Dealer Development Center 103 Dealer Development Center 104 Clutch Nut (LH Threads) 5.0 Kg.m Camshaft Sprocket Allen Bolt 1.4 Kg.m (Loctite 243) 4.5 Kg.m Rotor Mounting Bolt Starter Motor Mounting Bolts 1.1 Kg.m Kick Guide Allen Bolts 1.2 Kg.m Drain Bolt 2.5 Kg.m Cylinder Head Cover Bolts 3.5 Kg.m Cylinder Head Cover Nuts 1.0 ~ 1.5 Kg.m Spark Plugs (2 Nos.) 1.4 Kg.m Front Axle Nut 4.0 ~ 5.0 Kg.m Rear Axle Nut 8.0 ~ 10.0 Kg.m Torque Rod Nut 3.0 ~ 4.0 Kg.m Sleeve Nut 7.0 ~ 8.0 Kg.m Rear Sprocket Mtg. Nut 1.8 ~ 2.5 Kg.m (Loctite 243) Handle Bar Holder Bolts 2.0 ~ 2.2 Kg.m Steering Top Cap Bolt 3.5 Kg.m 0.5 Kg.m Stg. Stem Nut (slotted) Upper Clamp Allen Bolt 1.8 ~ 2.0 Kg.m Lower Clamp Bolt 2.5 ~ 3.5 Kg.m Swing Arm Pivot Nut 8.0 ~ 10.0 Kg.m RSA Mounting Dome Nut 3.5 ~ 4.0 Kg.m 2.2 ~ 2.8 Kg.m Caliper Install Bolts Brake Disc Allen Bolts 0.9 ~ 1.1 (Loctite 243) Banjo 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 Torque - Engine
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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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