DAELIM S4 50cc Service Manual
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DAELIM S4 50cc Service Manual

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  • Page 3: Table Of Contents

    Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. INSPECTIONS / ADJUSTMENTS No part of this publication may be reproduced without written permission of DAELIM Motor Co., Ltd., EXTERNAL PARTS LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION LH.

  • Page 5: Serial Number Location

    SERVICE INFORMATION 1. SERVICE INFORMATION SERIAL NUMBER LOCATION · · · · · · 1-1 LUBRICATION OIL· · · · · · · · · · · · · · · · · · · · 1-6 SPECIFICATIONS· · · · · · · · · · · · · · · · · · 1-2 WIRING DIAGRAM·...

  • Page 6: Specifications

    SERVICE INFORMATION SPECIFICATION I T E M SPECIFICATION OVERALL LENGTH 1.790mm OVERALL WIDTH 670mm OVERALL HEIGHT 1.102mm WHEEL BASE 1.250mm D I M E N S I O N S SEAT HEIGHT 750mm GROUND CLEARANCE 120mm DRY WEIGHT 94kg GROSS WEIGHT 224kg TYPE Underbone...
  • Page 7 SERVICE INFORMATION I T E M SPECIFICATION TYPE/ VENTURY BORE CV type(vacumm)/Φ16mm MODEL MARK PD19J CHOKE TYPE Auto-bystarter C A R B U R E T O R MAIN JET #110 PILOT SCREW REVERSE REVOLUTION SPEED 1 3/4 FLOAT LEVEL 11mm IDLE SPPED 1,700±100 rpm...

  • Page 8: Torque Values

    SERVICE INFORMATION TORQUE VALUES ENGINE THREAD DIA ITEM Q’TY TORQUE VALUE REFERENCE (mm) TAPPET ADJUSTING ROLL CAP kgf·m OIL DRAIN PLUG BOLT 2.5 kgf·m VALVE ADJUST SCREW LOCK NUT 1.1 kgf·m CYLINDER HEAD BOLT 1.1 kgf·m FLYWHEEL NUT 5.5 kgf·m Apply the engine oil DRIVE FACE NUT 5.5 kgf·m...

  • Page 9: Symbols / Abbreviations

    SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious vehicle part damage may result if instruction CAUTION accident may result if instructions are not WARNING...

  • Page 10: Lubrication Oil

    SERVICE INFORMATION LUBRICATION OIL ENGINE PARTS A P P L I C A T I O N A R E A R E M A R K S VALVE GUIDE / VALVE STEM WORKING AREA •SAE15W-40 or SAE10W-40 CONTACT AREA OF CAM SHAFT •API SL CONTACT AREA OF VALVE ROCKER ARM CAM SHAFT DRIVE CHAIN...

  • Page 11: Wiring Diagram

    SERVICE INFORMATION WIRING DIAGRAM WINKER RELAY MAGNETIC SWITCH FUEL TANK CDI UNIT REGULATOR FUEL COCK RECTIFIER FUEL HOSE SAI PIPE REAR BRAKE SIDE STAND CABLE SPEEDOMETER CABLE...
  • Page 12 SERVICE INFORMATION WINKER RELAY HORN FUEL TANK CDI UNIT MAGNETIC SWITCH IGNITION COIL REGULATOR RECTIFIER ACG COUPLER SAI PIPE MUFFLER FRONT BRAKE CALIPER...
  • Page 13 SERVICE INFORMATION MASTER CYLINDER SPEEDOMETER WINKER RELAY BRAKE HOSE HORN KEY SET...
  • Page 14 SERVICE INFORMATION BATTERY CABLE SAI PIPE ACG COUPLER REGURATOR RECTIFIER MAGNETIC SWITCH CDI UNIT FUEL TANK CARBURATOR...

  • Page 15: General Safety

    8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
  • Page 16 SERVICE INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
  • Page 17 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
  • Page 18 SERVICE INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.

  • Page 19: Caution When Wiring

    SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
  • Page 20 SERVICE INFORMATION •Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire •Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
  • Page 21 SERVICE INFORMATION •Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. •The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
  • Page 22 SERVICE INFORMATION •In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.

  • Page 23: Service Information

    2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION ··· 2-1 DRIVE BELT·········2-7 MAINTENANCE SCHEDULE ·· 2-3 BRAKE FLUID········2-8 FUEL LINE·········· 2-4 BRAKE PAD/SHOE····· 2-8 THROTTLE GRIP OPERATION·· 2-4 SIDE STAND········ 2-9 AIR CLEANER ······· 2-5 SUSPENSION ······· 2-9 SPARK PLUG ······· 2-5 FASTENING BOLTS, NUTS· · · 2-9 VALVE GAP ········...
  • Page 24 INSPECTIONS / ADJUSTMENTS TORQUE SPARK PLUG 1.2㎏f・m CYLINDER HEAD COVER BOLT 0.9㎏f・m VALVE ADJUSTING NUT 1.1㎏f・m TOOL WRENCH 8×9mm ADJUST WRENCH COMPRESSION GAUGE...

  • Page 25: Fuel Line

    INSPECTIONS / ADJUSTMENTS REGULAR INSPECTION SCHEDULE ● Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN ODOMETER READING(NOTE 1) FREQUENCY 500km...

  • Page 26: Throttle Grip Operation

    INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL STRAINER FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL COCK FUEL STRAINER FUEL STRAINER...

  • Page 27: Air Cleaner

    INSPECTIONS / ADJUSTMENTS AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER...

  • Page 28: Cylinder Compression Pressure

    INSPECTIONS / ADJUSTMENTS CAUTION •Inspect and adjust the valve clearance when the engine is cold(35 ℃ •Remove cooling fan cover. •Turn the flywheel counterclockwise , and align the TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN TURN...

  • Page 29: Transmission Oil

    INSPECTIONS / ADJUSTMENTS CARBURETOR IDL SPEED THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW ● Turn the main key to the left , disassemble the lock THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW...

  • Page 30: Brake Fluid

    INSPECTIONS / ADJUSTMENTS BRAKE FLUID BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW BRAKE FLUID CHECK WINDOW...

  • Page 31: Side Stand

    INSPECTIONS / ADJUSTMENTS SIDE STAND ● Erect the main stand. ● If pull the lower end of side stand by hand, check whether it moves smoothly. ● If it doesn’t move freely, pour grease into its pivot side. ● If it moves too freely, check the side stand spring. ●...

  • Page 32: Fastening Bolts, Nuts

    INSPECTIONS / ADJUSTMENTS WHEELS / TIRES NOTE •Check the tire pressure when the tires have been cooled off. Check the thread (the part making contact with the road surface)and side for being worn, cracked or damaged. Replace damaged tires. STANDARD PRESSURE ㎏...

  • Page 33: Lubrication Points

    INSPECTIONS / ADJUSTMENTS LUBRICATION POINTS Unless specifically designated, use generd grease to lubricate the lubrication points. For stiding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean regularly the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it.
  • Page 34 M E M O...

  • Page 35: External Parts

    3. EXTERNAL PARTS SERVICE INFORMATION···3-1 ·······3-6 FRONT COVER ASSEMBLY-DISASEMBLY PRECEDURE 3-2 ·········3-7 INNER BOX SEAT············3-2 ···3-7 FRONT FENDER COVER ·······3-3 LUGGAGE BOX ····3-8 FRONT UNDER COVER REAR CARRIER ·······3-3 ··· 3-8 FRONT HANDLE COVER ·······3-3 CENTER COVER ····3-8 REAR HANDLE COVER ········3-4 BODY COVER ·······3-9...

  • Page 36: Seat

    EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF FRAME COVERS FLOW CHART(ASSEMBLY/DISASSEMBLY) ● This chart shows arrows connected in the order of disassembling covers ① ⑥ ⑪ ⑯ SEAT BODY COVER FRONT COVER FRONT HANDLE COVER ② ⑦ ⑫ ⑰ LUGGAGE BOX REAR FENDER INNER BOX REAR HANDLE COVER...

  • Page 37: Seat Removal

    EXTERNAL PARTS SEAT REMOVAL / ASSEMBLY ● Unlock the seat lock by turing the main key to the left. ● Disassemble the frange nut and hinge pin ● Remove the seat ● Install in the reverse order of removal MAIN KEY MAIN KEY MAIN KEY MAIN KEY...
  • Page 38 EXTERNAL PARTS ● Loosen center cover TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS TAPPING SCREWS...
  • Page 39 EXTERNAL PARTS ● Loosen 5 tapping screws installed at body cover and BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER BODY COVER Disassemble rear fender BODY COVER...

  • Page 40: Under Cover

    EXTERNAL PARTS ● Untie 2 washer bolts in the side of floor panel. FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL FLOOR PANEL...

  • Page 41: Inner Box

    EXTERNAL PARTS INNER BOX REMOVAL / INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER INNER COVER...

  • Page 42: Front Under Cover

    EXTERNAL PARTS FRONT UNDER COVER REMOVAL / ASSEMBLY ● Disassemble the following parts. - Front cover, Front fender / Front wheel ● Untie washer screw, tapping screw installed on inner cover. ● Untie 1 washer bolt installed at front under cover. WASHER BOLT WASHER BOLT WASHER BOLT...

  • Page 43: Speedometer

    EXTERNAL PARTS SPEEDOMETER REMOVAL / SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER REAR HANDLE COVER REAR HANDLE COVER REAR HANDLE COVER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER REAR HANDLE COVER REAR HANDLE COVER REAR HANDLE COVER REAR HANDLE COVER REAR HANDLE COVER REAR HANDLE COVER SPEEDOMETER...
  • Page 44 M E M O...

  • Page 45: Lubrication System

    In your riding area based on the table shown on the right side ) Temperature to the air TRANSMISSION OIL 0.12L( Full capacity ) OIL CAPACITY 0.10L( at changing ) DAELIM Geguine mission oil or SAE 80W/90 RECOMMENDED OIL TORQUE VALUES TAPPET ADJUSTING HOLE CAP 1.5kgf·m OIL PUMP BOLT 1.1kgf·m...
  • Page 46 LUBRICATION SYSTEM TROUBLE SHOOTING Oil level low ●Natural oil consumption ●External oil leaking ●Worn piston ring or incorrect piston ring installation ●Worn valve guide or valve stem seal Oil contamination ●Oil or filter not changed often enough ●Faulty cylinder head gasket ●Piston ring worn Low or no oil pressure ●Clogged oil filter screen...

  • Page 47: Engine Oil Change

    (After oil change) 0.70 L ● Tighten the oil level gauge. ● Recommended engine oil : DAELIM genuine oil. API service classification SL grade Viscosity : 10W-40 ● Start the engine and let it idle for a few minutes. ● Stop the engine and check the engine oil level. If the oil level is low, add the recommended engine oil.

  • Page 48: Ac Generator

    LUBRICATION SYSTEM OIL PUMP INSPECTION ● Drain the engine oil. ● Untie 1 flange bolt and 2 tapping screws installed at cooling fan cover. COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER...
  • Page 49 LUBRICATION SYSTEM OIL PUMP DISASSEMBLY OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR...
  • Page 50 LUBRICATION SYSTEM ASSEMBLY ● Clean all parts with fresh cleaning oil. ● Install the inner and outer rotors into the oil pump body. ● Install the oil pump plate into the pump body. FAN SCREWS FAN SCREWS FAN SCREWS FAN SCREWS FAN SCREWS ●...
  • Page 51 LUBRICATION SYSTEM TRANSMISSION OIL INSPECTION ● Check the connection part of case for any leak. ● Loosen the oil check bolt and check to see if the oil overflows from the oil check hole. ● If the oil amount is not enough , loosen the oil check bolt and fill the recommended transmission oil to the oil filter hole.
  • Page 52 M E M O...
  • Page 53 5. FUEL SYSTEM SERVICE INFORMATION ·· 5-1 CARBURETOR INSULATOR· 5-6 TROUBLESHOOTING ···· 5-2 PILOT SCREW ADJUSTMENT·5-9 FUEL TANK········ 5-3 FUEL COCK········5-11 CARBURETOR·······5-3 SERVICE INFORMATION GENERAL SAFETY CAUTION ● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore the evaporated(gasfied) gasoline is highly explosive.
  • Page 54 FUEL SYSTEM TROUBLESHOOTING Back firing The vehicle does not start. ● Ignition system is damaged or works improperly. ● No gasoline in fuel tank. ● Mixture is too lean. ● Fuel is not coming out of carburetor. ● Too much fuel is flowing into cylinder. ●...

  • Page 55: Fuel Tank

    FUEL SYSTEM FUEL TANK REMOVAL ● Remove luggage box. ● Untie 4 flange bolts installed at fuel tank. FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT FRANGE BOLT...
  • Page 56 FUEL SYSTEM ● Untie screws installed at insulator. ● Disconnect carburetor. CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR REMOVAL TOP SET TOP SET TOP SET TOP SET TOP SET TOP SET...
  • Page 57 FUEL SYSTEM INSPECTION ● Check the jet needle for wear and replace if VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON...
  • Page 58 FUEL SYSTEM ● Remove the main jet, main jet holder, needle jet, slow jet, pilot screw. SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET SLOW JET...
  • Page 59 FUEL SYSTEM ● Disassemble accelerating pump. COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER COVER ● Loosen 2 screws, disconnect diaphragm, COMPRESSION COMPRESSION COMPRESSION COMPRESSION COMPRESSION COMPRESSION COMPRESSION COMPRESSION COMPRESSION...
  • Page 60 FUEL SYSTEM ● Assemble accelerating pump. CAUTION •Assemble jet neeld fitting at assembled hole. ● Assemble vacuum piston, jet needle, spring seat. ● Assemble compression spring. TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET TOM SET...
  • Page 61 FUEL SYSTEM CARBURETOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR DIASSEMBLY ● Disassemble luggage. ● Disassemble carburetor. ● Disassemble floating pressure fuel pump. ● Disassemble 2 fixed nuts of inlet pipe. ●...
  • Page 62 FUEL SYSTEM ④ Extend the hose(60mm) at the tail pipe and insert the THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW THROTTLE STOP SCREW...
  • Page 63 FUEL SYSTEM ④ When idling, check to see if the rotation is smoothly and to return is normal. ⑤ Turn the throttle stop screw until the 1000 rpm, and check the stopping of engine. If the engine is stop, adjust the pilot screw with a 1/8 ACCELERATING ACCELERATING ACCELERATING...
  • Page 64 M E M O...
  • Page 65 6. ENGINE REMOVAL/INSPECTION SERVICE INFORMATION····· 6-1 ENGINE REMOVAL/ASSEMBLY·· 6-2 SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation.
  • Page 66 ENGINE REMOVAL/INSPECTION ENGINE REMOVAL / ASSEMBLY CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR CARBURETOR ● Release the seat lock by turning the main key and open the seat. ●...
  • Page 67 ENGINE REMOVAL/INSPECTION ● Loosen rear cushion under bolt. REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT...
  • Page 68 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER...

  • Page 69: Troubleshooting

    7. BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER KICK STARTER· · · · · · 7-2 SERVICE INFORMATION···7-1 SERVICE STANDARD· · · · 7-1 DRIVE BELT· · · · · · · · 7-4 TROUBLESHOOTING· · · · 7-1 DRIVEN PULLEY ASS’Y·...

  • Page 70: Lh. Crank Case Cover Removal

    BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER LH. CRANK CASE COVER REMOVAL ● Loosen 10 flange bolts assemble at LH. Side cover. KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM KICK STARTER ARM...
  • Page 71 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER CHECK CIR CLIP CIR CLIP CIR CLIP CIR CLIP CIR CLIP CIR CLIP CIR CLIP KICK SPINDLE BUSH KICK SPINDLE BUSH KICK SPINDLE BUSH KICK SPINDLE BUSH KICK SPINDLE BUSH KICK SPINDLE BUSH KICK SPINDLE BUSH CIR CLIP CIR CLIP...

  • Page 72: Drive Belt

    BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVE BELT DRIVEN PULLEY ASS’ Y DRIVEN PULLEY ASS’ Y DRIVEN PULLEY ASS’ Y DRIVEN PULLEY ASS’ Y DRIVEN PULLEY ASS’ Y DRIVE FACE DRIVE FACE DRIVE FACE DRIVEN PULLEY ASS’ Y DRIVEN PULLEY ASS’...
  • Page 73 WIDTH belt if the service limit is exceeded. SERVICE LIMIT : 16.5mm NOTE ·Use only a genuine DAELIM replacement drive belt. ·Do not get oil or greasde on the drive belt or pulley side. ·Clean off any grease or oil before reinstalling.

  • Page 74: Driven Pulley Ass'y

    BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVEN PULLEY ASS’Y REMOVAL ● Remove the LH. crank case cover. (⇨7-2 ) ● By using universal holder, grip clutch outer and diassemble flange nut, then disassemble clutch outer. TOOL : UNIVERSAL HOLDER DRIVE FACE HOLDER ●...
  • Page 75 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Disassemble seal collar. DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP DRIVEN FACE COMP...
  • Page 76 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER INSPECTION BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER) BALL BEARING (OUTER)
  • Page 77 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Check damage or worn of movable drive face. ● Check whether worn of movable driven face guide home. ● Measure inner diameter of movable driven face. SERVICE LIMIT : 34.06MM MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE...
  • Page 78 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ASSEMBLY MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE MOVABLE DRIVEN FACE...

  • Page 79: Movable Drive Face

    BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER DRIVEN PULLEY ASSEMBLY ● Turn right driven pulley ass’y and widen DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB DRIVEN PULLEY SUB...
  • Page 80 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Disassemble kick starter rachet. ● Disassemble CVT cooling fan. ● Disassemble drive face. ● Disassemble drive face boss. CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN CVT COOLING FAN...
  • Page 81 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Check drive face. KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET KICK STARTER RATCHET...
  • Page 82 BELT TYPE CONTINUOUSLY VARIABLE TRANSMISSION / KICK STARTER ● Assemble drive face to the serration side of LH. Crank shaft, then assemble hext nut 12mm. FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT...
  • Page 83 M E M O...
  • Page 84 A.C. GENERATOR /RH. CRANK CASE COVER...
  • Page 85 8. A.C. GENERATOR /RH. CRANK CASE COVER SERVICES INFORMATION········8-1 COOLING FAN COVER··········8-2 AC GENERATOR·············8-4 RH. CRANK CASE COVER········8-4 SERVICE INFORMATION GENERAL SAFETY ● This section describes the removal and assembling of the A.C. generator. ● For the information of A.C. generator inspection, refer to the section 15. ●...

  • Page 86: Generator /Rh. Crank Case Cover

    A.C. GENERATOR /RH. CRANK CASE COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER COOLING FAN COVER...
  • Page 87 A.C. GENERATOR /RH. CRANK CASE COVER ● Loosen the flange nit securing the fly wheel and remove the flywheel using the A.C.G. rotor puller. CAUTION •The flywheel may easily remove if you rotate the puller while tapping the roller shaft metal hammer. •Always use a holder and a puller to remove the ACG ROTOR PULLER ACG ROTOR PULLER...

  • Page 88: Rh. Crank Case Cover

    A.C. GENERATOR /RH. CRANK CASE COVER ● If the universal holder cannot be used, remove the LH.crankcase cover at left side of the crankshaft, and hold the drive face with the drive face holder. TORQUE : 5.5kgf·m TOOL : UNIVERSAL HOLDER ●...
  • Page 89 A.C. GENERATOR /RH. CRANK CASE COVER ● Pull out gasket and dowel pin. DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN...
  • Page 90 CYLINDER HEAD / VALVES...

  • Page 91: Service Information

    9. CYLINDER HEAD / CYLINDER / PISTON SERVICE INFORMATION ···9-1 VALVE GUIDE········ 9-7 TROUBLE SHOOTING · · · · ··· 9-2 VALVE SEAT·········9-8 CAM SHAFT········· 9-3 IN / EX VALVE ASSEMBLY·· 9-8 CYLINDER HEAD·······9-5 CYLINDER HEAD ASSEMBLY· 9-10 VALVE SPRING········ 9-6 CAM SHAFT ASSEMBLY···...
  • Page 92 CYLINDER HEAD / VALVES TOOL -VALVE GUIDE REAMER -VALVE GUIDE DRIVER -VALVE SPRING COMPRESSOR TROUBLESHOOTING ● Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down test or by tracing noises to the top-end with a sounding rod or stethoscope. Low compression ●...
  • Page 93 CYLINDER HEAD / VALVES CAMSHAFT FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS...
  • Page 94 CYLINDER HEAD / VALVES ● Remove the cam chain from the cam shaft. CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT...

  • Page 95: Cylinder Head / Valve

    CYLINDER HEAD / VALVES ● Manually turn the shaft bearing outer race, and check if it turns smoothly. BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING ● Check damage or worn of bearing, if yes, replace it. BEARING BEARING BEARING BEARING BEARING...
  • Page 96 CYLINDER HEAD / VALVES ● Remove the valve spring compressor, valve spring, valve cotter, retainer, sparing and valve. VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING...
  • Page 97 CYLINDER HEAD / VALVES VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE...
  • Page 98 CYLINDER HEAD / VALVES ● Insert the valve guide at upside of cylinder head. TOOL: VALVE GUIDE DRIVE VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER...
  • Page 99 CYLINDER HEAD / VALVES ● For valve spring with varying pitch, install the valve springs with the narrow pitch end facing down. ● Install the spring retainer. ● Compress the valve springs and install the valve cotter. NOTE •Compressing the valve spring more than necessary when installing the valve cotters may cause looss of valve spring tension.
  • Page 100 CYLINDER HEAD / VALVES CYLINDER HEAD ASSEMBLY CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD...
  • Page 101 CYLINDER HEAD / VALVES ● Apply engine oil to the camshaft and install it on the cylinder head with the cam thread facing downward. ● Assembly the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top pf the cylinder head.
  • Page 102 CYLINDER HEAD / VALVES ● Install flange nut and tighten them driving with 2-3 times. TORQUE : 2.0kgf·m ● Pull out spring from cam chain tensioner lifter. BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT...
  • Page 103 M E M O...
  • Page 104 CYLINDER / PISTON...

  • Page 105: Cylinder / Piston

    10. CYLINDER / PISTON SERVICE INFORMATION···················10-1 TROUBLESHOOTING ····················10-1 CYLINDER··························10-2 PISTON· ··························10-3 PISTON / CYLINDER INSTALLATION··············10-5 SERVICE INFORMATION GENERAL SAFETY ● Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder pins.
  • Page 106 CYLINDER / PISTON CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER REMOVAL ● Remove the engine from the engine. ● Remove the cylinder head cover. ●...

  • Page 107: Piston Removal

    CYLINDER / PISTON ● Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT: 0.05MM PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON...
  • Page 108 CYLINDER / PISTON ● Inset the piston ring into the inside of cylinder, check the clearance of piston ring. FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE...
  • Page 109 CYLINDER / PISTON PISTON / CYLINDER INSTALLATION TOP RING MARK PISTON ASSEMBLY ● Clean the piston head, ring lands and skirts. SECOND RING NOTE •Be careful not to damage the piston and rings during assembly TOP RING •Carefully install the piston rings onto the piston with the markings facing up.
  • Page 110 CYLINDER / PISTON ● Install the new gasket and dowel pins. ● Coat the cylinder wall with clean the engine oil and lubricate the piston rings and install the cylinder. CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER...
  • Page 111 M E M O...
  • Page 112 TRANSMISSION/CRANKSHAFT/CRANKCASE...

  • Page 113: Transmission/Crankshaft/Crankcase

    SERVICE LIMIT CONNECTING ROD 0.1~0.3mm 0.5mm CRANK CONNECTING ROD BIG END 0.1~0.4mm 0.6mm SHAFT Right 0.1mm CRANK SHAFT SHAKING Left 0.1mm TRANSMISSION OIL Full capacity After oil change OIL CAPACITY 0.12L( 0.10L( RECOMMENDED OIL DAELIM genuine mission oil or SAE 80W/90...
  • Page 114 TRANSMISSION/CRANKSHAFT/CRANKCASE TORQUE CRANK CASE BOLT 1.1kgf·m TOOL - UNIVERSAL BEARING PULLER - CRANK SHAFT ASSEMBLER COLLAR SHAFT - DRIVE HANDLE - DRIVE OUTER - BEARING REMOVER SET TROUBLESHOOTING Engine Noise ● Connecting rod big and small ends loose. ● Crank pin bearing loose. Engine started but unable to move out ●...
  • Page 115 TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
  • Page 116 TRANSMISSION/CRANKSHAFT/CRANKCASE INSPECTION ● Check the drive shaft for wear or damage. DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT...
  • Page 117 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Replace the bearings if necessary. ● Press the bearing to the case with special tool. TOOL: BEARING REMOVER SET ASSEMBLY ● Install the drive shaft on the transmission cover. ● Install a new drive shaft oil seal. TOOL: CRANK ASSEMBLY SHAFT CRANK ASSEMBLY COLLAR ●...
  • Page 118 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Apply clean engine oil to the new bearing and insert by pressure to crank case. TOOL : DRIVER HANDLE, DRIVER OUTER ● Assemble the new final shaft oil seal. ● Assemble drive shaft to LH. Crank case. ● Assemble the new drive shaft oil seal. TOOL : DRIVER HANDLE ●...
  • Page 119 TRANSMISSION/CRANKSHAFT/CRANKCASE CRANK CASE REMOVAL ● Remove the engine from the frame. ● Remove the RH./LH. crank case cover. ● Remove the parts to disassemble crankcase. ● Loosen the 1 flange bolt from the RH. crank case. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
  • Page 120 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Check RH. Crank case. ● Check LH. Crank case. CRANK SHAFT REMOVAL ● If the bearing is left on the crankshaft, use a bearing puller to remove it. TOOL: UNIVERSAL BERING PULLER CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK CRANK...
  • Page 121 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big ends. TOOL: FEELER GAUGE SERVICE LIMIT: 0.5MM FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE FEELER GAUGE...
  • Page 122 TRANSMISSION/CRANKSHAFT/CRANKCASE CRANK CASE INSTALLATION ● Install the dowel pins and a new gasket. ● Pulling the cam chain and check to see if the crankshaft installed correctly. ● Install the RH. Crankcase to the LH. crank case. NOTE •Make sure that the gasket is completely attached without any clearance.
  • Page 123 M E M O...
  • Page 124 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM...
  • Page 125 12. FR. WHEEL / FR. BRAKE / FR. FORK / STEERING STEM SERVICE INFORMATION ···12-1 FRONT WHEEL ASSEMBLY··12-7 FRONT BRAKE ······12-7 TROUBLE SHOOTING··· 12-2 STEERING HANDLE·····12-3 BRAKE FLUID REPLACEMENT·12-10 FRONT CALIPER ···· 12-12 FRONT WHEEL REMOVAL··12-4 FRONT WHEEL BEARING···12-5 FRONT FORK······ 12-15 STEERING STEM ····...

  • Page 126: Troubleshooting

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM TROUBLESHOOTING Hard steering Bad working brake ● Steering bearing adjustment nut too tight. ● Mixed air in brake system ● Faulty steering stem bearings. ● Getting damp to brake fluid ●...

  • Page 127: Steering Handle

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM STEERING HANDLE FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER FRONT HANDLE COVER...

  • Page 128: Front Wheel / Front Fork / Steering / Brake

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Disconnect the throttle cable from the throttle grip HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR...
  • Page 129 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSPECTION ● Check the front axle for deflection. Place the front axle on a V-block, and measure deflection with a dial gauge. SERVICE LIMIT: 0.2 MM FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE FRONT AXLE...
  • Page 130 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ASSEMBLY ● Apply sufficient amount of grease to the bearing. DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A DRIVER HANDLE A...

  • Page 131: Front Wheel Assembly

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Align the wheel hub with the projection area of the SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX...

  • Page 132: Front Brake

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Measure the bent or twist of brake disk. TRANSMISSION OIL CAPACITY : 0.12 L ● If the bent or twist exceeds over the service limit, check the tolerance of wheel bearing ●...
  • Page 133 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Remove the cylinder, spring from the master cylinder. MASTER CYLINDER BODY STOP SWITCH ● Clean the inside of master cylinder, reserve, master piston with the brake fluid. LEVER DIAPHRAGM SPRING PLATE...

  • Page 134: Brake Fluid Replacement

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM NOTE •When installing the cups, do not allow to close the cup ends. •nstall the spring with it’s smaller direction of coil ends toward the piston. ● Install the cir clip to the mater cylinder groove firmly. TOOL: SNAP RING PLIER ●...
  • Page 135 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Remove the master cylinder cup cap. ● Remove the master cylinder cup cap, diaphragm plate, and diaphragm from the master cylinder. Connect the bleeder hose to the bleeder valve. Loosen the bleeder valve, and pump the brake lever repeatedly.

  • Page 136: Front Caliper

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ② Release the brake lever slowly and wait several BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW BLEEDER SCREW...
  • Page 137 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM REMOVAL ● Remove the pad spring, pad comp, caliper bracket, AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN...
  • Page 138 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Measure the caliper inner diameter. DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE...

  • Page 139: Front Fork

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM FRONT FORK ● Remove the front under cover. STEERING COMP STEERING COMP STEERING COMP STEERING COMP STEERING COMP STEERING COMP STEERING COMP ● Remove the front caliper. STEERING COMP STEERING COMP STEERING COMP STEERING COMP...
  • Page 140 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Remove the dust seal. DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL...
  • Page 141 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSPECTION ● Place the fork spring on a level place, and measure the free length. ● If the free length deviates from the service limit, replace the springs with now ones. SERVICE LIMIT: 232 MM FRONT FORK SPRING FRONT FORK SPRING...
  • Page 142 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Assemble the fork pipe to the bottom case. ● Assemble the springs to the fork pipe. NOTE •Install the spring with the smaller pitch side facing downward. ● Accurately assemble the stop ring to the bottom case.
  • Page 143 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Fill a prescribed amount of automatic transmission fluid in to the fork pipe. CAPACITY: 90 ㎤ ㎤ ● Slowly press the fork tube 2-3 times to discharge air. ●...

  • Page 144: Steering Stem

    FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM STEERING STEM REMOVAL ● Remove the handle cover. ● Remove the rear handle cover. ● Remove the front cover. HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR...
  • Page 145 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM INSTALLATION ● Apply grease to steering bottom con race, then assemble steering stem ball ass’y. ● Assemble steering stem to frame body head pipe. ● Apply grease to frame body head pipe,then assemble steering stem ball ass’y.
  • Page 146 FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEM ● Assemble the following parts. HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR...
  • Page 147 M E M O...
  • Page 148 REAR WHEEL / REAR BRAKE / REAR CUSHION...
  • Page 149 13. REAR WHEEL / REAR BRAKE / REAR CUSHION SERVICE INFORMATION···13-1 REAR BRAKE·······13-4 TROUBLE SHOOTING····13-2 REAR CUSHION······13-6 REAR WHEEL········13-3 SERVICE INFORMATION GENERAL SAFETY ● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.
  • Page 150 REAR WHEEL / REAR BRAKE / REAR CUSHION TROUBLE SHOOTING Rear wheel wobbling or vibration ● Deformed wheel, rim ● Bad tire ● Axle bad fastening ● Bad tire air pressure ● Improper wheel balancing Soft rear suspension ● Bad spring ●...
  • Page 151 REAR WHEEL / REAR BRAKE / REAR CUSHION REAR WHEEL REMOVAL ● Erect the motorcycle on the main stand. ● Remove the muffler. MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER...

  • Page 152: Rear Brake

    REAR WHEEL / REAR BRAKE / REAR CUSHION INSTALLATION LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...
  • Page 153 REAR WHEEL / REAR BRAKE / REAR CUSHION REMOVAL ● Manually open the brake shoe and remove it. BRAKE SHOE ● Remove the shoe spring from the brake shoe. SHOE SPRING SHOE SPRING BRAKE CAM BRAKE SHOE ● Loosen the rear brake arm fixing bolt. ●...

  • Page 154: Rear Cushion

    REAR WHEEL / REAR BRAKE / REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION...
  • Page 155 REAR WHEEL / REAR BRAKE / REAR CUSHION INSPECTION ● Measure the rear cushion spring free length. ● Check the damper rod for deflection or damage. SERVICE LIMIT: 185 MM INSTALLATION ● Install the spring, stop rubber. ● Apply thread locking agent to the lock nut, and install the rear cushion compressor attachment on damper rod.
  • Page 156 CHARGING SYSTEM WINKER RELAY FUEL TANK CDI UNIT M A G N E T I C SWITCH FUEL COCKE REGULATER RECTIFIER FUEL HOSE SAI PIPE REAR BRAKE CABLE SPEEDOMETER CABLE SIDE STAND C H A R G I N G D I A G R A M FUSE(7A) AC.

  • Page 157: Charging System

    14. CHARGING SYSTEM SERVICE INFORMATION·····14-1 CHARGING SYSTEM INSPECTION· 14-4 TROUBLE SHOOTING· · · · · 14-2 AC GENERATOR INSPECTION·14-5 B AT T E RY · · · · · · · · ·14-3 REGULATOR RECTIFIER INSPECTION·14-5 SERVICE INFORMATION WARNING ·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.
  • Page 158 CHARGING SYSTEM TROUBLE SHOOTING Low power(engine running) No power(key turned on) ● Battery undercharged ● Dead battery ● Battery is failing - Low fluid level ● Charging system failure - Complete discharged ● Disconnected battery cable Intermittent power ● Main fuse cut ●...

  • Page 159: Battery Charging

    CHARGING SYSTEM BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY BATTERY SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW SCREW...
  • Page 160 CHARGING SYSTEM CAUTION •Current flow larger than the range selected may BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖ TERMINAL BATTERY⊖...
  • Page 161 CHARGING SYSTEM ● Measure the resistance between the yellow and white lead. ● If the resistance values are much larger than the specified value, or if there is continuity between terminals and earth terminals, replace the stator with a new one. RESISTANCE VALUE: 0.5~1.5Ω...
  • Page 162 IGNITION SYSTEM WINKER RELAY FUEL TANK HORN CDI UNIT MAGNETIC SWITCH IGNITION COIL REGULATOR RECTIFIER ACG COUPLER FRONT BRAKE CALIPER SAI PIPE MUFFLER I G N I T I O N S Y S T E M SIDE STAND S/W KILL S/W IGNITION SPARK...

  • Page 163: Ignition System

    15. IGNITION SYSTEM PULSE GENERATOR INSPECTION· 15-3 SERVICE INFORMATION· · · ·15-1 IGNITION COIL INSPECTION·· 15-4 TROUBLE SHOOTING····15-2 CDI UNIT INSPECTION····15-3 SERVICE INFORMATION GENERAL SAFETY ● Follow the steps described in the troubleshooting flow chart when servicing the igntion system ●...
  • Page 164 IGNITION SYSTEM TROUBLE SHOOTING Spark plug does not emit sparks. UNUSUAL CONDITION POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER) 1. Cranking speed is low. - Battery is low or kick power is weak. 2. Poorly connected connectors or an open circuit in ignition Low peak voltage.
  • Page 165 IGNITION SYSTEM CDI UNIT INSPECTION CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT...
  • Page 166 IGNITION SYSTEM IGNITION COIL INSPECTION ● Remove the luggage box ( 3-2) ● Remove the primary wire. NOTE •Since the resistance value of primary coil is inherently very small, it is difficult to distinguish it from a shorted wire. ● Measure the peak voltage of the ignition coil primary side first.
  • Page 167 MEMO...

  • Page 168: Starter System

    STARTING SYSTEM WINKER RELAY FUEL TANK CDI UNIT M A G N E T I C SWITCH FUEL COCK REGULATER RECTIFIER FUEL HOSE SAI PIPE REAR BRAKE CABLE SPEEDOMETER CABLE SIDE STAND S T A R T E R S Y S T E M C I R C U I T STARTER FUSE...
  • Page 169 16. STARTING SYSTEM STARTER MOTOR ······ 16-3 SERVICE INFORMATION···· 16-1 TROUBLE SHOOTING ···· 16-2 STARTER MAGNETIC SWITCH·16-6 SERVICE INFORMATION GENERAL SAFETY ● The starter motor can be maintained without removing the engine from the vehicle. ● Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury.
  • Page 170 STARTING SYSTEM TROUBLE SHOOTING Starter motor does not rotate (No response from starter motor). ● Check to see if the fuse is burned out. ● Check to turn on the lamp of stop switch. Remove the starter moter " " wire, connect With the main switch turned to ON, squeeze in to the battery "...

  • Page 171: Starter Motor

    STARTING SYSTEM STARTER MOTOR FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE FLANGE BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT BOLT...
  • Page 172 STARTING SYSTEM ● the brush spring, and then remove the brush. ● Measure the brush length. Replace the brush if it is BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH...
  • Page 173 STARTING SYSTEM STARTER MOTOR ASSEMBLY ● Install the brush and brush spring to the brush hold set. ● Apply grease to both ends of the armature shaft, and install the 2 washers. FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET FRONT BRACKET...
  • Page 174 STARTING SYSTEM STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH...

  • Page 175: Lights / Switches / Horn

    17. LIGHTS// SWITCHES / HORN SERVICE INFORMATION ·····17-1 SPEEDOMETER ········17-3 TROUBLE SHOOTING······17-1 MAIN SWITCH········17-4 HANDLE BAR SWITCH··· · ··17-4 HEADLIGHT BULB REPLACEMENT·17-2 FRONT WINKER·······17-2 HORN············17-5 FRONT/REAR STOP SWITCH· ·· 17-5 REAR COMBINATION LIGHT·· 17-3 REAR WINKER········17-3 FUEL UNIT··········17-6 SERVICE INFORMATION GENERAL SAFETY ●...

  • Page 176: Front Winker

    LIGHTS// SWITCHES / HORN HEADLIGHT BULB REMOVAL ● Remove the front under cover. HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB ● Disconnect the headlight wiring. HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB HEADLIGHT BULB...

  • Page 177: Rear Combination Light

    LIGHTS// SWITCHES / HORN REAR COMBINATION LIGHT BULB REPLACEMENT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT TAIL LIGHT...

  • Page 178: Main Switch

    LIGHTS// SWITCHES / HORN ● Disconnect the RH./LH.switch wire and remove the SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER speedometer and the 3 tapping screws securing the rear handle cover.

  • Page 179: Horn

    LIGHTS// SWITCHES / HORN DIMMER SWITCH BAT3 PURPLE DG/Y BLUE COLOR HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER HANDLE SWITCH COUPLER...

  • Page 180: Fuel Unit

    LIGHTS// SWITCHES / HORN - When the brake lever is released - NO CONTINUITY RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER RELEASE THE LEVER...

  • Page 181: Troubleshooting

    18. TROUBLESHOOTING ENGINE WON’T START OR HARD TO START ··········· 18-1 ENGINE STALLS, HARD TO START, ROUGH IDLING··········18-2 POOR PERFORMANCE AT LOW SPEED AND IDLING ········ 18-3 POOR OPERATION ·····················18-4 ENGINE WON’T START OR HARD TO START CAUSE OF TROUBLE ·No fuel to fuel tank.
  • Page 182 ENGINE STALLS, HARD TO START, ROUGH IDLING CAUSE OF TROUBLE Open the drain screw, and check fuel Fuel not supplied to ·No fuel to fuel tank. flow to the carburetor. the carburetor. ·Clogged fuel tube. ·Clogged float valve. ·Clogged fuel tank cap. ·Clogged fuel strainer.
  • Page 183 POOR PERFORMANCE AT LOW SPEED AND IDLING CAUSE OF TROUBLE Smoothly accelerate engine. Engine speed does not ·Clogged air cleaner. increase sufficiently. ·Insufficient fuel supply. ·Clogged fuel tank cap air hole Engine speed increases. ·Clogged muffler. Check the ignition timing. Abnormal ·Faulty CDI unit.
  • Page 184 POOR OPERATION CLUTCH DRIVE / DRIVEN PULLEY CAUSE OF TROUBLE Engine starts but vehicle won’t move. ·Worn or damaged drive belt. ·Damaged ramp plate. ·Faulty weight roller. ·Faulty movable drive face. ·Damaged driven pulley weight shoe spring. ·Faulty transmission. ·Seized transmission. Engine stalls or vehicle creeps.
  • Page 185 POOR FRONT/REAR SUSPENSION PERFORMANCE CAUSE OF TROUBLE ·Weak cushion spring Soft suspension. ·Overloaded ·Oil leakage from damper unit ·Bent fork pipe or cushion rod Hard suspension. ·Worn slider Suspension noisy. ·Damaged cushion stopper rubber...
  • Page 186 MEMO...

  • Page 187: Service Manual

    SERVICE MANUAL 2010. 03 PRINTED C C O O P P Y Y P P R R O O H H I I B B I I T T 2010. 03 PUBLICATION...
  • Page 188 SM62-1003-01E...

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