DAELIM S3 Service Manual
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DAELIM S3 Service Manual

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SM63-1010-01E

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Summary of Contents for DAELIM S3

  • Page 1 SM63-1010-01E...

  • Page 2: Crankcase / Transmission/ Crank Shaft

    SERVICE INFORMATION INSPECTION / ADJUSTMENT EXTERNAL PARTS LUBRICATION SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION LH. CRANK CASE COVER / CONTINOUSLYVARIABLE TRANSMISSION AC GENERATOR / FLY WHEEL CYLINDER HEAD / VALVE CYLINDER / PISTON CRANKCASE / TRANSMISSION/ CRANK SHAFT FRONT WHEEL / FRONT FORK / STEERING REAR WHEEL / REAR CUSHION BRAKES CHARGING SYSTEM...

  • Page 3: Service Information

    SERVICE INFORMATION SERIAL NUMBER LOCATION SYMBOLS / ABBREVIATIONS 1-12 SPECIFICATION CAUTIONS AT WORK 1-13 TWIST TORQUE CAUTIONS AT ASSEMBLY, SPECIAL TOOL DISASSEMBLY 1-13 PARTS COMPOSITION MAP CAUTIONS AT WIRING 1-17 SERIAL NUMBER LOCATIONS...

  • Page 4: Specification

    SERVICE INFORMATION SPECIFICATION OVERALLLENGTH 2,110 mm 2,140 mm 750 mm 750 mm OVERALLWIDTH 1,200 mm 1,215 mm OVERALLHEIGHT WHEEL BASE 1,500 mm 1,500 mm DIMENSIONS 745 mm 762 mm SEAT HEIGHT GROUND CLEARANCE 136 mm 143 mm DRYWEIGHT 159 kgs 159 kgs 170 kgs 170 kgs...

  • Page 5: Clutch Transmission

    SERVICE INFORMATION CLUTCH DRY PLATE SHOE TYPE TRANSMISSION Automatic Transmission(V-belt type) TRANSMISSION TRANSMISSION PRIMARYREDUCTION RATIO 2.786(39T/14T) TRANSMISSION SECONDARYREDUCTION 3.462(45T/13T) RATIO TRANSISTOR IGNITION SYSTEM 0° BTDC / 1,600(rpm) IGNITION TIMING IDLE AC GENERATOR 12V-17A/ 5,000(rpm) BATTERY CAPACITY 12V 10AH SPARK PLUG CR8EH - 9 SPARK PLUG GAP 0.8 - 0.9mm...
  • Page 6 SERVICE INFORMATION TORQUES STEERING STEM NUT M26×1.0 STEERING TOPTHREAD 0.2 ~ 0.3 M26×1.0 BOTTOM BRIDGE(FORK PIPE) BOLT 7.0 ~ 8.0 M10×1.25 HANDLE POST NUT 5.5 ~ 6.5 M10×1.25 U-NUT FRONT WHEELAXLE NUT M12×1.25 5.0 ~ 7.0 U-NUT REAR WHEELAXLE NUT M16×1.5 12 ~ 13 U-NUT...
  • Page 7 SERVICE INFORMATION CYLINDER HEAD COVER BOLT 1.0 ~ 1.2 M6×1.0 CAP HOLER BOLT 1.0 ~ 1.2 M6×1.0 CAM CHAIN GUIDE BOLT 1.0 ~ 1.2 M6×1.0 CYLINDER HEAD SOCKET 3.5 ~ 4.5 Engine oil applied M10×1.25 CYLINDER BOLT 1.0 ~ 1.2 M6×1.0 SPARK PLUG 1.5 ~ 1.7...
  • Page 8 SERVICE INFORMATION TOOL ACG ROTOR PULLER Used for disassembly ACG Rotor from Crank shaft VALVE GUIDE DRIVER Used at the time of replacing valve guide VALVE GUIDE RIMMER 〃 BEARING REMOVER SET Used at the time of disassembling bearings of crank case THREAD ADAPTER Used at thetime of assembling crank shaft to crank case ASSEMBLY SHAFT...

  • 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 vehicle part damage WARNING Indicates dangerous areas. may result if instruction are not followed WARNING Serious accidents may result if instructions are not Indicates general cautions.
  • Page 10 SERVICE INFORMATION PARTS COMPOSITION MAP STRAIGHT RH. CENTER SIDE RH. FRONT SIDE RH. REAR SIDE LH. CENTER SIDE LH. REAR SIDE LH. FRONT SIDE TOTAL AREA DETAIL COMPOSITON MAP...
  • Page 11 SERVICE INFORMATION COMBINATION METER ASS’ Y CODE WINKER RELAY DESS RECEIVER FR. BRAKE HOSE HAZARD / START SWITCH CODE WATER PATH TUBE HEAD LIGHT ASS’ Y CODE COMBINATION SWITCH TUBE DESS CORD COMP FUEL PUMP RELAY FUEL LEAD LOCK CABLE LIGHT RELAY SEAT OPEN SWITCH CODE STARTER CONTROL RELAY...
  • Page 12 SERVICE INFORMATION BATTERY(12V 10AH) FUEL BREATHER TUBE FUEL SPLY TUBE FUEL HOSE SEAT LOCK CABLE CHARGING SOCKET WIRE METER SOCKET WIRE INJECTOR EMI ASS’ Y 와이어 하네스 INJECTOR CODE HIGH TENSION CODE EMI CODE TRUNK LAMP CODE LF ANTENNA STARTER MOTOR CABLE STARTER MOTOR CABLE LF ANTENNA CODE OXYGEN SENSOR COUPLER...
  • Page 13 SERVICE INFORMATION SEAT LOCK CABLE WIRE HARNESS SEAT OPEN SOLENOID ECU COMP SEAT OPEN SOLENOID CODE ECU GROUND CONNECTION CODE TOTAL SENSOR WIRE WIRE HARNESS ENGINE BREATHE TUBE SEAT LOCK CABLE ENGINE BREATHER TUBE BREATHER TUBE GUIDE LH. REAR SIDE WIRE CLIP ACG CODE COMP REGULATOR RECTIFIER...
  • Page 14 SERVICE INFORMATION REAR BRAKE HOSE PIPE HIGH TENSION CODE WATER PATH TUBE THERMO SENSOR REGULATOR RECTIFIER CODE ACG CODE START MAGNETIC(+) CABLE ACG CODE COMP REAR BRAKE HOSE BATTERY(-) CABLE ACG CODE COMP FUEL HOSE CLIP THERMO SENSOR CODE SCANNER COUPLER INJECTOR COUPLER TPS CODE ISA CODE...

  • 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 5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data dur- remove the cleaning oil with compressed air. Apply oil ing installation. When installing, return to the state to seal face during installation.
  • Page 17 SERVICE INFORMATION 13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open- • Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way longitudinal hanging.
  • Page 18 SERVICE INFORMATION 21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of interior from the infiltration of dust. each case of the engine while removing gasket materi- al completely. Remove damaged contact surface by wiping with the oil stone equally.
  • Page 19 SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord ter- When connecting different cord, attach color tube minal using tester, contact the tester plug behind of the around the connector.
  • Page 20 SERVICE INFORMATION •Turn off the main switch before connecting/dis-con- •When disconnecting the coupler, disconnect it while necting. 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.

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