d
tig
hte
nin
g
of
the
2
M6
b
olts
part
ially
m
asked
b
y
the
‘Fo
otr
est’
.
A B
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r118
Deale
r D
eve
lop
ment
Cente
r117
Us
ing
S
pe
cia
l T
oo
l :
Dri
ft
74
93
09
89
Fit
:
•‘P
isto
n’
•‘P
isto
n P
in’
•‘C
irclip
’
Usin
g
Sp
ec
ial
To
ol
: R
oto
r
Ho
lde
r H
6 0
72
1 0
0
Fit
:
•‘W
ash
er’
•‘B
olt’
To
p E
nd
Fit
:
•2
‘D
ow
els
’
•B
lock B
ase G
asket
Usin
g
Sp
ec
ial
To
ol
: O
utp
ut
sp
roc
ke
t h
old
er
37
10
30
53
Fit
:
•‘B
ush
’.
•‘S
pro
cket’
.
•‘P
late
drive S
pro
cket’
.
•2
‘B
olts’
(Use l
octite
24
3).
Fit
:
•‘2
Do
wel’
•‘G
asket’
Fit
:
•‘M
ag
neto
Co
ver’
•5
‘B
olts’
•N
eu
tral
sw
itch
co
up
ler
No
te
: P
lace
cle
an
pie
ce
of
clo
th
on
the
‘Cra
nkcase’
bo
tto
m
end
b
ecause t
heir i
s c
hance o
f ring
snap
falli
ng
do
wn w
hile
fitm
ent.
Fit
:
•H
ead
gasket
•2
‘D
ow
els
(A
)
•‘C
hain
Gu
ide’
(No
n t
en
sio
ner
sid
e)
No
te :
Ho
ldin
g th
e chain
firm
ly b
ring
th
e p
isto
n assly
to
T
DC
p
ositio
n
and
E
nsure
‘T
’ m
ark
o
n
the
roto
r is
m
atc
hin
g
with
genera
tor
co
ver
mark
.
No
te :
Ap
ply
th
in la
yer
of
oil
in cylin
der
bo
re an
d p
isto
n assly
w
hen
slid
ing
in
sid
e f
or
ease i
n f
itm
en
t.
Usin
g
Sp
ec
ial
To
ol
: P
isto
n
Rin
g H
old
er
37
10
DJ 3
0
Fit
:
•S
lid
e
the
‘C
am
C
ha
in’
up
rig
ht
wit
h
so
ft
co
pp
er
wire /
Th
read
in
to c
ylin
der
•S
lide
the
pis
ton
assly
in
to
cylin
der
Fit
:
•‘C
ylin
der
Head
Assly
’.•
2 D
ow
els
Fit
:
•‘S
park
Plu
g S
leeve’.
•‘G
rub
Scre
w’.
•
‘Sp
ark
Plu
g’
No
te
: B
efo
re
fitt
ing
th
e
sle
eve
sp
ark
p
lug
ap
ply
th
in
layer
of
mo
lyb
denum
dis
ulp
hid
e g
rease o
n t
he e
ntr
y c
ham
bers
fo
r th
e ‘
O’
ring
s.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
A
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r120
Deale
r D
eve
lop
ment
Cente
r119
AA
Fit
:
•‘C
am
Sh
aft
’.•
‘Co
llar’
.
Usin
g S
p.
To
ol -
37
10
DH
36
Fit
:
•‘C
am
Sp
rocket’
.•
‘Sp
ecia
l W
ash
er’
. •
‘Alle
n B
olt’
No
te :
•E
nsure
th
e
sp
rocket
mark
s
are
alig
ned
ho
rizo
nta
lly
with
cylin
der
head
to
p m
achin
ed
face a
nd
the p
isto
n i
s a
t T
DC
.
•S
ecure
the ‘
Cam
Chain
Sp
rocket’
in t
he s
pecia
l to
ol
firm
ly a
nd
then
tig
hte
n t
he s
pro
cket
alle
n b
olt.
•E
nsure
th
at
the
‘O’
mark
o
n
washer
alw
ays
faces
outw
ard
s
when
tig
hte
nin
g t
he a
llen b
olt.
Fit
:
•‘C
am
Sh
aft
Cap
’.
•A
pp
ly
thin
la
yer
of
liqu
id
gasket
to h
ead
co
ver
•‘H
ead
Co
ver’
No
te :
•D
o
no
t ap
ply
liq
uid
g
asket
on
to
the
cam
shaft
cap
and
o
ther
insid
e m
ounting
are
as.
•R
efe
r S
kill
Tip
fo
r m
ore
deta
ils
Fit
:
•‘C
op
per
Pla
ted
Wash
er’
•T
igh
ten
bo
lts a
s p
er
seq
uen
ce
Ist
: 4
Do
med
cap
nu
t
IIn
d:
4 L
on
g b
olts o
f H
ead
Co
ver
IIIrd
: 2
Lo
ng
est
bo
lts o
f H
ead
co
ver
No
te
: Im
pro
per
tig
hte
nin
g
seq
uence
of
bo
lts
may
cause
perm
anent
warp
ag
e i
n c
ylin
der
head
co
ver
and
it
can g
et
dam
ag
ed
perm
anently.
II
II
III
I
Fit
:
•‘C
am
Ch
ain
Ten
sio
ner’
•2
‘B
olt’
•R
ele
ase t
he t
en
sio
ner
plu
ng
er
bo
lt
•‘D
ust
cap
’ an
d ‘
O’
rin
g’
Ad
just
:
•C
heck a
nd
ad
just
the t
ap
pet
cle
ara
nce
Fit
:
•T
ap
pet
cap
with
‘O
’ rin
g•
Cap
mag
neto
co
ver
No
te
: A
lways
ensure
th
at
the
pis
ton
is
at
the
end
o
f co
mp
ressio
n
str
oke
and
‘T
’ is
seen
fro
m
‘Tim
ing
In
sp
ectio
n
Win
do
w’
at
genera
tor
co
ver.
When a
dju
sting
tap
pet
cle
ara
nce.
Inle
t V
alv
e :
0.0
5 m
m
Exh
au
st
Valv
e :
0
.1 m
m
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
bly
- E
ng
ine
Assem
bly
- E
ng
ine
Deale
r D
eve
lop
ment
Cente
r122
Deale
r D
eve
lop
ment
Cente
r121
Re
mo
ve
:
•F
ron
t axle
self l
ockin
g n
ut(
A)
•F
ron
t axle
(B
)
•D
ista
nce p
iece (
C)
•W
heel
sen
so
r (D
)
•P
ull
ou
t fr
on
t w
heel
assly
Re
mo
ve
:
•2
alle
n b
olts (
A)
(on
eith
er
sid
e)
•F
ron
t m
ud
gu
ard
assem
bly
Re
mo
ve
:
•R
ub
ber
gro
mm
et
(A)
•2
Alle
n b
olts (
B)
Re
mo
ve
:
•S
peed
om
ete
r sen
so
r cab
le
fro
m
wh
eel
(A)
an
d
fro
m
fen
der
cla
mp
(B
)
Sk
ill
Tip
: K
eep
it
asid
e s
afe
ly
Re
mo
ve
:
•C
alip
er
assem
bly
fro
nt
mo
un
tin
g b
olt (
A)
Sk
ill
Tip
: P
lace w
ed
ge b
etw
een p
ad
s.
Rem
ove f
ront
bra
ke l
ever.
Sk
ill
Tip
:
Pain
ted
p
art
s sho
uld
b
e hand
led
w
ith utm
ost
care
to
avo
id
scra
tches
B
A
A
AC
DB
A B
C
Re
mo
ve
:
•L
oo
sen
bo
lt (
C)
•P
ull
do
wn
fo
rk l
eg
assem
bly
by s
low
ly r
ota
tin
g i
t
•S
imila
rly
carr
y
ou
t th
e
sam
e
pro
ced
ure
to
ta
ke
ou
t o
ther
sid
e
fork
leg
Re
mo
ve
:
•B
ello
w c
lam
p (A
)
•B
ello
w (B
)
•B
olt f
ork
(C
) fr
om
th
e t
op
of
fro
nt
fork
assem
bly
alo
ng
with
th
e ‘
O’
rin
g
Re
mo
ve
:
•S
eat
fork
sp
rin
g (8
Alle
n b
olt)
•S
pacer
tub
e
•W
ash
er
•S
prin
g
•F
ork
oil
in a
co
nta
iner
•T
he d
ust
seal an
d t
he s
nap
rin
g o
ver
the o
il seal
Re
co
mm
en
de
d O
il C
ap
ac
ity p
er
fork
tu
be
Ap
pro
x 1
45
+ 2
.5 m
l. (
Dra
in a
nd
refill)
Usin
g S
pe
cia
l T
oo
l :
Fo
rk f
or
Cy
lin
de
r H
old
er
Ha
nd
le
-
37
18
30
06
& A
da
pte
r fo
r F
ork
- 3
7 1
83
0 1
1
Re
mo
ve
:
•A
llen
scre
w t
hat
is l
ocate
d a
t b
ott
om
with
th
e h
elp
of
alle
n
key
(A)
by
ho
ldin
g
the
fork
p
isto
n
with
th
e
help
o
f a
ad
ap
ter
(B) an
d h
old
er
•P
isto
n a
ssem
bly
Usin
g S
pe
cia
l T
oo
l :
Fro
nt
Fo
rk T
ub
e E
xtr
ac
tor
- 7
4 9
31
0 1
5
Re
mo
ve
:
•T
he i
nn
er
tub
e a
ssem
bly
will
no
t co
me i
tself b
ecau
se o
f tw
o D
U
bu
sh
es f
itte
d.
On
e b
ush
is f
itte
d o
n i
nn
er
tub
e a
nd
oth
er
bu
sh
is
fitt
ed
in
ou
ter
tub
e.
•F
it th
e fr
on
t fo
rk tu
be o
n th
e veh
icle
b
y assem
blin
g th
e sp
ecia
l to
ol
(A)
an
d l
ock i
t at
nu
mb
er
pla
te m
ou
ntin
g s
cre
w.
•R
ota
te
the
sp
ecia
l to
ol
han
dle
to
sep
era
te
the
inn
er
tub
e
fro
m
ou
ter
tub
e a
s s
ho
wn
in
th
e f
ig.
Sk
ill
Tip
:
•
Fit t
he f
ork
tu
be w
ith
ou
t to
uch
ing
head
lig
ht
fairin
g•
Ro
tate
sp
ecia
l to
ol
with
ou
t h
ittin
g n
um
ber
pla
te.
C A B
BA
A
Re
mo
ve
:
•In
ner
tub
e (
B)
of
fro
nt
fork
with
DU
bu
sh
•O
il seal
(C)
for
ou
ter
tub
e
•G
uid
e b
ush
wash
er
(D)
•S
pacer
•B
ush
ing
B
C
D
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
A
Dis
mantlin
g F
ront
Fo
rkD
ism
antlin
g F
ront
Fo
rk
Deale
r D
eve
lop
ment
Cente
r124
Deale
r D
eve
lop
ment
Cente
r123
Usin
g S
p.
To
ol :
Fo
rk f
or
cylin
de
r h
old
er
ad
ap
ter
- 3
7 1
83
0 0
8/1
1
Fit
:
•P
lace F
ork
cylin
der
set
in th
e in
ner
tub
e,
cylin
der
base &
p
lace
it i
n o
ute
r tu
be.
Ho
ld t
he p
isto
n w
ith
th
e h
elp
of
sp
ecia
l to
ol.
•B
olt i
t fr
om
lo
wer
sid
e o
f o
ute
r tu
be w
ith
Alle
n k
ey.
•G
uid
e b
ush
, w
ash
er
•O
il seal
usin
g s
pecia
l to
ol
(A)
•S
nap
Rin
g
•D
ust
seal
•S
prin
g a
nd
fill
oil.
•S
eat
fork
sp
rin
g a
nd
Co
llar
fork
.
•B
olt
Sim
ilarly c
arr
y o
ut
the s
am
e p
roced
ure
to
assem
ble
th
e o
ther
fork
.
Fit
:
•F
ron
t w
heel
assem
bly
.
•F
ron
t axle
(A
)
•T
igh
ten
self l
ock n
ut
•C
all
ipe
r
as
se
mb
ly
an
d
tig
hte
n 2
bo
lts
•S
pe
ed
om
ete
r se
nso
r c
ab
le
co
nn
ectio
n.
Fit
:
•S
lide t
he f
ron
t fo
rk a
ssly
in
th
e f
ork
ho
lder
•A
llen
bo
lts
•B
olt f
ork
at
the t
op
en
d
Sim
ilarly
carr
y
ou
t th
e
sam
e
pro
ced
ure
fo
r fitm
en
t o
f th
e
oth
er
sh
ock a
bso
rber.
Fit
:
•F
ron
t fe
nd
er
•2
Alle
n b
olts (
A)
(2 o
n e
ith
er
sid
e)
Sk
ill
Tip
:
The P
art
N
am
e &
N
o w
ritt
en o
n o
il seal
sho
uld
fa
ce up
sid
e
i.e.
tow
ard
s t
echnic
ian w
hile
fitting
.
Ca
uti
on
:
Do
n’t
ap
ply
excess
gre
ase
or
any
oth
er
lub
ricant
on
the
wheel
senso
r case.
A
A
A
Ma
ste
r C
ylin
de
r
Wo
rkin
g:
Wh
en
th
e b
rake l
ever
is i
n i
dle
co
nd
itio
n,
there
is n
o p
ressu
re i
nsid
e
the c
ylin
der.
Th
e f
eed
& c
om
pen
satio
n a
pert
ure
are
op
en
& c
on
nect
the p
ressu
re c
ham
ber
& c
om
pen
satio
n c
ham
ber
to r
eserv
oir.
Wh
en
th
e b
rake le
ver
is o
pera
ted
, th
e p
ush
ro
d p
ush
es th
e p
isto
n
insid
e th
e cylin
der.
A
sm
all
qu
an
tity
o
f flu
id re
turn
s fr
om
p
ressu
re
ch
am
ber
to r
eserv
oir b
efo
re p
rim
ary
seal
co
mp
lete
ly b
locks t
he f
eed
ap
ert
ure
. O
nce t
his
co
nd
itio
n i
s a
ch
ieved
, an
y f
orc
e e
xert
ed
on
th
e
lever
is t
ran
sfo
rmed
in
to p
ressu
re i
n t
he b
rake c
ircu
it.
Wh
en
th
e b
rake l
ever
is r
ele
ased
, th
e p
isto
n i
s p
ressed
back q
uic
kly
b
y th
e re
turn
sp
rin
g to
its id
le p
ositio
n.
Du
e to
th
is,
a vacu
um
is
g
en
era
ted
in
th
e p
ressu
re c
ham
ber
& t
he f
luid
in
th
e c
om
pen
satio
n
ch
am
ber
flo
ws to
p
ressu
re ch
am
ber
thro
ug
h th
e p
rim
ary
seal, th
e
exte
rnal
ed
ges o
f w
hic
h f
lex a
pp
roxim
ate
ly t
o a
llow
flu
id t
o p
ass t
o
pre
ssu
re c
ham
ber.
Aft
er
retu
rn o
f th
e m
aste
r cyl. p
isto
n,
the c
alip
er
retr
acts
(aft
er
so
me r
ela
tive t
ime d
ela
y). T
his
cau
ses t
he f
luid
in
th
e
pre
ssu
re c
ham
ber
to r
etu
rn t
o t
he r
eserv
oir t
hro
ug
h f
eed
ap
ert
ure
.
Ma
ste
r C
ylin
de
r D
ism
an
tlin
g a
nd
Asse
mb
lin
g
Dis
ma
ntl
ing
:
•R
em
ove f
ron
t b
rake s
witch
an
d i
ts c
on
nectio
n (
A)
•R
em
ove f
ron
t b
rake l
ever
by r
em
ovin
g t
he n
ut
an
d p
ivo
t b
olt (
B)
•T
he p
ush
ro
d b
oo
t (O
ne en
d o
f th
e b
oo
t is
h
eld
in
a g
roo
ve in
th
e p
ush
ro
d a
nd
its
oth
er
(larg
er)
en
d i
s h
eld
in
a g
roo
ve i
n t
he
cylin
der
bo
dy).
•T
op
co
ver
by r
em
ovin
g 2
scre
ws (
C)
•N
ylo
n C
ap
(D
)
•R
ub
ber
dia
ph
rag
m (
E)
A
B
C
DE
Dia
phra
gm
Reserv
oir
Secondary
seal
Spring
Com
pensation o
pera
ture
Pis
ton
Com
pensattio
nC
ham
ber
Mast
er
cylin
der
bod
y
Prim
ary
seal
Pre
ssure
Cham
ber
Outlet P
ort
Feed a
pera
ture
Cover
Air V
ent
Bra
ke L
ever
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Assem
blin
g F
ront
Fo
rkFro
nt
Dis
c B
rake
Deale
r D
eve
lop
ment
Cente
r126
Deale
r D
eve
lop
ment
Cente
r125
•B
rake
flu
id
fro
m
the
reserv
oir
with
th
e
help
o
f syrin
ge/s
yp
ho
n
pu
mp
•M
aste
r cylin
der
alo
ng
w
ith
h
ose
assem
bly
fr
om
h
an
dle
b
ar
by
rem
ovin
g t
he 2
fla
ng
ed
8 b
olts (
F)
on
th
e c
lam
p.
•B
rake h
ose f
rom
maste
r cylin
der
ou
ter
by r
em
ovin
g b
an
jo b
olt (
G)
•W
ipe o
ut
cle
arly t
he o
ute
r su
rface o
f m
aste
r cylin
der.
•H
old
th
e m
aste
r cylin
der
in a
so
ft j
aw
vic
e.
•R
em
ove
circlip
w
ith
th
e
help
o
f a
plie
r,
by
pre
ssin
g
the
pis
ton
slig
htly i
nsid
e t
he b
ore
, w
ith
a n
ylo
n o
r w
oo
den
ro
d.
•T
ake
ou
t th
e
pis
ton
assem
bly
alo
ng
w
ith
th
e
Retu
rn
sp
rin
g
by
pu
llin
g i
t o
ut.
If
tra
nsp
are
nt
win
do
w
in
the
c
ylin
de
r b
od
y
for
leve
l in
dic
ati
on
ne
ed
s r
ep
lac
em
en
t (d
ue
to
da
ma
ge
, e
tc.)
pro
ce
ed
as f
ollo
ws:-
•R
em
ove L
ock R
ing
on
th
e w
ind
ow
w
ith
scre
w d
river
•R
em
ove w
ind
ow
an
d ‘
O’
rin
g.
Sk
ill
Tip
:
• E
nsure
that
there
sho
uld
no
t b
e a
ny s
pill
ag
e o
f b
rake f
luid
on
p
ain
ted
part
s
Sa
fety
Tip
:
• T
ake c
are
of
yo
ur
eyes w
hile
wo
rkin
g w
ith b
rake f
luid
.
G
F
Ma
ste
r C
ylin
de
r A
sse
mb
ly :
•N
ever
allo
w
min
era
l o
il to
co
me
in
co
nta
ct
with
seal
or
oth
er
rub
ber
part
s o
f d
isc b
rake,
sin
ce it w
ill cau
se d
am
ag
e to
th
ese
part
s.
•F
ree p
lay a
t th
e e
nd
of
the l
ever
is p
rovid
ed
to
en
su
re t
hat
in t
he
free
co
nd
itio
n,
the
pis
ton
d
oes
no
t re
main
in
th
e
pu
sh
ed
co
nd
itio
n,
Th
is en
su
res th
at
there
is
n
o p
ressu
re in
th
e syste
m
wh
en
th
e b
rake i
s n
ot
ap
plie
d.
Ca
lipe
rB
od
y
Carr
ier
Bra
cket
Dis
cP
ad
Du
st
Seal
Dis
c
Pis
ton
Pis
ton
Pin
Dis
cP
ad
Seal
Ca
lip
er
Asse
mb
ly
Wo
rkin
g :
In t
he b
rake r
ele
ased
co
nd
itio
n,
the b
rake f
luid
in
sid
e t
he c
alip
er
is a
t atm
osp
heric p
ressu
re a
nd
th
e d
isc r
ota
tes f
reely
as t
he p
ad
s d
o n
ot
pre
ss a
gain
st
it.
Wh
en
th
e
bra
ke
lever
is
op
era
ted
, th
e
pre
ssu
re
gen
era
ted
in
th
e
hyd
rau
lic c
ircu
it a
cts
on
th
e c
alip
er
pis
ton
s.
Th
e c
alip
er
in t
urn
pu
sh
th
e f
rictio
n p
ad
on
th
e s
ide o
f th
e c
alip
er
bo
dy a
gain
st
the r
ota
tin
g
dis
c.
Th
e f
rictio
n p
ad
on
th
e o
ther
sid
e o
f th
e d
isc a
lso
pre
sses a
gain
st
the d
isc d
ue t
o r
eactio
n f
orc
e o
n c
alip
er
bo
dy.
Th
us b
oth
th
e f
rictio
n
pad
s p
ress a
gain
st
the d
isc,
there
by g
en
era
tin
g b
rakin
g t
orq
ue.
Wh
en
th
e l
ever
is r
ele
ased
, th
e p
ressu
re i
n t
he h
yd
rau
lic c
ircu
it r
etu
rn
to a
tmo
sp
heric l
evel. T
he f
rictio
n p
ad
s r
etu
rn t
o i
dle
po
sitio
n d
ue t
o
retu
rn o
f th
e c
alip
er
pis
ton
s w
hic
h i
s d
ue t
o t
he s
prin
g a
ctio
n o
f th
e
seals
.
Wh
en
th
e p
ad
s w
ear,
th
e p
isto
ns m
ove f
urt
her
tow
ard
s t
he D
isc d
urin
g
bra
ke a
pp
licatio
n,
bu
t aft
er
rele
ase o
f p
ressu
re t
hey r
etr
act
on
ly t
o t
he
exte
nt
allo
wed
by t
he s
prin
g a
ctio
n o
f th
e s
eal. T
he p
isto
ns t
here
fore
ta
ke u
p n
ew
po
sitio
ns i
n i
dle
co
nd
itio
n,
an
d t
hu
s p
rovid
e a
uto
matic
ad
justm
en
t to
co
mp
en
sate
fo
r p
ad
wear.
Du
e t
o t
his
reaso
n,
there
is
no
need
fo
r fr
ee p
lay a
dju
stm
en
t in
th
e B
rake L
ever
in M
aste
r C
ylin
der.
Dis
ma
ntl
ing
of
Ca
lip
er
Dis
ma
ntl
ing
th
e A
sse
mb
ly
•R
em
ove c
alip
er
mo
un
tin
g b
olts (
A)
•R
em
ove b
an
jo b
olt (
B)
•R
em
ove c
alip
er
fro
m f
ork
Re
mo
va
l o
f P
ad
s :
•R
em
ove t
he p
ad
reta
inin
g b
od
y’s
Alle
n b
olt
•R
em
ove t
he p
ad
s
•R
em
ove t
he p
ad
sp
rin
g f
rom
th
e c
alip
er
bo
dy w
ith
a s
cre
w d
river
Pis
ton
an
d P
isto
n S
ea
l R
em
ova
l :
•W
ipe o
ut
cle
an
ly,
the o
ute
r su
rface o
f th
e c
alip
er.
•R
em
ove L
H p
ad
reta
inin
g c
ase b
y r
em
ovin
g a
llen
bo
lts
•P
ut
a w
oo
den
wed
ge i
n b
etw
een
th
e p
isto
n a
nd
calip
er.
•B
low
co
mp
ressed
air i
nto
cylin
der
thro
ug
h b
en
zo
bo
lt h
ole
wh
ere
th
e b
rake h
ose w
as f
itte
d,
with
th
e a
ir p
ressu
re,
the p
isto
n w
ill b
e
pu
sh
ed
ou
t o
f cylin
der.
BA
Ble
ed
er
Scre
w
Ho
se
Ban
joB
olt
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Fro
nt
Dis
c B
rake
Fro
nt
Dis
c B
rake
Deale
r D
eve
lop
ment
Cente
r128
Deale
r D
eve
lop
ment
Cente
r127 B
rak
e F
luid
fo
r D
isc
Bra
ke
s
Alw
ays u
se o
nly
reco
mm
en
ded
bra
ke f
luid
fro
m s
eale
d c
on
tain
er
to e
nsu
re d
ura
bili
ty o
f th
e s
yste
m.
Never
reu
se b
rake f
luid
rem
oved
fro
m a
syste
m.
Imp
ort
an
t p
oin
ts o
n 2
wh
ee
ler
dis
c b
rak
e s
yste
m :
1.
Sin
ce f
ron
t d
isc b
rake i
s m
ore
po
werf
ul
than
dru
m b
rake,
ap
ply
fro
nt
an
d r
ear
bra
ke t
og
eth
er
gra
du
ally
. A
vo
id b
rakin
g d
urin
g t
urn
ing
.
2.
Use o
nly
DO
T 3
or
DO
T 4
bra
ke f
luid
fro
m a
seale
d c
on
tain
er
fro
m r
eco
mm
en
ded
makes.
3.
Do
no
t ap
ply
min
era
l o
il fo
r cle
an
ing
an
y b
rake p
art
s.
Use o
nly
bra
ke f
luid
fo
r cle
an
ing
th
e s
eals
.
4.
Do
n
ot
ap
ply
m
inera
l b
ased
g
rease o
n b
ore
, p
isto
ns an
d seals
o
f m
aste
r cylin
der
an
d calip
er.
A
pp
ly
on
ly r
eco
mm
en
ded
assem
bly
flu
id.
5.
Do
no
t u
se c
ott
on
clo
th t
o w
ipe c
ylin
der
bo
re,
fib
res o
f clo
th w
ill r
em
ain
in
cylin
der
bo
re s
urf
ace.
6.
En
su
re d
ust
free c
on
ditio
n d
urin
g a
ssem
bly
.
7.
Do
no
t p
olis
h f
rictio
n d
isc w
ith
san
d p
ap
er,
as h
ard
part
icle
s d
ep
osited
in
th
e l
inin
g m
ay d
am
ag
e s
teel
dis
c.
8.
Wh
ile filli
ng
th
e re
serv
oir aft
er
ble
ed
ing
, en
su
re th
at
dro
ps o
r sp
lash
es d
o n
ot
rem
ain
o
n th
e p
ain
ted
su
rface o
r p
lastic s
urf
ace,
sin
ce b
rake f
luid
is c
orr
osiv
e.
Wa
rnin
g :
Do
no
t ap
ply
hig
h p
ressure
co
mp
ressed
air,
whic
h w
ill c
ause
the p
isto
n t
o j
um
p o
ut
of
the c
ylin
der.
The p
isto
n s
ho
uld
be t
aken o
ut
gra
dually
w
ith
mo
dera
tely
co
mp
ressed
air.
Care
to
b
e
taken
no
t to
d
am
ag
e t
he s
ealin
g s
urf
ace o
f th
e i
nle
t p
ort
while
ap
ply
ing
air p
ressure
.
•D
o
no
t p
lace
yo
ur
fin
ger
in
fro
nt
of
the
pis
ton
w
hile
ap
ply
ing
co
mp
ressed
air t
o p
ush
it
ou
t.
•R
em
ove p
isto
n s
eal
usin
g a
th
in p
art
lik
e a
th
ickn
ess g
au
ge,
etc
.
Ca
uti
on
: B
e c
are
ful
no
t to
dam
ag
e i
nsid
e (
bo
re s
ide)
of
the c
ylin
der.
Sk
ill
Tip
:
While
assem
blin
g
use
loctite
p
aste
243
on
alle
n
bo
lt
for
mo
unting
LH
pad
reta
iner
case.
•A
ssem
ble
th
e c
alip
er
assly
in
revers
e o
rder
of
dis
man
tlin
g
Air
Ble
ed
ing
of
Dis
c B
rak
e S
yste
m :
�F
or
air b
leed
ing
fr
om
fr
on
t H
yd
rau
lic b
rake syste
m firs
t to
p u
p th
e
maste
r cylin
der
with
hyd
rau
lic o
il.
�O
pera
te th
e b
rake le
ver
slo
wly
in
o
rder
to g
et
fille
d th
e o
il in
th
e
circu
it.
�C
on
nect
tran
sp
are
nt
tub
e
to
the
ble
ed
er
scre
w
at
calip
er
or
syp
ho
n p
um
p
�
Op
era
te
the
bra
ke
lever
an
d
keep
ing
in
p
ressed
p
ositio
n
loo
sen
s
the b
leed
er
scre
w s
o t
hat
so
me o
il escap
es w
ith
th
e a
ir b
ub
ble
s.
�K
eep
o
n
op
era
tin
g
the
bra
ke
lever
till
the
air
bu
bb
le
escap
e
ou
t co
mp
lete
ly th
rou
gh
b
leed
er
scre
w,
an
d to
p u
p th
e m
aste
r cylin
der
if
req
uired
.
�O
nce
the
air
escap
es
ou
t fr
om
th
e
ho
se
pip
e
the
bra
ke
lever
meets
resis
tan
ce,
wh
ich
in
dic
ate
s c
om
ple
tio
n o
f air b
leed
ing
�A
fter
co
mp
letin
g
the
ble
ed
ing
, to
p
up
th
e
maste
r cylin
der
up
to
th
e m
axim
um
level
mark
.
•A
lso
syp
ho
n p
um
p c
an
be u
sed
fo
r air b
leed
ing
Bra
ke
Dis
cIn
sp
ect
du
rin
g
every
5
00
0
Km
. an
d e
very
25
00
Km
th
ere
aft
er.
Ch
ec
k
for
ex
ce
ss
ive
s
co
rin
g
mark
s o
n f
rictio
n s
urf
ace
of
dis
c,
an
d r
un
ou
t.
Ma
ste
r C
ylin
de
r &
Ca
lip
er
Ins
pe
ct
ev
ery
5
00
0
Km
fo
r le
akag
e.
Bra
ke
Ho
se
Insp
ec
t fo
r le
aka
ge
&
d
am
ag
e
du
rin
g every
serv
ice /
every
2
50
0
Km
.
Bra
ke
Pa
ds
lIn
sp
ect
du
rin
g
every
2
50
0
Km
th
ere
aft
er
for
wear
an
d
co
nd
itio
n
of
linin
gs.
Insp
ec
tio
n a
nd
Ma
inte
na
nc
e F
req
ue
nc
y
Ch
ec
k P
oin
tsF
req
ue
nc
y
Bra
ke
Flu
id L
eve
l /
Le
aka
ge
Insp
ec
t d
uri
ng
e
ve
ry
se
rvic
e
/ every
2
50
0
Km
re
fil
up
to
u
pp
er
limit (t
ill ste
p o
n th
e in
ner
sid
e o
f th
e r
eserv
oir)
if l
evel
is l
ow
.
Rep
lace b
rake flu
id e
very
tw
o y
ears
. (In
severe
o
pera
tin
g
co
nd
itio
ns,
rep
lace in
a y
ear.
)
Bra
ke
Le
ve
r O
pe
rati
on
Insp
ect
du
rin
g every
serv
ice/e
very
2
50
0 K
m
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Fro
nt
Dis
c B
rake
Fro
nt
Dis
c B
rake
Ba
tte
ry
Te
ch
nic
al
Sp
ec
ific
ati
on
:
•T
yp
e &
Cap
acity
12
V -
9 A
H
0•
Sp
ecific
gra
vity o
f ele
ctr
oly
te
1.2
4 f
or
use a
bo
ve 1
0C
for
initia
l filli
ng
of
new
batt
ery
0•
Sp
ecific
gra
vity o
f ele
ctr
oly
te
1.2
8 f
or
use a
bo
ve 1
0C
for
initia
l filli
ng
of
new
batt
ery
•In
itia
l ch
arg
ing
du
ratio
n1
0 ~
15
hrs
•In
itia
l ch
arg
ing
cu
rren
t0
.9 t
o 1
Am
p
Deale
r D
eve
lop
ment
Cente
r130
Deale
r D
eve
lop
ment
Cente
r129 In
itia
l C
ha
rgin
g P
roc
ed
ure
1.
Fill
each
cell
with
b
att
ery
g
rad
e
su
lfu
ric
acid
o
f th
e co
rrect
Sp
. g
ravity (1
.24
at
roo
m te
mp
. 0
for
use a
bo
ve
10
C
an
d
1.2
8
at
roo
m
tem
p.
0fo
r u
se b
elo
w1
0C
).
2.
Allo
w
the
batt
ery
to
sta
nd
fo
r 3
0
min
. aft
er
filli
ng
.
3.
Keep
ven
t p
lug
s
op
en
. C
on
nect
batt
ery
to
ch
arg
er
an
d c
harg
e a
t 0
.9 A
mp
.
4.
Ch
arg
e
co
ntin
uo
usly
fo
r 1
0~
15
h
ou
rs
takin
g
Sp
. g
ravity re
ad
ing
s every
h
ou
r. F
ully
ch
arg
ed
c
on
dit
ion
is
in
dic
ate
d
wh
en
a
ll
ce
lls
are
g
assin
g fr
eely
an
d even
ly an
d sh
ow
n
o rise in
sp
ecific
gra
vity o
ver
3 s
uccessiv
e r
ead
ing
s.
5.
Aft
er
ch
arg
ing
p
ush
ven
t p
lug
s str
ip firm
ly in
to
pla
ce a
nd
wash
o
ff
acid
sp
illag
e
with
w
ate
r an
d d
ry t
he b
att
ery
.
Ch
ec
kin
g t
he
Sp
ec
ific
Gra
vit
y
Th
e c
harg
e c
on
ditio
n o
f th
e i
nd
ivid
ual
cell
can
be
ch
ecked
by m
easu
rin
g S
p.
gra
vity o
f ele
ctr
oly
te i
n
that
cell.
Th
e s
pecific
gra
vity o
f ele
ctr
oly
te c
an
be
ch
ec
ke
d
by
usin
g
Hyd
rom
ete
r h
avin
g
sm
all
dia
mete
r sp
ou
t.
Fo
r m
easu
rin
g t
he S
p.
gra
vity b
rin
g t
he e
lectr
oly
te
in
the
Hyd
rom
ete
r to
eye
level,
an
d
read
th
e
gra
du
atio
ns
on
th
e
flo
at
scale
b
ord
erin
g
on
th
e
low
er
men
iscu
s
(i.e
. cu
rved
d
ow
n
po
rtio
n
of
ele
ctr
oly
te
su
rface)
as
sh
ow
n
in
the
fig
ure
. A
fter
ch
arg
ing
is
o
ver,
fit
the
filli
ng
cap
s
str
ip,
wash
acid
sp
illag
e
with
w
ate
r.
Dry
th
e
batt
ery
. E
nsu
re
term
inals
are
cle
an
.
Ba
tte
ry I
nsta
lla
tio
n:
Insta
ll th
e b
att
ery
on
veh
icle
as d
escrib
ed
belo
w
a.
En
su
re
tha
t in
a
ll
six
c
ells
the
le
ve
l o
f ele
ctr
oly
te i
s n
ear
the m
axim
um
level
mark
.
b.
To
cle
an
an
d d
ry th
e su
rface w
ipe th
e to
p o
f th
e b
att
ery
with
a c
lean
clo
th.
Insta
ll th
e
hap
pen
s,
the c
hem
ical
reactio
ns w
ith
in t
he b
att
ery
are
aff
ecte
d a
nd
resu
lts i
n l
oss o
f cap
acity.
Mo
stly
the c
au
ses o
f su
lph
atio
n a
re a
s u
nd
er
:
a.
Un
derc
harg
ing
.
b.
Sta
nd
ing
in
a p
art
ially
o
r co
mp
lete
ly d
isch
arg
e
co
nd
itio
n f
or
lon
g t
ime.
c.
Lo
w
ele
ctr
oly
te
level
: If
ele
ctr
oly
te
level
is
perm
itte
d
to
fall
belo
w
the
top
o
f th
e
batt
ery
p
late
s,
then
th
e
exp
osed
su
rfaces w
ill h
ard
en
an
d w
ill b
eco
me
su
lph
ate
d.
d.
Ad
din
g a
cid
: I
f acid
is a
dd
ed
to
a c
ell
in w
hic
h
su
lph
ati
on
e
xis
ts
the
c
on
dit
ion
w
ill
be
ag
gra
vate
d.
e.
Hig
h s
pecific
gra
vity :
If
sp
ecific
gra
vity i
s h
igh
er
than
th
e
reco
mm
en
ded
valu
e,
then
su
lph
atio
n
may o
ccu
r.
f.H
igh
te
mp
.:
Hig
h
tem
pe
ratu
re
ac
ce
lera
tes
su
lph
ati
on
, p
art
icu
larl
y
of
an
id
le,
part
ially
dis
ch
arg
ed
batt
ery
.
V
olt
ag
e o
f th
e s
ulp
ha
ted
ba
tte
ry :
-
Cells
o
f th
e
su
lph
ate
d
batt
ery
w
ill
sh
ow
lo
w
sp
ecific
gra
vity.
Fo
llow
th
e p
roced
ure
giv
en
belo
w.
•C
heck v
oltag
e b
efo
re c
harg
ing
.
•C
harg
e f
or
2 h
ou
rs
•C
heck v
oltag
e e
very
1 h
ou
r. I
f vo
ltag
e i
ncre
ases
then
co
ntin
ue c
harg
ing
. B
ut
if v
oltag
e d
oes n
ot
inc
rea
se
, d
isc
on
tin
ue
c
ha
rgin
g.
Oth
erw
ise
b
att
ery
ch
arg
er
will
get
perm
an
en
tly d
am
ag
ed
. If
batt
ery
is n
ot
bad
ly s
ulp
hate
d (
i.e.
vo
ltag
e m
ore
th
an
9 v
olts),
then
b
att
ery
can
b
e
reviv
ed
b
y
sp
ecia
l tr
eatm
en
t. I
n s
uch
case i
t is
ad
vis
ab
le t
o
giv
e
su
lph
ate
d
batt
ery
to
au
tho
rised
d
eale
r o
f b
att
ery
m
an
ufa
ctu
rer
for
ne
ce
ssa
ry
sp
ec
ial
treatm
en
t.
Ba
tte
ry M
ain
ten
an
ce
Fo
r th
e o
ptim
um
p
erf
orm
an
ce an
d lo
ng
er
batt
ery
lif
e t
he m
ain
ten
an
ce o
f b
att
ery
is i
mp
ort
an
t.
a.
Alw
ays k
eep
th
e b
att
ery
cle
an
an
d d
ry.
b.
Vis
ually
in
sp
ect
the
su
rface
of
the
batt
ery
co
nta
iner.
If
there
are
an
y s
ign
s o
f cra
ckin
g o
r ele
ctr
oly
te
leakag
e
fro
m
batt
ery
, re
pla
ce
the
batt
ery
.
Ne
ve
r a
dd
a
cid
o
r o
rdin
ary
ta
p
wa
ter
for
top
pin
g u
p s
inc
e t
his
will
sh
ort
en
Ba
tte
ry l
ife
.
No
n U
se
Ma
inte
na
nc
e
Wh
en
th
e
veh
icle
is
lik
ely
to
re
main
o
ff-r
oad
fo
r lo
ng
er,
tim
e
(say
mo
re
than
a
mo
nth
) th
en
N
on
U
se
M
ain
ten
an
ce
sh
ou
ld
be
c
arr
ied
o
ut
as
follo
ws
oth
erw
ise
the
batt
ery
m
ay
get
su
lph
ate
d
an
d p
erm
an
en
tly
dam
ag
ed
.
a.
Rem
ove
the
batt
ery
fr
om
veh
icle
.
b.
Main
tain
ele
ctr
oly
te
at
‘U
pp
er
Level’.
c.
Du
rin
g
off
serv
ice
perio
d,
batt
ery
sh
ou
ld
be
ch
arg
ed
o
nce
a
mo
nth
.
d.
Keep
th
e b
att
ery
fu
lly c
harg
ed
.
e.
Sto
re t
he b
att
ery
in
co
ol, d
ry p
lace.
f.K
ee
p
the
b
att
ery
a
wa
y
fro
m
rain
, d
ew
, m
ois
ture
an
d
direct
su
nlig
ht.
Ho
w
to D
ete
rmin
e C
on
dit
ion
of
Ba
tte
ry
Sp
ecific
g
ravity
ch
eck:
- W
heth
er
batt
ery
is
fu
lly
ch
arg
ed
o
r p
art
ially
ch
arg
ed
, it
will
alw
ays
sh
ow
sam
e
“no
lo
ad
vo
ltag
e”
of
12
vo
lts
or
mo
re
(un
les
s
ba
tte
ry
ce
lls
a
re
da
ma
ge
d
du
e
to
su
lph
atio
n
etc
).
Bu
t sp
ecific
g
ravity
of
the
fully
ch
arg
ed
b
att
ery
an
d p
art
ially
ch
arg
ed
b
att
ery
w
ill
be
diffe
ren
t.
Fu
lly
ch
arg
ed
b
att
ery
w
ill
sh
ow
S
p.
gra
vity
of
1.2
40
w
hile
p
art
ially
ch
arg
ed
b
att
ery
w
ill sh
ow
le
ss sp
ecific
g
ravity.
Th
ere
fore
, sp
ecific
g
ravity ch
eck is
very
im
po
rtan
t to
kn
ow
co
nd
itio
n
of
the b
att
ery
.
batt
ery
in
sid
e t
he b
ox p
rovid
ed
on
flo
or
bo
ard
. F
aste
n th
e b
att
ery
firm
ly w
ith
b
racket
& alli
ed
fa
ste
ners
.
c.
Co
nn
ect
cab
les
to
the
po
sitiv
e
an
d
neg
ative
term
inals
p
rop
erl
y.
Revers
e
co
nn
ectio
ns
will
d
am
ag
e t
he c
harg
ing
syste
m p
erm
an
en
tly.
d.
Alw
ays
co
nn
ec
t th
e
“n
eg
ati
ve
(e
art
hlin
g)
term
inal”
at
Iast.
e.
Cle
an
th
e
ba
tte
ry
term
ina
ls
an
d
ca
ble
co
nn
ectio
ns.
Sm
ear
them
w
ith
p
etr
ole
um
je
lly
to a
vo
id c
orr
osio
n
g.
Ch
eck
that
the
batt
ery
cab
le
co
nn
ectio
ns
are
firm
an
d cab
les d
o n
ot
rub
ag
ain
st
an
y m
eta
l co
mp
on
en
ts.
Ba
tte
ry C
ha
rgin
g P
roc
ed
ure
:
Th
is
is
a
M.F
(M
ain
ten
an
ce
Fre
e)
batt
ery
. T
his
b
att
ery
is
n
ot
havin
g an
y exh
au
st
tub
e in
ste
ad
it
has a
un
iqu
e v
en
t m
ech
an
ism
.
Th
e ele
ctr
oly
te le
vel
in th
is M
.F.
batt
ery
n
eed
s to
b
e to
pp
ed
u
p w
ith
d
istille
d w
ate
r o
nce in
a year.
In
case
batt
ery
in
d
isch
arg
ed
an
d
need
s
to
be
ch
arg
ed
u
sin
g
batt
ery
ch
an
ged
p
roced
ure
is
as
follo
ws :
•R
em
ove b
att
ery
fro
m v
eh
icle
•C
lean
batt
ery
th
rou
gh
ly
•R
em
ove v
en
t p
lug
str
ip
•T
op
u
p
level
with
d
istille
d
wate
r in
b
etw
een
M
in a
nd
Max.
level
•C
on
ne
ct
ba
tte
ry
to
ch
arg
e
an
d
en
su
re
resp
ective t
erm
inal
are
co
nn
ecte
d p
rop
erly
•S
et
ch
arg
ing
cu
rren
t at
0.9
A D
C
•C
ha
rge
b
att
ery
fo
r 3
/4
hrs
.,
the
n
ch
ec
k
vo
ltag
e a
nd
sp
ecia
l g
ravity.
•V
olt
ag
e
sh
ou
ld
be
12
.5
vo
lts
an
d
sp
ecia
l g
ravity i
n a
ll 6
cells
sh
ou
ld b
e 1
.24
0.
Th
is i
s a
co
nfirm
atio
n c
heck f
or
a f
ully
ch
arg
ed
batt
ery
.
•D
isco
nn
ect
the b
att
ery
fro
m t
he c
han
ger.
•F
it v
en
t p
lug
str
ip f
irm
ly.
•C
on
nect
batt
ery
on
to
veh
icle
.
•A
pp
ly
pe
tro
leu
m
jelly
on
to
th
e
ba
tte
ry
term
inal.
Ba
tte
ry
Su
lph
ati
on
A
su
lph
ate
d
batt
ery
is
o
ne
wh
ich
h
as
been
le
ft
sta
nd
ing
in
a
d
isc
ha
rge
d
co
nd
itio
n
or
un
derc
harg
ed
to
th
e
po
int
wh
ere
ab
no
rmal
lead
su
lph
ate
h
as fo
rmed
o
n th
e p
late
s (S
ulp
hate
cells
lo
oks lik
e w
hite c
rysta
l lik
e s
ug
ar)
. W
here
th
is
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Read
H
ere
Hyd
rom
ete
r
Main
tenance -
Ele
ctr
icals
Main
tenance -
Ele
ctr
icals
Re
lay (
Insp
ec
tio
n U
sin
g M
ult
ime
ter)
:
•A
lso
th
is r
ela
y c
an
be c
hecked
on
ele
ctr
on
ic T
est
jig.
Deale
r D
eve
lop
ment
Cente
r132
Deale
r D
eve
lop
ment
Cente
r131Sw
itc
he
s :
a.
Fro
nt
Bra
ke
Lig
ht
Sw
itc
h I
nsp
ec
tio
n :
i.T
urn
ON
th
e ig
nitio
n s
witch
.ii.
Th
e b
rake L
igh
t L
ED
Bla
nk s
ho
uld
get
on
w
hen
th
e f
ron
t b
rake (L
ever
is p
ressed
) is
ap
plie
d.
iii.
If it
do
es n
ot,
ch
eck t
he F
ron
t b
rake s
witch
.
Lever
Pre
ssed
Lever
Rele
ased
Bro
wn
Blu
e
b.
Re
ar
Bra
ke
Lig
ht
Tim
ing
In
sp
ec
tio
n :
i.T
urn
ON
th
e i
gn
itio
n s
witch
.ii.
Ch
eck
the
op
era
tio
n
of
the
rear
bra
ke
co
ils
lig
ht
sw
itc
h
by
de
pre
ssin
g
the
b
rake p
ed
al
iii.
If i
t d
oes n
ot
op
era
te a
s s
pecifie
d,
ad
just
the
bra
ke
ligh
t sw
itch
o
r ch
eck
Rear
bra
ke s
witch
Ped
al P
ressed
Ped
al R
ele
ased
Bro
wn
Blu
e
c.
Fu
el
Le
ve
l In
dic
ato
r :
i.F
or
kn
ow
ing
th
en
q
uan
tity
o
f fu
el
insid
e
the fu
el
tan
k at
a g
lan
ce,
is p
rovid
ed
o
n
Sp
eed
o c
on
sle
. T
he fu
el
gau
ge w
ork
s o
n
the p
rin
cip
le o
f ‘v
ariab
le re
sis
tan
ce’.
T
he
fuel
gau
ge w
ork
s o
n D
.C s
up
ply
. ii.
Fo
r ch
eckin
g
the
resis
tan
ce
acro
ss
the
sen
der
an
d
acro
ss
the
gau
ge,
make
the
co
nn
ectio
ns
veri
fy
the
read
ing
s,
make
the
co
nn
ectio
ns
verify
th
e
read
ing
s
as
tab
ula
ted
belo
w
Tan
k (F
loat)
Co
nn
ectio
nR
esis
tan
ce
Wh
ite /
Yello
w
Mete
r
1
0 W
Bla
ck /
Yello
w
Fu
ll
(Hig
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po
sitio
n)
Em
pty
(Lo
west
po
sitio
n)
4 -
10
W
95~
105 W
d.
Ne
utr
al
Sw
itc
h :
i.T
he n
eu
tral
sw
itch
w
ill b
e in
O
N p
ositio
n
on
ly
wh
en
th
e
en
gin
e
is
in
ne
utr
al
po
sitio
n.
ii.T
he
neu
tral
lig
ht
will
no
t g
low
w
hen
veh
icle
is i
n g
eare
d p
ositio
n
‘ON
’ (V
eh
icle
in
neu
tral)
‘OF
F’
(Veh
icle
in
gear)
Bro
wn
Blu
e
e.
Ign
itio
n S
wit
ch
:
‘OF
F’
‘ON
’
Bro
wn
Wh
ite
Bla
ck /
Wh
ite
Bla
ck /
Yello
w
g.
Sta
tor
Pla
te C
oils I
nsp
ec
tio
n :
i.D
isco
nn
ect
sta
tor
pla
te c
ou
ple
rii.
Set
mu
ltim
ete
r o
n o
hm
ran
ge.
(Oh
m M
ete
r)
•P
ick
up
Co
il R
esis
tan
ce
:
Mete
r +
ve
Mete
r -v
e
Re
ad
ing
Ra
ng
eC
on
ne
cti
on
s
2 K
WW
hite/R
ed
Bla
ck/Y
ello
w
20
0+
22
oh
m
•E
xc
ito
r C
oil :
Me
ter
+ve
Me
ter
-ve
Re
ad
ing
Ra
ng
e
20
0 W
Red
Bla
ck/Y
ello
w1
4+
1.4
W
•B
att
ery
Ch
arg
ing
Co
il :
Me
ter
+ve
Me
ter
-ve
Re
ad
ing
Ra
ng
e
20
0 W
Blu
e/W
hite
Blu
e/W
hite
1.3
+0
.13
W
•L
igh
tin
g C
oil :
Me
ter
+ve
Me
ter
-ve
Re
ad
ing
Ra
ng
e
20
0 W
Yello
w/R
ed
Bla
ck/Y
ello
w0
.7+
0.0
7W
CD
I U
nit
an
d H
. T
. C
oil I
nsp
ec
tio
n :
•C
DI
un
it c
an
be c
hecked
usin
g O
K H
.T.
co
il o
n E
lectr
on
ic T
est
jig
•S
imila
rly
H.T
. C
oil
can
b
e
ch
ecked
u
sin
g
OK
C
DI
un
it
on
ele
ctr
on
ic T
est
jig
H.T
. C
oils :
(In
sp
ec
tio
n U
sin
g M
ult
ime
ter)
•M
easu
re t
he p
rim
ary
win
din
g r
esis
tan
ce a
s f
ollo
ws
•C
on
nect
the h
an
d t
este
r b
etw
een
th
e c
oil
term
inals
.
•M
easu
re t
he s
eco
nd
ary
win
din
g r
esis
tan
ce a
s f
ollo
ws
•R
em
ove t
he p
lug
cap
by t
urn
ing
it
co
un
ter
clo
ckw
ise.
•C
on
nect
the t
este
r b
etw
een
th
e s
park
plu
g l
ead
s.
•M
easu
re p
rim
ary
win
din
g r
esis
tan
ce.
•M
easu
re s
eco
nd
ary
win
din
g r
esis
tan
ce.
•If t
he v
alv
e d
oes n
ot
matc
h a
s p
er,
rep
lace t
he c
oil.
Prim
ary
Win
din
g0
.40
to
0.4
9 O
hm
s
Seco
nd
ary
Win
din
g4
.23
to
5.1
7 K
Oh
ms
Co
il R
esis
tan
ce
Mete
r +
ve
Mete
r -v
eR
ead
ing
X 2
00
Oh
m5
5+
5.5
Oh
mG
reen
/Wh
ite
Bro
wn
•If
the
mete
r re
ad
s
as
sp
ecifie
d,
the
ign
itio
n
co
il w
ind
ing
s
are
p
rob
ab
ly
go
od
. H
ow
ever,
if
the
ign
itio
n
syste
m
still
do
es
no
t p
erf
orm
as
it
sh
ou
ld
aft
er
all
oth
er
co
mp
on
en
ts
have
been
ch
ecked
test
rep
lace t
he c
oil
with
on
e k
no
wn
.
•V
isu
ally
in
sp
ect
the s
eco
nd
ary
win
din
g l
ead
.
•If i
t sh
ow
s a
ny d
am
ag
e,
rep
lace t
he c
oil.
Fu
se
In
sp
ec
tio
n (
Ca
pa
cit
y =
10
Am
p)
•In
sp
ect
the f
use e
lem
en
t
•If i
t is
blo
wn
ou
t, r
ep
lace t
he f
use.
•If
a
fuse
fails
d
uri
ng
o
pera
tio
n,
the
ele
ctr
ical
syste
m
to
dete
rmin
e
the
cau
se,
an
d
then
re
pla
ce
it
with
a
new
fu
se
of
pro
per
am
pera
ge.
Ca
uti
on
:
When re
pla
cin
g a fu
se b
e sure
th
e new
fu
se m
atc
hes th
e
sp
ecifie
d fu
se ra
ting
fo
r th
at
circuit.
Insta
lling
o
f a fu
se w
ith a hig
her
rating
may c
ause d
am
ag
e t
o w
irin
g a
nd
co
mp
onents
.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Main
tenance -
Ele
ctr
icals
Main
tenance -
Ele
ctr
icals
Deale
r D
eve
lop
ment
Cente
r134
Deale
r D
eve
lop
ment
Cente
r133 R
ec
tifi
er
& R
eg
ula
tor
Asse
mb
ly :
AC
Vo
lta
ge
Me
asu
rem
en
t :
To
measu
re A
C v
oltag
e,
op
en
th
e h
ead
ligh
t h
ou
sin
g.
Sta
rt t
he e
ng
ine a
nd
set
it a
t 4
00
0+
25
RP
M.
En
su
re
that
the h
ead
ligh
t, t
ail
ligh
t, S
peed
om
ete
r lig
ht
are
‘O
N’
an
d t
he d
ipp
er
sw
itch
is a
t ‘H
i b
eam
’ p
ositio
n.
Co
nn
ect
AC
vo
ltm
ete
r in
p
ara
llel
acro
ss
the
AC
circu
it
load
b
y
co
nn
ectin
g
the
+ve
mete
r le
ad
to
re
d/b
lack l
ead
fro
m t
he d
ipp
er
sw
itch
an
d t
he -
ve m
ete
r le
ad
to
gro
un
d.
Measu
re
AC
lig
htin
g
vo
ltag
e
at
40
00
+2
5
RP
M.
Th
e
vo
ltag
e
sh
ou
ld
be
13
.5+
0.5
V
. S
top
th
e
en
gin
e.
Dis
co
nn
ect
the m
ete
r le
ad
s.
Reassem
ble
th
e h
ead
ligh
t h
ou
sin
g.
DC
C
ha
rgin
g
Vo
lta
ge
M
ea
su
rem
en
t :
(Us
e
full
y
ch
arg
ed
b
att
ery
w
hil
e
me
asu
rin
g)
To
m
easu
re th
e D
C vo
ltag
e;
set
the m
ete
r at
20
VD
C ra
ng
e.
Co
nn
ect
the m
ete
r +
ve le
ad
to
w
hite
fro
m
RR
u
nit
an
d
mete
r -v
e
lead
to
g
rou
nd
. S
tart
th
e e
ng
ine a
nd
set
it a
t 4
00
0+
25
R
PM
. M
easu
re
the
vo
ltag
e
with
an
d
with
ou
t h
ead
ligh
t sw
itch
to
th
e O
N p
ositio
n.
Sto
p th
e
en
gin
e d
isco
nn
ect
the m
ete
r le
ad
s.
Me
ter
Ra
ng
eS
pe
cif
ica
tio
n a
t 4
00
0+
25
RP
M
AC
2o
Vo
lt1
3.7
+ 0
.3 V
AC
Lig
hti
ng
Cir
cu
it :
Me
ter
Ra
ng
eS
pe
cif
ica
tio
n a
t 4
00
0+
25
RP
M
DC
20
Vo
lt1
4 ~
15
V
Me
ter
Ra
ng
eC
on
ne
cti
on
Sp
ec
ific
ati
on
DC
10
AM
eter
+ve
W
hite
/Bla
ckte
rmin
al o
f R
/R
Met
er +
ve
Wh
ite/B
lack
term
inal
of
R/R
Ba
tte
ry D
C C
ha
rgin
g c
urr
en
t :
(Use
fu
lly
ch
arg
ed
ba
tte
ry w
hile
me
asu
rin
g)
To
m
easu
re
the
DC
ch
arg
ing
cu
rren
t,
set
the
mete
r at
20
AD
C.
Co
nn
ect
mete
r+ve
lead
to
W
hite/b
lack le
ad
fr
om
R
R U
nit an
d m
ete
r -v
e
lead
to
batt
ery
+ve l
ead
.
Sta
rt
the
en
gin
e
an
d
set
it
at
40
00
+2
5
RP
M.
Measu
re
the
DC
ch
arg
ing
cu
rren
t.
Th
e
DC
ch
arg
ing
cu
rren
t sh
ou
ld b
e 2
A
m
ax sto
p th
e
en
gin
e
an
d
dis
co
nn
ect
mete
r le
ad
s.
Co
nn
ect
the R
R u
nit a
nd
batt
ery
Met
er -
ve
Bat
tery
(+)
lead
(Wh
ite)
2 A
max
at
40
00
+25
RP
M
L/W
L/W
W
RE
GU
LA
TO
R R
EC
TIF
IER
UN
IT
L/W
L/W
W
MA
GN
ETO
B
FUSE
(10 A
mp
s.)
R
W/B
STA
RTE
R R
ELAY
WIT
H D
AM
PER
BATT
ERY
12V-9
Ah
L/W
L/W
Multim
ete
r co
nnecte
d in
Parr
alle
l w
ith B
att
ery
fo
r checkin
g D
C c
harg
ing
vo
ltag
e
14.2
MA
GN
ETO
.90
L/W
L/W
W
B
FUSE
(10 A
mp
s.)
R
W/B
STA
RTE
R R
ELAY
WIT
H D
AM
PER
BATT
ERY
12V-9
Ah
L/W
L/W
W
L/W
L/W
Mu
ltim
ete
r co
nn
ecte
d
in S
eries w
ith
Batt
ery
fo
r ch
eckin
g D
C
ch
arg
ing
Cu
rren
t
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
INSTRUMENT CLUSTER
Y/R
Y
R
Y
W
Y/R
MA
GN
ETO
B
FU
SE
10 A
mps
R
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
BA
TTER
Y12V
-9A
h
PO
SIT
ION
LA
MP
12V
-5W
- 2 N
OS
.
B/Y RR/B
R
R/B
O F F
O N
R/Y
WBr
HEA
D L
AM
PA
SS
Y/L
AM
P12V
-35/3
5W
HS
1
IGN
ITIO
NS
WIT
CH
R
R/B
B/Y R W
PIN
NO
.3H
IGH
BEA
M I
ND
ICA
TO
R
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
PIN
NO
.11
CO
MM
ON
GR
OU
ND
PIN
NO
.13
PO
SIT
ION
LA
MP
ON
- IN
PU
T
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
BO
DY
CO
NTR
OL U
NIT
R/Y
R/B
AC
IN
PU
T&
OU
TP
UT
WBr
R R/B
R/Y
20 PIN COUPLER WITH DUST COVER
CO
NTR
OL
SW
ITC
H R
H
REG
ULA
TO
RR
EC
TIF
IER
UN
IT
Y/R
Y
TAIL
/S
TO
PLED
A
SS
LY
RR
B/Y
B/Y
Br
Br
NO
.P
LA
TE
LA
MP
5 W
LIG
HTIN
GC
OIL
13.5
-+
RE
GU
LA
TO
R R
EC
TIF
IER
UN
IT
Main
tenance -
Ele
ctr
icals
Main
tenance -
Ele
ctr
icals
Deale
r D
eve
lop
ment
Cente
r136
Deale
r D
eve
lop
ment
Cente
r135
Sp
ee
do
me
ter/
Ta
ch
om
ete
r C
on
so
le
Th
e
sp
eed
om
ete
r h
as
a
wid
e
Dig
ital
LC
D
scre
en
w
ith
a
ora
ng
e
backlit
dis
pla
y m
od
e f
or
su
perb
vis
ibili
ty o
f d
isp
lay d
urin
g n
igh
t rid
ing
co
nd
itio
n.
Th
is e
ntire
sp
eed
o c
on
so
le h
ou
ses f
ollo
win
g :
•A
larg
e a
nalo
gu
e t
ach
om
ete
r w
ith
self t
estin
g m
ech
an
ism
.
•A
red
LE
D i
nd
icato
r sh
ow
ing
lo
w f
uel
level in
sid
e
the
fuel
tan
k.
An
d als
o in
dic
ate
s a flash
ing
sig
nal
wh
en
en
gin
e R
PM
exceed
s
ab
ove 9
00
0 R
PM
. T
hu
s e
nsu
rin
g s
afe
ty o
f rid
er
an
d e
ng
ine.
•D
igital
Dis
pla
ys f
or
-O
do
mete
r
-T
rip
mete
r (U
niq
ue fa
cili
ty o
f restin
g th
e trip
mete
r 1
& 2
resp
ectively
)-
Fu
el l
evel i
nd
icato
r
•A
ro
w o
f in
dic
atio
n L
ED
dis
pla
yin
g f
un
ctio
nin
g o
f
-N
eu
tral
Lig
ht
-H
igh
beam
-T
urn
sig
nal
-S
ide s
tan
d O
N
wit
h
a
un
iqu
e
Da
y-N
igh
t m
od
e
fun
cti
on
ing
fe
atu
re
for
rid
ers
co
nven
ien
ce a
nd
safe
ty.
Ve
hic
le S
pe
ed
Se
nso
r
•N
on
C
on
tac
t W
he
el
Se
nso
r :
In L
CD
sp
eed
o co
nso
le th
ere
are
no
p
hysic
al
mo
vin
g p
art
s as sen
sin
g o
f w
heel
sp
eed
is
th
rou
gh
a N
on
Co
nta
ct
hall
eff
ect
Sen
so
r.T
he
hall
sen
so
r is
a
ele
ctr
on
ic
sw
itch
w
hic
h
op
era
tes
du
e
to
mag
netic field
. T
he sen
so
r h
as 3
w
ires su
pp
ly,
eart
h an
d o
utp
ut
wh
en
ever
du
rin
g
rota
tio
ns
of
wh
eel
mag
net
passes
thro
ug
h
sen
so
r.
A
sig
nal
is
giv
en
to
sp
eed
om
ete
r th
rou
gh
a
wire
to
sp
eed
om
ete
r w
hic
h d
isp
lays s
peed
of
veh
icle
in
km
/hr.
•T
ail
La
mp
:
Th
e
illu
min
atio
n
for
Tail
lam
p
an
d
Bra
ke
lam
p
are
do
ne
thro
ug
h
2
row
s
of
LE
D’s
each
. T
hese
are
h
igh
in
ten
sity
LE
D’s
th
e m
ain
ad
van
tag
e o
f th
ese L
ED
’s is
th
ey co
nsu
me very
less p
ow
er.
i.e
LE
D c
on
su
mes 3
W p
ow
er
ag
ain
st
21
W p
ow
er
of
a
co
nven
tio
nal
bra
ke
lam
p.
Wh
en
yo
u
op
era
te
ligh
t co
ntr
ol
sw
itch
to
g
low
b
ut
inte
nsity
will
b
e
very
lo
w.
As
so
on
as
yo
u
op
era
te
bra
ke
sw
itch
th
e
brig
htn
ess
of
LE
D
incre
ases
to
siz
e
yo
u b
rig
ht
ligh
t.
Th
is
ch
an
geo
ver
of
inte
nsity
is
main
tain
ed
w
ith
th
e
help
o
f
ele
ctr
on
ic circu
it p
laced
in
sid
e T
ail
Lam
p C
on
so
le assly
an
d is
a
tota
lly s
eale
d u
nit.
Ho
rn S
witch
Pass S
witch
Head
Lig
ht
Hig
h B
eam
Ho
rnB
CU
BC
UN
ote
:
The
sp
eed
om
ete
r co
nso
le
has
a
uniq
ue
built
in
mem
ory
lo
gic
fu
nctio
n
whic
h
sto
res
all
the
data
lik
e
dis
tance c
overe
d e
tc.
in i
ts m
em
ory
even i
f D
C s
up
ply
is d
isco
nnecte
d.
•B
ac
k-l
it,
No
n-c
on
tac
t H
an
dle
ba
r sw
itc
he
s
:
Th
e
co
ntr
ol
sw
itch
es
on
b
oth
sid
es
of
the
han
dle
bar
are
co
nven
tio
nal to
lo
ok a
s,
in t
erm
s o
f sw
itch
po
sitio
nin
g.
Th
e m
ain
featu
res o
f th
ese a
re
...
•O
pera
tio
n is b
ased
on
no
n-c
on
tact
•S
witch
ing
is d
on
e w
ith
ou
t p
hysic
al
co
nta
ct
•T
here
is n
o w
ear
an
d t
ear
•L
ife
wo
uld
b
e
eq
ual
to
that
of
the
bik
e
itself.
•T
he
o
pe
rati
on
al
forc
e
req
uir
ed
fo
r th
e
sw
itch
es h
as b
een
kep
t as l
ow
as p
ossib
le
to
giv
e
a
ligh
t fe
el
an
d
red
uce
fatig
ue
for
the r
ider.
Wo
rkin
g o
f S
wit
ch
es :
Th
ese a
re n
on
-co
nta
ct
typ
e
sw
itch
es,
so
in
ste
ad
o
f co
nta
ct
set
it
co
nsis
ts
of
hall
sen
so
r an
d m
ag
net
co
mb
inatio
n.
Wh
en
ever
an
y
han
dle
bar
sw
itch
es
is
pre
ssed
th
e
hall
sen
so
r g
ets
o
pera
ted
an
d
its
ou
tpu
t sig
nal
is
giv
es
to
a
BC
U
(Bo
dy
Co
ntr
ol
Un
it)
an
d
BC
U
furt
her
calc
ula
tes
an
d
giv
es
pre
cis
e
sig
nal
to
the
resp
ective u
nit f
or
fun
ctio
nin
g.
e.g
.
•S
elf
In
dic
ato
r S
wit
ch
:
In
the
co
nven
tio
nal
typ
e
of
sw
itch
es
the
rid
er
has
to
man
ually
d
ep
ress
the
Tu
rn
Ind
icato
r kn
ob
o
r re
turn
th
e
Tu
rn
ind
ica
tor
kn
ob
to
it
s
no
n-s
ign
allin
g
po
sitio
n.
In
UG
III
there
is
n
o
sep
ara
te
pre
ss
to
off
b
utt
on
s f
or
can
celli
ng
sid
e i
nd
icato
r sig
nal. T
his
fe
atu
re i
s a
ch
ieved
by p
rovid
ing
a s
elf c
an
celli
ng
h
all
sen
so
r an
d m
ag
net
fitt
ed
on
ste
erin
g c
olu
mn
assem
bly
.
Th
is
can
cella
tio
n
sig
nal
is
pro
cessed
th
rou
gh
B
CU
an
d th
en
sid
e in
dic
ato
rs are
sw
itch
ed
o
ff.
T
he s
elf c
an
celli
ng
featu
re a
uto
matically
tu
rns o
f th
e in
dic
ato
r o
f th
e in
dic
ato
r u
nd
er
3 c
on
ditio
ns.
•T
he f
irst
ind
icatio
n i
s w
hen
aft
er
the t
urn
has
been
co
mp
lete
d an
d th
e h
an
dle
bar
co
mes
to a str
aig
ht
ah
ead
p
ositio
n,
the in
dic
ato
rs
sw
itch
off
by t
hem
selv
es.
•T
he s
eco
nd
co
nd
itio
n i
s w
hen
th
e r
ider
has
se
lec
ted
a
ri
gh
t o
r le
ft
turn
b
ut
no
t p
hysic
ally
do
ne t
he t
urn
an
d i
s c
on
tin
uin
g t
o
go
str
aig
ht
ah
ead
an
d m
ay b
e u
naw
are
o
f th
e e
nab
led
tu
rn s
ign
al
too
. A
tim
er
fun
ctio
n
ge
ts
en
ab
led
w
hic
h
sw
itc
he
s
off
th
e
ind
icato
rs a
fter
a p
re-s
et
tim
e.
•T
he
third
co
nd
itio
n
is
wh
en
th
e
rid
er
has
sele
cte
d f
or
eg
. a left
tu
rn,
bu
t ch
an
ges h
is
min
d
an
d
wan
ts
to
co
ntin
ue
str
aig
ht
ah
ead
. T
he
rid
er
has
on
ly
to
re-s
ele
ct
the
op
po
site
sid
e
ind
icato
r ag
ain
to
can
cel
the
pre
vio
usly
sele
cte
d
ind
icatio
n.
(Th
ere
is
n
o
dep
ress
to
can
cel
fun
ctio
n)
Th
e o
ther
featu
re w
hic
h h
as b
een
in
co
rpo
rate
d in
th
e s
witch
es i
s t
he i
llum
inatio
n o
f th
e t
ell-
tale
ico
ns.
Th
e i
llum
inatio
n i
s b
acklit
by L
ED
’s w
hic
h a
gain
are
lo
ng
-life an
d h
ave a p
leasan
t b
luis
h-w
hite g
low
to
th
em
. A
ll th
e
ico
ns
like
the
turn
in
dic
ato
rs,
low
b
eam
, h
igh
beam
, h
orn
, sta
rter
etc
. g
low
wh
en
th
e
Park
ing
or
Head
ligh
t sw
itch
es a
re p
ut
ON
.
Ch
ec
kin
g o
f sw
itc
he
s o
n h
an
dle
b
ar
: A
s lik
e in
co
nven
tio
nal
sw
itch
es,
sin
ce
sw
itch
is
n
ot
havin
g
an
y
ele
ctr
ical
co
nta
ct,
W
e
can
’t
ch
eck
the
sw
itch
fu
nctio
nin
g (
Co
ntin
uity)
by m
ultim
ete
r. B
ut
it c
an
be
ch
ecked
on
ele
ctr
on
ic t
est
jig.
•C
lutc
h S
wit
ch
: T
he c
lutc
h s
witch
has 3
wires
an
d it
has c
on
tact
co
nfig
ratio
n o
f
Th
is
ve
hic
le
is
no
t h
avin
g
inte
rlo
ck
rela
y
Inste
ad
its w
ork
ing
is
ta
ken
care
o
f b
y clu
tch
Lig
ht
Gre
en
Yello
w/G
reen
Bla
ck/Y
ello
w
OF
F C
lutc
h
Lever
Rele
ased
ON
Clu
tch
L
ever
Rele
ased
•B
od
y
Co
ntr
ol
Un
it
(BC
U)
: T
his
is
a
seale
d
Ele
ctr
ic
Co
ntr
ol
Un
it
locate
d
insid
e
head
lig
ht
assly
.
-In
case o
f o
verlo
ad
o
r sh
ort
circu
it,
BC
U
has
a
sh
ort
cir
cu
it/o
verl
oad
p
reven
tio
n
facili
ty.
-T
his
veh
icle
d
oes n
ot
have a flash
er.
T
he
flash
er
op
era
tio
n
is
carr
ied
o
ut
by
BC
U
on
ly.
-In
case
of
failu
re
of
on
e
of
the
fila
men
ts
of
head
la
mp
. T
he B
CU
w
ill au
tom
atically
c
ha
ng
eo
ve
r to
II
nd
fi
lam
en
t.
Th
is
is
pro
vid
ed
fo
r sa
fety
ri
de
r d
uri
ng
n
igh
t d
rivin
g c
on
ditio
ns.
-If
c
us
tom
er
op
era
ted
s
tart
er
sw
itc
h
co
ntu
nu
ou
sly
3
tim
es
in
a
go
fo
r 4
th
c
ran
kin
g
BC
U
wil
l d
isa
ble
c
ran
kin
g
op
era
tio
n
an
d
next
cra
nkin
g
wo
uld
b
e
po
ssib
le
aft
er
20
se
co
nd
o
nly
. T
his
fe
atu
re
is
ad
de
d
wh
ich
g
ive
s
be
tte
r b
att
ery
life.
Ma
inte
na
nc
e :
•E
nsu
re
no
d
ire
ct
hig
h
pre
ssu
re
wa
ter
wate
r is
ap
plie
d
on
S
peed
o
co
nso
le
an
d
wh
eel
sen
so
r.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Main
tenance -
Ele
ctr
icals
Main
tenance -
Ele
ctr
icals
Deale
r D
eve
lop
ment
Cente
r138
Deale
r D
eve
lop
ment
Cente
r137
•S
pe
ed
o
co
nso
le
sh
ou
ld
no
t b
e
ke
pt
inverte
d
•E
nsu
re
there
are
n
o
scra
tch
es/b
reakag
e
on
co
nso
le c
over
`•
Do
n’t
op
en
ru
bb
er
pin
s lo
cate
d o
n b
ack
sid
e
of
sp
eed
o
un
der
an
y
un
der
an
y
circ
um
sta
nces.
•E
nsu
re
sp
ee
do
c
on
so
le
an
d
ha
rne
ss
matin
g
co
up
ler
is
alw
ays
co
vere
d
by
rub
ber c
over.
•H
an
dle
w
he
el
se
nso
r c
are
fully
w
hile
w
ork
ing
o
n
fron
t b
rake
dru
m
rela
ting
p
rob
lem
s.
•E
nsu
re s
en
so
r cab
le is
inta
ct.
•D
o
no
t ap
ply
in
g
rease
or
lub
rican
t in
b
etw
een
the ro
tatin
g p
arts
.•
Do
n
ot
op
en
co
ntro
l sw
itch
es
an
d
do
n’t
ap
ply
an
y g
rease o
r lub
rican
t.
B/Y
INS
TR
UM
EN
T C
LU
STE
R
Y/R
L/W
L/WY
B Y/ W
B/Y
B/Y
B/Y
SIDE STANDSWITCH
B/Y
R/W
HORN (RH)
RY
B/Y
Br/
B
W
B/Y
Y/R
W/R
L/W
R L/W
COIL
PULS
ING
MAGNETO
B
B/WB/Y
B
B
STARTERMOTOR
R
FUSE10 Amps
R
W/B
STARTER RELAY70A RATING
BATTERY12V-9Ah
Lg
Lg
B/Y
W/Y
FUEL LEVELGAUGE
POSITION LAMP12V-5W- 2 Nos.
B
Br
B/Y
W/Y
Lg
Gr
G
R
R/B
R
B/Y
B/Y
R/B
OFF
ON
Y/R
L/W
L/W
W R/R B
/Y
B/Y
Br/
B
B/Y
GG
B Y/
B/Y
B/Y
B/Y
/B YB/Y
/B Y/B Y
L/B Y
R/R W
/B Y
L
GrGr
Br L
LBr
GG
Br L
LBr
R/Y
B/W
W
Br
GrGr
NEUTRALSWITCH
HORN (LH)
SIGNALLAMPREAR LH
SIGNALLAMPREAR RH
REAR BRAKESWITCHFRONT BRAKE SWITCH
SIGNAL LAMPFRONT LH
HEAD LAMPASSY/LAMP
12V-35/35W HS1
IGNITIONSWITCH
SIGNAL LAMPFRONT RH
LAMP 12V-10W
EARTH-FRAME
CABLE ASSY. RED
CABLEASSEMBLYEARTH
CLUTCHSWITCH
Y/G
B/Y
Br
Y/G
B/Y
O/B
r
O/B
r
Y/G
SPARKPLUG
H.T.COIL
B/R
SWITCH ASSY.
R
Lg
Lg
R/W
Br
R/B
O/Br
W/Y
L/W
Gr
G
Lg
B
B/Y
R
W
PIN NO.1VEHICLE SPEED SENSOR + INPUT
PIN NO.2INSTRUMENT CLUSTER + INPUT
PIN NO.3HIGH BEAM INDICATOR
PIN NO.4TALE-TELL SIDE STAND INDICATOR
PIN NO.5FUEL GAUGE INDICATOR
PIN NO.6VEHICLE SPEED SENSOR OUTPUT
PIN NO.7TALE-TELL BLINKER- RH INPUT
PIN NO.8TALE-TELL BLINKER- LH INPUT
PIN NO.9TALE-TELL NEUTRAL INDICATOR
PIN NO.10TACHOMETER
PIN NO.11COMMON GROUND
PIN NO.13POSITION LAMP ON- INPUT
PIN NO.20PERMANENT BATTERY + INPUT
O/Br
R/W R/W
L/W
L/W B/Y
VEHICLESPEED
SENSORSWITCH- BODY CONTROL UNIT
FROMLH SWITCH
FROMS.C.B. UNIT
R/Y
R/B Br/
B
G Gr
R/W
R/W
NOT USED
B/Y
W/R
B Br
KIL SWITCH
HALL SENSOR ASSLY(S.C.B. UNIT)
MAGNET ASSLY(S.C.B. UNIT)
AC INPUT& OUTPUT
DC INPUT& OUTPUT
W/R R
B/R
POSITIVE SUPPLY
LH SIDE IND. OUTPUT
RH SIDE IND. OUTPUT
GROUND
ASSY.LIGHTNO.PLATE
R
B Y/
TAILLAMPASSY
TAIL/STOPLED
B/Y
B/W
W
Br
R
R/B
B/Y
R/Y
B/Y
20 P
IN C
OU
PLER
WIT
H D
US
T C
OV
ER
FROMRH SWITCH
CONTROLSWITCH
RH
CONTROLSWITCH LH
REGULATOR
C.D.I. ASSY.
SPARKPLUG
H.T.COIL
Y/R
L/W
L/WY
B Y/ W
Puls
ar
DT
S-i
UG
-III-180cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
UG
-III-180cc Tra
inin
g N
ote
s
No
tes :
Main
tenance - E
lectric
als
Main
Ele
ctric
al W
iring
Dia
gra
m
Deale
r D
eve
lop
ment
Cente
r140
Deale
r D
eve
lop
ment
Cente
r139Ig
nit
ion
Cir
cu
it :
Bra
ke
Lig
ht
Cir
cu
it :
Ho
rn C
irc
uit
:
ILCO PULSING
MA
GN
ET
O
O F F
O N
B/W
B/Y
IGN
ITIO
NS
WIT
CH
B
B/Y
W/R
B/R
RE
ED
SW
ITC
HA
SS
Y. (
TP
S)
SP
AR
KP
LU
G
H.T
. C
OIL
No
. 2
(Fo
rS
eco
nd
ary
Sp
ark
Plu
g)
B/R
H.T
. C
OIL
No
. 1
(Fo
rP
rim
ary
Sp
ark
Plu
g)
B/W
B/Y
B/WW
/R
B/Y
W/R
B/Y
W/R
B/WC.D
.I.
AS
SY.
G Y
SP
AR
KP
LU
G
R
R
RR
EX
CIT
ER
CO
IL
Kil
l S
wit
ch
MA
GN
ETO
L/W
L/WL/W
L/W
W
W
FU
SE
10 A
mps
RW/B
STA
RTER
RELA
Y70A
RA
TIN
G
BA
TTER
Y12V
-9A
h
R
REG
ULA
TO
RR
EC
TIF
IER
UN
IT
B/Y
B/Y
BA
TTER
YC
HA
RG
ING
CO
IL
B
FR
ON
T B
RA
KE
SW
ITC
H
O F F
O N
WBr
IGN
ITIO
NS
WIT
CH
L B/Y
ST
OP
LA
MP
LE
DB
AN
K
B/Y
EA
RT
H-F
RA
ME
W
FU
SE
10
Am
ps
W/B
STA
RT
ER
RE
LA
Y7
0A
RA
TIN
G
Br
LL
Br
RE
AR
BR
AK
ES
WIT
CH
Br
LL
Br
BA
TT
ER
Y1
2V
-9A
h
R
B
CO
NTR
OL
SW
ITC
H L
H
BO
DY
CO
NTR
OL U
NIT
B/Y
EA
RTH
-FR
AM
E
B/Y
Br/B
B/Y
W
FU
SE
10 A
mps
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
IGN
ITIO
NS
WIT
CH
O N
Br
Br
O F F
W
Br
Br/B Br/B
W
B/Y Br/B
HO
RN
(R
H)
HO
RN
(LH
)
B/Y
BA
TTER
Y12V
-9A
h
R
B
Ba
tte
ry C
ha
rgin
g C
irc
uit
:
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ind
ivid
ual
Circuit D
iag
ram
sIn
div
idual
Circuit D
iag
ram
s
TURN SIGNALSELF CANCELLATION DEVICE
PO
SIT
IVE S
UP
PLY
LH
SID
E I
ND
. O
UTP
UT
RH
SID
E I
ND
. O
UTP
UT
GR
OU
ND
PIN
NO
.7TA
LE-T
ELL B
LIN
KER
- R
H I
NP
UT
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
- IN
PU
T
PIN
NO
.8TA
LE-T
ELL B
LIN
KER
- LH
IN
PU
T
PIN
NO
.11
CO
MM
ON
GR
OU
ND
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
O F F
O N
Br
IGN
ITIO
NS
WIT
CH
WBr
B/Y
EA
RTH
-FR
AM
E
W
FU
SE
10 A
mps
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
B/Y
Gr
Gr
SIG
NA
LLA
MP
REA
RR
H
W
B/Y
B/Y W
Gr
Gr
B/Y
B/Y
Gr
Gr
SIG
NA
L L
AM
PFR
ON
T R
H
B/Y
B/Y
B/Y
W
Gr
B/Y
Br
B/Y
B/Y
Gr
BO
DY
CO
NTR
OL U
NIT
GG
SIG
NA
L L
AM
PFR
ON
T L
HG
G
SIG
NA
LLA
MP
REA
RLH
BA
TTER
Y12V
-9A
h
R
GG
G
Br
Br
Br
CO
NTR
OL
SW
ITC
H L
H
B
O F F
O N
IGN
ITIO
NS
WIT
CH
W
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
PIN
NO
.5FU
EL G
AU
GE I
ND
ICA
TO
R
B/Y
W/Y
FU
EL L
EV
EL G
AU
GE
B/Y
EA
RTH
-FR
AM
E
W/Y
W/Y W
INSTRUMENT CLUSTER
W
W
FU
SE
10 A
mps
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
BA
TTER
Y12V
-9A
h
R
W/Y
PIN
NO
.11
CO
MM
ON
GR
OU
ND
B/Y
B/Y
SPEEDOMETER COUPLER
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
Br
Br
Br
Br
B
INSTRUMENT CLUSTER
Y/R
Y
R
Y
W
Y/R
MA
GN
ETO
B
FU
SE
10 A
mps
R
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
BA
TTER
Y12V
-9A
h
PO
SIT
ION
LA
MP
12V
-5W
- 2 N
OS
.
B/Y RR/B
R
R/B
O F F
O N
R/Y
WBr
HEA
D L
AM
PA
SS
Y/L
AM
P12V
-35/3
5W
HS
1
IGN
ITIO
NS
WIT
CH
R
R/B
B/Y R W
PIN
NO
.3H
IGH
BEA
M I
ND
ICA
TO
R
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
PIN
NO
.11
CO
MM
ON
GR
OU
ND
PIN
NO
.13
PO
SIT
ION
LA
MP
ON
- IN
PU
T
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
BO
DY
CO
NTR
OL U
NIT
R/Y
R/B
AC
IN
PU
T&
OU
TP
UT
WBr
R R/B
R/Y
20 PIN COUPLER WITH DUST COVER
CO
NTR
OL
SW
ITC
H R
H
REG
ULA
TO
RR
EC
TIF
IER
UN
IT
Y/R
Y
TAIL
/S
TO
PLED
Ass
lyR
R
B/Y
B/Y
Br
Br
NO
.P
LA
TE
LA
MP
5 W
LIG
HTIN
GC
OIL
INSTRUMENT CLUSTER
WB
FU
SE
10 A
mps
RW/B
STA
RTER
RELA
Y70A
RA
TIN
G
BA
TTER
Y12V
-9A
h
BBr
B/Y
O F F
O N
WBr
IGN
ITIO
NS
WIT
CH
Br
L/W B B/Y W
PIN
NO
.1V
EH
ICLE S
PEED
SEN
SO
R +
IN
PU
T
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
PIN
NO
.6V
EH
ICLE S
PEED
SEN
SO
R O
UTP
UT
PIN
NO
.10
TAC
HO
METER
PIN
NO
.11
CO
MM
ON
GR
OU
ND
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
L/W
VEH
ICLE
SP
EED
SEN
SO
R
W
Br
B/Y
20 PIN COUPLER WITH DUST COVER
C.D
.I.
AS
SY.
R/W
R/W
B
B
B/Y
B/Y
Deale
r D
eve
lop
ment
Cente
r142
Deale
r D
eve
lop
ment
Cente
r141AC
Lig
hti
ng
Cir
cu
it :
Sid
e I
nd
ica
tor
Cir
cu
it :
Fu
el In
dic
ato
r C
irc
uit
:S
pe
ed
om
ete
r a
nd
Ta
ch
om
ete
r C
irc
uit
:
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ind
ivid
ual
Circuit D
iag
ram
sIn
div
idual
Circuit D
iag
ram
s
Deale
r D
eve
lop
ment
Cente
r144
Deale
r D
eve
lop
ment
Cente
r143
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
PIN
NO
.9TA
LE-T
ELL N
EU
TR
AL I
ND
ICA
TO
R
INSTRUMENT CLUSTER
Lg
Lg
Lg
NEU
TR
AL S
WIT
CH
O F F
O N
IGN
ITIO
NS
WIT
CH
WW
W
FU
SE
10 A
mps
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
Lg
W
W
PIN
NO
.11
CO
MM
ON
GR
OU
ND
B/Y
B/Y
BA
TTER
Y12V
-9A
h
R
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
Br
Br
B
Br
Br
Br
O F F
O N
IGN
ITIO
NS
WIT
CH
W
W
FU
SE
10
Am
ps
W/B
STA
RT
ER
RE
LA
Y7
0A
RA
TIN
G
B/Y
EA
RT
H-F
RA
ME
B/Y
B/Y
SID
E S
TAN
D S
WIT
CH
O/Br
O/Br
INSTRUMENT CLUSTER
PIN
NO
.4TA
LE
-TE
LL
SID
E S
TAN
D I
ND
ICA
TO
R
PIN
NO
.11
CO
MM
ON
GR
OU
ND
PIN
NO
.20
PE
RM
AN
AN
T B
AT
TE
RY
+ I
NP
UT
O/B
r
B/Y
B/Y
W
W
W
SPEEDOMETER COUPLER
BA
TT
ER
Y1
2V
-9A
h
B
R
PIN
NO
.2IN
ST
RU
ME
NT
CL
US
TE
R +
IN
PU
T
Br
Br
Br
Br
Sta
tor
Mo
tor
Cir
cu
it :
Ne
utr
al L
igh
t C
irc
uit
:
Sid
e S
tan
d I
nd
ica
tio
n C
irc
uit
:
O F F
O N
IGN
ITIO
NS
WIT
CH
W
FU
SE
10 A
mps
W/B
STA
RTER
RELA
Y70A
RA
TIN
G
Lg
NEU
TR
AL
SW
ITC
H
Y/G
B/Y
Y/G
B/Y
Lg
Lg
B/Y
EA
RTH
-FR
AM
E
INSTRUMENT CLUSTER
PIN
NO
.9TA
LE-T
ELL N
EU
TR
AL I
ND
ICA
TO
R
PIN
NO
.20
PER
MA
NEN
T B
ATTER
Y +
IN
PU
T
Lg
Lg
W
Y/G
W
STA
RTER
MO
TO
R
BA
TTER
Y12V
-9A
h
R
R
BO
DY
CO
NTR
OL U
NIT
DC
IN
PU
T&
OU
TP
UT
CO
NTR
OL
SW
ITC
H R
H
Br
Br
Br
W
B/Y
PIN
NO
.2IN
STR
UM
EN
T C
LU
STER
+ I
NP
UT
PIN
NO
.11
CO
MM
ON
GR
OU
ND
Br
Br
Ple
ase n
ote
that
Sta
rter
Sw
itch i
s e
nab
le o
nly
if K
ill S
witch i
s i
n‘O
FF
’ co
nd
itio
n.
B
R/W
R/W
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ind
ivid
ual
Circuit D
iag
ram
sIn
div
idual
Circuit D
iag
ram
s
Deale
r D
eve
lop
ment
Cente
r146
Deale
r D
eve
lop
ment
Cente
r145
Hig
h F
ue
l C
on
su
mp
tio
n
Ch
eck i
dlin
g R
PM
as p
er
sp
ecific
ati
on
Ad
just
idlin
g t
o s
pecifie
d i
dlin
g r
pm
by i
dlin
g a
dju
sting
scre
w
1st
Ste
p :
Id
lin
g R
PM
Rela
ted
No
t
OK
Co
nti
nu
ed
....
.
OK
Ch
eck a
ir f
ilte
r fo
am
ele
men
t fo
r
no
clo
gg
ing
/
co
rrect
oil s
oakin
g
Cle
an a
ir f
ilter
foam
ele
ment
(fin
e &
co
rse)
as p
er
SO
P i
f clo
gg
ed
/ e
xcess o
il so
aked
2n
d S
tep
: A
ir I
nd
ucti
on
Rela
ted
No
t
OK
OK
If O
K
Cle
an a
ir i
nta
ke d
uct
if b
locked
/ c
log
ged
Ch
eck f
ree m
ovem
en
t
of
ch
oke
kn
ob
3rd
Ste
p :
Ch
oke R
ela
ted
No
t
OK
OK
Lub
ricate
/ R
ep
lace c
ho
ke p
lung
er
if s
ticky /
jam
If O
K
Cle
an c
ho
ke p
lung
er
if s
ticky /
jam
Idlin
g R
PM
1400
+ 1
00
Co
nti
nu
ed
....
.
OK
Ch
eck a
ccele
rato
r
cab
le f
ree p
lay f
or
TP
S f
un
cti
on
Ad
just
accele
rato
r cab
le f
ree p
lay
4th
Ste
p :
TP
S R
ela
ted
No
t
OK
OK
If O
K
If O
K
Rep
lace a
ccele
rato
r cab
leif s
ticky /
jam
Ch
eck f
ron
t w
heel
for
free r
ota
tio
n
Ad
just
fro
nt
bra
ke l
ever
free p
lay
if l
ess t
han
sp
ecifie
d
Check d
isc f
or
run
ou
t
5th
Ste
p :
Fro
nt
Wh
eel
Ro
tati
on
Rela
ted
No
t
OK
OK
2~3
mm
Fro
nt B
rake
Lev
er F
ree
Pla
y
2~3
mm
Acc
eler
ator
C
able
Fre
e P
lay
If O
K
If O
K
Check p
rop
er
fitm
ent
of
wh
eel
bearin
g D
isc s
ide
Usin
g f
ollo
win
g s
eq
uence T
igh
ten
th
e f
aste
ners
as
Axle
Nut,
Mud
gaurd
Mo
un
tin
g B
olts,
Lo
wer
‘T’, U
pp
er
‘T’,
Cap
nu
t
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r148
Deale
r D
eve
lop
ment
Cente
r147
Co
nti
nu
ed
.....
Ch
eck r
ear
wh
eel
for
free r
ota
tio
n
Ad
just
rear
bra
ke f
ree p
lay i
fle
ss t
han s
pecifie
d
6th
Ste
p :
Rear
Wh
eel
Ro
tati
on
Rela
ted
No
t
OK
If O
K
Lub
ricate
rear
bra
ke p
ed
al
shaft
if
dry
/ s
ticky
If O
K
Lub
ricate
rear
bra
ke c
am
if
sticky /
jam
OK
OK
Ch
eck c
lutc
h c
ab
le
for
free p
lay &
sm
oo
th o
pera
tio
n
Ad
just
clu
tch l
ever
free p
lay i
fle
ss /
mo
re t
han s
pecifie
d
7th
Ste
p :
Clu
tch
Cab
le R
ela
ted
No
t
OK
If O
K
Co
rrect
clu
tch c
ab
le r
outing
If O
K
Rep
lace c
lutc
h c
ab
le c
om
ple
teif s
ticky /
jam
25 ~
30
mm
Rea
r B
rake
Ped
al F
ree
Pla
y
2~3
mm
Clu
tch
Cab
leF
ree
Pla
y
OK
Co
nti
nu
ed
....
.
OK
Ch
eck s
park
plu
g
for
no
fo
ulin
g /
co
rrect
heat
ran
ge
& g
ap
. C
heck b
oth
sp
ark
plu
g f
or
DT
S-i
en
gin
e
Cle
an &
ad
just
sp
ark
plu
g g
ap
as p
er
sp
ecific
atio
n
8th
Ste
p :
Sp
ark
Plu
g R
ela
ted
No
t
OK
If O
K
Rep
lace s
park
plu
g b
y r
eco
mm
en
ded
one i
f in
co
rrect
heat
ran
ge
If O
K
Rep
lace s
park
plu
g i
f fo
ule
dO
K
Ch
eck c
arb
ure
tto
r
for
co
rrect
air
fu
el
mix
ture
wit
h
the h
elp
of
‘CO
’
gas a
naly
ser
Ad
just
VC
scre
w a
sp
er
sp
ecific
atio
n &
CO
lim
it
9th
Ste
p :
Carb
ure
tto
r R
ela
ted
No
t
OK
If O
K
Co
rrect
‘e’
clip
po
sitio
nas p
er
sp
ecific
atio
n
If O
K
Cle
an c
arb
ure
tto
r b
od
y a
ir p
assag
es
if c
log
ged
If O
K
Rep
lace c
arb
ure
tto
r je
ts i
f w
orn
ou
t
If O
K
Rep
lace n
eed
le v
alv
e &
its
seat
if w
orn
out
Sta
ndar
d C
O %
= 1
.75
to 2
.25%
Std.
VC
Scr
ew S
ettin
gs =
2.5
+2 T
urns
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r150
Deale
r D
eve
lop
ment
Cente
r149
Co
nti
nu
ed
....
.
OK
OK
OKC
he
ck
ign
itio
n t
imin
g
Rep
lace C
DI
if t
imin
g i
s i
nco
rrect
11
th S
tep
: I
gn
itio
n T
imin
g R
ela
ted
No
t
OK
If O
K
Rep
lace r
oto
r if c
am
po
sitio
n w
ron
gle
ad
ing
to
in
co
rrect
ign
itio
n t
imin
g
If O
K
Rep
lace H
.T.
co
il fo
r m
alfu
nctio
nin
g
Ch
ec
k T
PS
fo
r
co
rre
ct
ga
p /
fre
e
mo
ve
me
nt
/ m
ag
ne
t
pre
se
nc
e /
co
nti
nu
ity
Ad
just
gap
betw
een
mag
net
& r
eed
sw
itch
as p
er
sp
ecific
atio
n i
f fo
un
d m
ore
10
th S
tep
: T
PS
Re
late
d
No
t
OK
If O
K
Cle
an
TP
S s
witch
if s
tuck u
p /
sticky o
pera
tio
n
If O
K
Rep
lace m
ag
net
if m
issin
g
If O
K
Rep
lace T
PS
sw
itch
if
reed
sw
itch
sh
ort
/ o
pen
circu
ited
2.5
mm
Sta
ndar
d G
apB
etw
een
Mag
net
&R
eed
Sw
itch
Ch
eck
co
mp
ressio
n
pre
ssu
re.
Perf
orm
dry
& w
et
co
mp
ressio
n
test
If c
om
pre
ssio
n p
ressu
rein
wet
test
is N
OT
OK
Ch
eck &
Rec
tify
cylin
der
head
rela
ted
rea
so
ns
If c
om
pre
ssio
n p
ressu
rein
wet
test
is O
K
Ch
ec
k &
Re
cti
fycylin
der
blo
ck
rela
ted
rea
so
ns
Co
rrect
valv
e t
imin
gif m
ark
on c
am
sp
rocket
no
t alig
nin
gw
ith c
yl. h
ead
when
roto
r ‘T
’ m
ark
is
alig
ned
with
cra
nkcase L
.H.
mark
Cle
an
co
mp
ressio
nrin
g &
pis
ton
gro
ove
if s
ticky /
jam
OK
12th
Ste
p:
En
gin
e C
om
pre
ssio
n P
ressu
re R
ela
ted
* R
eset
valv
e t
ap
pet
cle
ara
nce a
s p
er
sp
ecs.
if f
ound
less
Rep
lace p
isto
n r
ing
set
if c
om
pre
ssio
n r
ing
wo
rn o
ut
Cle
an v
alv
e g
uid
e &
valv
e s
tem
if
gu
mm
ysu
bsta
nce d
ep
osited
Rep
lace c
ylin
der
blo
ck
pis
ton
assem
bly
if w
orn
out
/excessiv
e c
leara
nce
Rectify
valv
e s
eat
and
valv
e
face b
y l
ap
pin
g i
f p
itte
d /
wo
rn o
ut
/ excess c
arb
on
dep
ositio
n I
nsp
ect
De-c
om
p
mechanis
m f
or
stickness
Rep
lace c
ylin
der
pis
ton
assem
bly
if p
art
ially
seiz
ed
Rep
lace i
nle
t &
exh
aust
valv
e i
f b
ent
Inle
t
0.05
mm
0.10
mm
*Sta
ndar
d Ta
ppet
C
lear
ance
Exh
aust
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r152
Deale
r D
eve
lop
ment
Cente
r151
Po
or
Pic
k-u
p &
Po
or
Ac
ce
lera
tio
n
No
t
OK
Ch
eck f
uel
for
no
ad
ult
era
tio
n /
co
nta
min
ati
on
Rep
lace f
uel
fro
m p
etr
ol
tank,
co
ck
& c
arb
ure
tto
r b
ow
l
1st
Ste
p :
Fu
el
Rela
ted
OK
Ch
eck a
ir i
nd
ucti
on
syste
m f
or
no
ch
oke-u
p /
no
clo
gg
ing
i.e
. co
rrect
qu
an
tity
& s
mo
oth
su
pp
ly o
f air
Cle
an a
ir i
nta
ke d
uct
if b
locked
2n
d S
tep
: A
ir I
nd
ucti
on
Rela
ted
OK
Cle
an a
ir f
ilter
foam
ele
ment
as p
er
SO
P i
f clo
gg
ed
/ e
xcess o
il so
aked
If O
K
No
t
OK
Ch
eck c
arb
ure
tto
r
for
co
rrect
air
fu
el
mix
ture
wit
h t
he h
elp
of
CO
gas a
naly
ser
Re-a
dju
st
V.C
. scre
w a
s p
er
sp
ecific
atio
ns
3rd
Ste
p :
Carb
ure
tto
r R
ela
ted
No
t
OK
If O
K
Co
rrect
‘e’
clip
po
sitio
nas p
er
sp
ecific
atio
n
If O
K
Cle
an m
ain
jet,
pilo
t je
t if c
log
ged
If O
K
Cle
an c
arb
ure
tto
r air &
mix
ture
passag
es i
f clo
gg
ed
If O
K
Co
rrect
dia
phra
gm
po
sitio
n i
f w
rong
If O
K
Rep
lace c
arb
ure
tto
r p
isto
n v
alv
e a
ssly
if d
iap
hra
gm
punctu
red
Co
nti
nu
ed
.....
Stan
dard
Set
tings
= 2
.5+2
.0 t
urns
OK
‘e’
Clip
pos
ition
= 2
nd f
rom
top
Co
nti
nu
ed
....
.
Ch
ec
k
co
mp
ressio
n
pre
ssu
re.
Pe
rfo
rm d
ry
& w
et
co
mp
ressio
n
test
If c
om
pre
ssio
n p
ressu
rein
wet
test
is N
OT
OK
Ch
ec
k &
Re
cti
fyc
ylin
der
he
ad
rela
ted
re
aso
ns
If c
om
pre
ssio
n p
ressure
in w
et
test
is O
K
Ch
eck &
Rec
tify
cylin
der
blo
ck
rela
ted
re
aso
ns
Co
rrect
valv
e t
imin
gif n
ot
OK
Cle
an c
om
pre
ssio
nrin
g &
pis
ton r
ing
if s
ticky /
jam
OK
Reset
valv
e t
ap
pet
cle
ara
nce i
f no
tas p
er
sp
ecific
atio
ns
Rep
lace p
isto
n r
ing
set
if c
om
pre
ssio
nrin
g w
orn
out
Skill
Tip
:
•D
o n
ot
scrib
e.
•C
lean
by
Aceto
ne/C
CL
4.
Rep
lace c
ylin
der
blo
ck
pis
ton
assly
if
wo
rn o
ut
/ excessiv
e c
leara
nce
Skill
Tip
:
En
su
re
cy
lin
de
r &
p
isto
n
are
o
f th
e
sa
me
g
rou
p
wh
ile
re
pla
cin
g.
Rep
lace c
ylin
der
pis
ton a
ssem
bly
if p
art
ially
seiz
ed
Tig
hte
n c
ylin
der
head
bo
lts i
f lo
ose
Rep
lace c
yl. h
d.
gasket
if t
orn
/ c
ut
/ p
ressed
Rep
lace c
ylin
der
head
if s
park
plu
g m
tg.
ho
leth
read
s w
ashed
ou
t
Carr
y o
ut
surf
ace f
acin
g/
Rep
lace c
ylin
der
head
if w
arp
ag
e i
s e
qu
al
too
r m
ore
th
an 0
.05
mm
4th
Ste
p:
En
gin
e C
om
pre
ssio
n P
ressu
re R
ela
ted
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r154
Deale
r D
eve
lop
ment
Cente
r153
Ch
eck
co
mp
ressio
n
pre
ssu
re.
Perf
orm
dry
& w
et
co
mp
ressio
n
test
Co
nti
nu
ed
fro
mb
ack p
ag
eC
on
tin
ued
fro
mb
ack p
ag
e
Cle
an v
alv
e g
uid
e &
valv
e s
tem
if
dep
osited
with
gum
my s
ub
sta
nce
OK
Rectify
valv
e s
eat
& v
alv
e f
ace b
yla
pp
ing
if
pitte
d /
wo
rn o
ut
/ excess
carb
on d
ep
ostio
n
Rep
lace i
nle
t /
exhaust
valv
e i
f b
en
t
If c
om
pre
ssio
n p
ressu
rein
wet
test
is N
OT
OK
If c
om
pre
ssio
n p
ressu
rein
wet
test
is O
K
Co
nti
nu
ed
.....
‘A’
Gro
up
63.4
78~6
3.48
8
Pis
ton
Sta
ndar
d D
iam
eter
‘B’
Gro
up
63.4
88~6
3.49
8
‘A’
Gro
up
63.5
0~63
.508
Cyl
inde
r S
tand
ard
Dia
met
er
‘B’
Gro
up
63.5
08~6
3.51
5
Insp
ect
De-c
om
pre
ssio
nm
echanis
m f
or
stickyness
Pis
ton
rin
g t
o g
roo
ve c
leara
nce
Std
Lim
itS
erv
ice L
imit
To
p R
ing
: 0
.06 m
m0.1
6 m
m
Co
mp
ressio
n R
ing
En
d G
ap
Std
Lim
itS
erv
ice L
imit
0.1
5 ~
0.3
0 m
m0.5
0 m
m
Ve
hic
le p
ullin
g t
o o
ne
sid
e
No
t
OK
No
t
OK
Ch
eck s
teeri
ng
fo
r
free m
ovem
en
t
by r
ota
tin
g h
an
dle
on
eit
her
sid
e
1st
Ste
p :
Ste
eri
ng
Rela
ted
If s
tg.
jam
, lo
osen f
ront
fork
sid
e b
olts,
top
bo
lts,
ste
ering
rin
g n
ut
& a
dju
st
the s
teering
fo
r fr
ee m
ovem
ent.
Retig
hte
n t
he b
olts a
s p
er
SO
P s
eq
uen
ce.
Ch
eck r
ear
wh
eel
alig
nm
en
t w
.r.t
.
dri
ve c
hain
ad
juste
rs
OK
OK
Set
bo
th s
ide
drive c
hain
ad
juste
rs e
qu
ally
Rep
lace h
and
le b
ar
if b
ent
Ch
eck h
an
dle
bar
&
up
per
ho
lder
bkt.
for
alig
nm
en
tIf
OK
No
t
OK
Rep
lace f
ork
up
per
ho
lder
bra
cket
if m
isalig
ned
OK
Rep
lace f
ork
inn
er
pip
es i
f b
ent
Ch
eck f
ork
in
ner
pip
e
& u
nd
er
ho
lder
bra
cket
for
alig
nm
en
tIf
OK
No
t
OK
Rep
lace f
ork
und
er
ho
lder
bra
cket
‘T’
if b
en
t
OK
2n
d S
tep
: C
hain
Ad
juste
r R
ela
ted
3rd
Ste
p :
Han
dle
Bar
Rela
ted
4th
Ste
p :
Fo
rk I
nn
er
Pip
e R
ela
ted
Co
nti
nu
ed
....
.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r156
Deale
r D
eve
lop
ment
Cente
r155
No
t
OK
Ch
ec
k s
win
g a
rm
for
alig
nm
en
tR
ep
lace s
win
g a
rm i
f b
en
t
OK
Rep
lace f
ram
e i
f m
isalig
ned
at
ste
erin
g t
ub
e a
rea
Ch
ec
k f
ram
e f
or
alig
nm
en
tIf
OK
No
t
OK
Rep
lace f
ram
e i
f m
ou
ntin
g h
ole
of
sw
ing
arm
is o
blo
ng
ed
5th
Ste
p :
Sw
ing
Arm
Re
late
d
6th
Ste
p :
Fra
me
Alig
nm
en
t R
ela
ted
OK
Kic
k l
eve
r n
ot
retu
rnin
g
Rep
lace k
ick l
ever
if b
en
t /
kic
k b
oss
restin
g a
rea w
orn
ou
t /
no
t flat
Ch
ec
k k
ick l
eve
r
asse
mb
ly f
or
no
fou
lin
g w
ith
sile
nc
er,
for
inta
ct
co
nd
itio
n
Rep
lace k
ick b
oss i
f kic
k l
ever
restin
g a
rea w
orn
ou
t /
no
t flat
No
t
OK
If O
K
If O
K
Rep
lace k
ick b
oss i
f sp
lines /
serr
atio
ns w
orn
ou
t
1st
Ste
p :
Kic
k L
eve
r A
sse
mb
ly R
ela
ted
OK
OK
OK
Dis
ma
ntl
e c
lutc
h
co
ve
r &
ch
ec
k k
ick
sh
aft
asse
mb
ly f
or
•
Co
rre
ct
tim
ing
of
ratc
he
t g
ea
r w
.r.t
.
kic
k s
ha
ft
•
Re
turn
sp
rin
g
ten
sio
n O
.K.
En
gin
e O
/H a
nd
Rep
lace k
ick s
haft
retu
rn
sp
rin
g i
f w
eak
No
t
OK
If O
K
Matc
h t
he d
ot
mark
on
ratc
het
gear
w.r
.t.
do
t m
ark
on
kic
k s
haft
en
d i
f tim
ing
in
co
rrect
2n
d S
tep
: K
ick S
ha
ft R
ela
ted
Ch
ec
k k
ick g
uid
e
sc
rew
s f
or
tig
htn
ess
an
d i
nta
ct
co
nd
itio
n
Tig
hte
n k
ick g
uid
e a
llen
bo
lts b
y a
pp
lyin
glo
ctite
63
8 i
f lo
ose
No
t
OK
If O
K
Rep
lace k
ick g
uid
e a
llen
bo
lts i
f sh
eare
d o
ff
3rd
Ste
p :
Kic
k G
uid
e R
ela
ted
Ch
ec
k c
ran
kc
ase
RH
kic
k b
oss a
rea
for
inta
ct
co
nd
itio
n
Rep
lace c
ran
kcase R
H i
f cra
cked
at
kic
k b
oss a
rea
4th
Ste
p :
Cra
nkc
ase
L.H
. R
ela
ted
No
t
OK
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r158
Deale
r D
eve
lop
ment
Cente
r157
Clu
tch
slip
pa
ge
If O
K
No
t
OK
No
t
OK
Ch
ec
k c
lutc
h l
eve
r
fre
e p
lay
1st
Ste
p :
Clu
tch
Le
ve
r F
ree
Pla
y R
ela
ted
Set
clu
tch
lever
free p
lay
as p
er
sp
ecific
atio
ns
OK
Ch
ec
k c
lutc
h l
eve
r
op
era
tio
n f
or
sm
oo
th w
ork
ing
Dis
man
tle,
rectify
& r
efit
clu
tch
lever
if s
ticky
Rep
lace c
lutc
h c
ab
le i
f sticky /
jam
If O
K
No
t
OK
OK
Ch
ec
k e
ng
ine
oil l
eve
l
an
d v
isc
osit
y
To
p u
p e
ng
ine o
il le
vel
if l
ess t
han
sp
ecifie
d
Rep
lace e
ng
ine o
il if v
isco
sity n
ot
OK
If O
K
No
t
OK
OK
Ch
ec
k c
lutc
h r
ele
ase
me
ch
an
ism
fo
r
sm
oo
th o
pe
rati
on
Rep
lace c
lutc
h r
ele
ase l
ever
if b
en
t /
O.D
. o
vers
ize
Rep
lace c
lutc
h c
over
if r
ele
ase l
ever’
s
pare
nt
ho
le u
nd
ers
ize /
oval
2n
d S
tep
: C
lutc
h C
ab
le R
ela
ted
3rd
Ste
p :
En
gin
e O
il R
ela
ted
4th
Ste
p :
Clu
tch
Re
lea
se
Me
ch
. R
ela
ted
If O
K
Rep
lace r
ack &
‘C
lutc
h R
ele
ase S
haft
’if t
eeth
wo
rn o
ut
/ d
am
ag
ed
OK
Std
. F
ree
Pla
yfo
r C
lutc
h Le
ver
2~3
mm
Co
nti
nu
ed
....
.
If O
K
No
t
OK
OK
Dis
ma
ntl
e c
lutc
h &
ch
ec
k a
ll
co
mp
on
en
ts f
or
co
rre
ct
dim
en
sio
ns
& n
o a
bn
orm
al
we
ar
Rep
lace c
lutc
h s
prin
gs i
f fr
ee l
en
gth
is l
ess t
han
sta
nd
ard
Rep
lace f
rictio
n p
late
sif w
orn
ou
t /
bu
rnt
/ fr
ictio
n b
on
din
g g
iven
aw
ay
If O
K
Rep
lace s
teel
pla
tes
if w
orn
ou
t /
bu
rnt
/ g
lazy
5th
Ste
p :
Clu
tch
Asse
mb
ly R
ela
ted
If O
K
Rep
lace c
lutc
h c
en
ter
(clu
tch
hu
b)
if w
orn
ou
t
If O
K
Rep
lace c
lutc
h w
heel
if w
orn
ou
t
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r160
Deale
r D
eve
lop
ment
Cente
r159
Dri
ve
ch
ain
no
ise
No
t
OK
No
t
OK
No
t
OK
Ch
ec
k d
rive
ch
ain
for
sla
ckn
ess
& l
ub
ric
ati
on
1st
Ste
p :
Ch
ain
Ad
justm
en
t R
ela
ted
Ad
just
sla
ckn
ess a
s p
er
sp
ecific
atio
n &
lub
ricate
th
e c
hain
by S
AE
90
oil
OK
Cha
in S
lack
ness
= 3
0 ~
35 m
m
Ch
ec
k c
ha
in c
ove
r
for
co
rre
ct
fitm
en
t
& a
lig
nm
en
t
Refit
ch
ain
co
vers
pro
perly
Fit P
VC
str
ips i
f m
issin
g
If O
K
No
t
OK
If O
K
Rep
lace c
hain
co
ver
bo
lts &
wash
ers
by O
.E.
on
es i
f to
uch
ing
to
ch
ain
If O
K
Co
rrect
alig
nm
en
t o
f sw
ing
arm
bra
ckets
if
ben
t
Ch
ec
k r
ea
r w
he
el
sp
roc
ke
t b
olt
s
for
tig
htn
ess
OK
OK
Tig
hte
n b
olts t
o s
pecifie
d t
orq
ue i
f lo
ose
Ch
ec
k o
utp
ut
sp
roc
ke
t c
olla
r
for
fre
e r
ota
tio
n
Carr
y o
ut
san
din
g o
pera
tio
n o
f co
llar
I.D
.&
ap
ply
SA
E 9
0 o
il if c
olla
r ja
mo
n O
/P s
haft
O.D
.
OK
2n
d S
tep
: C
ha
in C
ove
r R
ela
ted
3rd
Ste
p :
Sp
roc
ke
t M
tg.
Bo
lt R
ela
ted
4th
Ste
p :
En
gin
e S
pro
cke
t C
olla
r R
ela
ted Co
nti
nu
ed
....
.
No
t
OK
OK
OK
Ch
ec
k d
am
pe
r
rub
be
rs o
f
rea
r w
he
el
sp
roc
ke
t
for
no
ab
no
rma
l w
ea
r
Rep
lace d
am
per
rub
bers
if
wo
rn o
ut
Dis
ma
ntl
e c
ha
in -
sp
roc
ke
t a
ssly
. &
ch
ec
k f
or
we
ar
& a
lig
nm
en
t
Alig
n e
ng
ine s
pro
cket
& r
ear
wh
eel
sp
rockets
No
t
OK
If O
K
Rep
lace d
rive c
hain
if
20
lin
k l
en
gth
is m
ore
th
an
serv
ice l
imit
If O
K
Rep
lace c
hain
sp
rocket
kit i
f w
orn
ou
t
Std
. Li
mit
254
~ 25
4.6
mm
260
mm
Driv
e C
hain
20
Link
Len
gth
Ser
. Li
mit
5th
Ste
p :
Re
ar
Da
mp
er
Ru
bb
er
Re
late
d
6th
Ste
p :
Ch
ain
Sp
roc
ke
t R
ela
ted
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r162
Deale
r D
eve
lop
ment
Cente
r161
Sile
nc
er
no
ise
No
t
OK
Ch
eck s
ilen
cer
mo
uth
secu
rin
g n
uts
for
tig
htn
ess
1st
Ste
p :
Mo
un
tin
g N
uts
Rela
ted
2n
d S
tep
: G
asket
Rela
ted
3rd
Ste
p :
Silen
cer
Gu
ard
Rela
ted
4th
Ste
p :
Fo
otr
est
Fo
ulin
g R
ela
ted
Tig
hte
n s
ilencer
mo
uth
nuts
if
loo
se
No
t
OK
Ch
eck s
ilen
cer
mo
uth
gasket
for
inta
ct
co
nd
itio
n
Rep
lace s
ilencer
mo
uth
gasket
(gasket
exhaust)
if
pre
ssed
OK
No
t
OK
Ch
eck s
ilen
cer
gu
ard
secu
rin
g s
cre
ws /
allen
bo
lts
for
tig
htn
ess
Tig
hte
n s
ilencer
guard
scre
ws /
alle
n b
olts
if l
oo
se.
Ap
ply
lo
ctite
243.
OK
No
t
OK
Ch
eck s
ilen
cer
for
ben
d p
ipe n
ot
fou
lin
g w
ith
rid
er’
s f
oo
t re
st
Co
rrect
sile
ncer
fitm
ent
if f
oulin
gw
ith r
ider’
s f
oo
t re
st
OK
Tig
hte
nin
g T
orq
ue =
1.4
~1
.9 K
gm
OK
Co
nti
nu
ed
.....
5th
Ste
p :
Mu
ffle
r R
ela
ted
6th
Ste
p :
To
rqu
e E
xp
an
sio
n c
ham
ber
Rela
ted
OK
No
t
OK
Ch
ec
k s
ile
nc
er
for
inta
ct
ba
ffle
pla
tes
Rep
lace s
ilen
cer
if b
aff
le p
late
/p
late
s a
re l
oo
se
OK
No
t
OK
Ch
ec
k s
ile
nc
er
Exh
au
sT
EC
ch
am
be
r
for
no
no
ise
Tig
hte
n ‘
CO
’ n
ozzle
bo
lt i
f lo
ose /
rep
lace
sile
ncer
if n
ozzle
giv
en
aw
ay
Rep
lace s
ilen
cer
if n
ois
e i
n E
xh
au
sT
EC
ch
am
ber
du
e t
o p
ain
t so
lidifie
d f
rom
in
sid
e
If O
K
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r164
Deale
r D
eve
lop
ment
Cente
r163
Torq
ue
Ste
eri
ng
sti
ck
y /
Ja
m m
ove
me
nt
Ch
ec
k s
tee
rin
g r
ing
nu
t &
ce
nte
r
nu
t /
bo
lt f
or
co
rre
ct
tig
htn
ess
(No
ove
r ti
gh
ten
ing
)
1st
Ste
p :
Ste
eri
ng
Rin
g N
ut
Re
late
d
Lo
osen
ste
erin
g c
en
ter
nu
t /
bo
lt,
fork
sid
e c
lam
p b
olts a
nd
fork
to
p b
olts,
ste
erin
g r
ing
nu
t&
tig
hte
n t
hem
in
seq
uen
ce a
s p
er
S.O
.P.
to s
pecifie
d t
orq
ue
No
t
OK
No
t
OK
OK
Ch
ec
k s
tee
rin
g r
ac
es
for
co
rre
ct
fitm
en
tR
efit
ste
erin
g r
aces a
s p
er
S.O
.P.
if f
itte
d i
n t
ilted
co
nd
itio
n
2n
d S
tep
: S
tee
rin
g R
ac
es F
itm
en
t R
ela
ted
No
t
OK
OK
Ch
ec
k c
on
dit
ion
of
ste
eri
ng
ra
ce
s f
or
no
pit
tin
g m
ark
s
& s
tee
rin
g b
alls f
or
no
ru
sti
ng
/ b
rea
ka
ge
Rep
lace s
teerin
g r
aces &
balls
if p
itte
d /
ru
sty
resp
ectively
3rd
Ste
p:
Stg
. R
ac
es C
on
dit
ion
Re
late
d
No
te
: L
ub
ricate
ste
erin
g
races
an
d
balls
b
y
Serv
o
Gem
RR
-3 g
rease a
t every
10
,00
0 K
ms.
Des
crip
tion
Tigh
teni
ng T
orqu
es i
n K
gm
Ste
erin
g ce
nter
spec
ial
nut
/bo
lt
For
k si
de b
olts
For
k to
p bo
lts
Ste
erin
grin
g nu
t
3.5
Kgm
2.5~
3.5
Kgm
2.5~
3.5
Kgm
0.5
Kgm
Po
or
bra
kin
g -
Dis
c b
rak
e s
yste
m
No
t
OK
Ch
ec
k b
rake
flu
idin
ma
ste
r c
ylin
de
rfo
r c
orr
ec
t le
ve
l
1st
Ste
p :
Ma
ste
r C
ylin
de
r R
ela
ted
To
p-u
p m
aste
r cylin
der
by u
sin
g
DO
T-3
/DO
T-4
bra
ke f
luid
if
flu
id
level
is b
elo
w m
inim
um
mark
If O
K
2n
d S
tep
: B
rake
Dis
c P
ad
Re
late
d
3rd
Ste
p :
Ca
lip
er
Re
late
d
4th
Ste
p :
Bra
ke
Dis
c R
ela
ted
Iden
tify
so
urc
e o
f le
akag
e,
rectify
&
to
p-u
p l
eakag
e i
f an
y,
if b
rake f
luid
level
is l
ow
pre
matu
rely
OK
No
t
OK
Ch
ec
k d
isc
pa
ds f
or
su
rfa
ce
co
nd
itio
nC
lean
dis
c p
ad
s b
y e
mery
pap
er
if f
ou
nd
w
ate
r so
aked
, o
il /
gre
ase s
oaked
, g
lazed
OK
No
t
OK
Ch
ec
k d
isc
pa
ds
for
thic
kn
ess
Rep
lace d
isc p
ad
s i
f w
orn
o
ut
beyo
nd
serv
ice l
imit
Dis
c P
ad L
inin
g T
hick
ness
Sta
ndar
d Li
mit
Ser
vice
Lim
it
7.4
mm
3.8
mm
7.4
mm
3.8
mm
OK
No
t
OK
Ch
ec
k o
il s
ea
l o
f
Ca
lip
er
pis
ton
fo
r
inta
ct
lip
co
nd
itio
n
Rep
lace C
alip
er
seals
if
- seal
lips w
orn
o
ut,
defo
rmed
, b
ecam
e h
ard
.
OK
No
t
OK
Ch
ec
k b
rake
dis
c f
or
thic
kn
ess &
alig
nm
en
tR
ep
lace b
rake d
isc i
f w
orn
ou
t,
run
ou
t exceed
s s
erv
ice l
imit.
Dis
c D
isc
Run
out
Sta
ndar
d Li
mit
Ser
vice
Lim
it
Less
tha
n 0.
2 m
m0.
2 m
m
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
r165
Sp
on
gy b
rak
es -
Dis
c b
rak
e s
yste
m
No
t
OK
Ch
eck b
rake f
luid
level
in
maste
r cylin
der
1st
Ste
p :
Maste
r C
ylin
der
Rela
ted
To
p u
p m
aste
r cylin
der
by D
OT
-3/D
OT
-4
bra
ke f
luid
only
if
fluid
level
is b
elo
w m
inim
um
mark
.
OK
No
t
OK
Ch
eck b
rake h
ose,
Calip
er
an
d
Maste
r cylin
der
for
no
leakag
es.
Identify
so
urc
e o
f le
akag
e,
rectify
&to
p-u
p i
f b
rake f
luid
level
is b
elo
w
min
imum
mark
OK
No
t
OK
Ch
eck D
isc B
rake
syste
m f
ree
fro
m a
ir t
rap
pin
g.
Carr
y o
ut
air b
leed
ing
of
dis
c b
rake s
yste
m a
s p
er
SO
P
OK
No
t
OK
Ch
eck m
aste
r
cylin
der
ven
t h
ole
s
for
no
clo
gg
ing
.
Cle
an m
aste
r cylin
der
co
ver
&vent
ho
les i
f clo
gg
ed
d
ue t
o o
xid
atio
n /
dust.
OK
No
t
OK
Ch
eck m
aste
r cylin
der
dia
ph
rag
m f
or
no
defo
rmati
on
teare
d o
ff
Rep
lace d
iap
hra
gm
by n
ew
one
if d
efo
rmed
/ t
orn
.
OK
No
t
OK
Ch
eck m
aste
r
cylin
der
pri
mary
seal
for
no
wear.
Rep
lace p
rim
ary
seal
of
maste
r cylin
der
if w
orn
out.
OK
No
t
OK
Ch
eck f
or
free
flo
ati
ng
mo
vem
en
t
of
Calip
er.
Cle
an &
Lub
ricate
calip
er
pin
s b
ysili
co
n g
rease /
bra
ke f
luid
if
jam
.
2n
d S
tep
: B
rake F
luid
leakag
e R
ela
ted
3rd
Ste
p :
Air
Tra
pp
ing
Rela
ted
4th
Ste
p :
Maste
r C
ylin
der
Rela
ted
4th
Ste
p :
Calip
er
Rela
ted
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
DT
Si
Tro
ub
le S
ho
oting
Deale
r D
eve
lop
ment
Cente
rP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Deale
r D
eve
lop
ment
Cente
rP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
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