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DAELIM S2-125 Service Manual

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How to use this manual

This manual explains how to maintain procedure for the
S2-125 manufactured by DAELIM MOTOR CO., LTD.
To ensure safety and optimal operating conditions of the
vehicle, carry out regular inspections according to the
Sections 1 through 2 provide information on overall
vehicle; section 3, assembly and disassembly procedures
for external components, and section 4 describes
maintenance procedure for the engine, frame and
electrical systems.
To facilitate use of this manual, each page starts with
Disassembly and system diagrams, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide.
Contents of this manual and specifications are subject
to change without prior notice for improvement of
vehicle quality.
No part of this publication may be reproduced without
written permission of DAELIM Motor Co.,Ltd.,
Contents
Inspections / Adjustments
EMS(Engine Management System)
Engine Removal / Installation
LH, Crank Case Cover
Continuously Variable
A.c Generator / Starter Clutch
Cylinder Head / Valves
Transmission / Crank Shaft
Crank Case
Front Wheel / Front Fork
/ Steering / Brake
Rear Wheel / Rear Brake /
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

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Summary of Contents for DAELIM S2-125

  • Page 1: How To Use This Manual

    Contents How to use this manual Service Information This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO., LTD. Inspections / Adjustments To ensure safety and optimal operating conditions of the External Parts vehicle, carry out regular inspections according to the maintenance schedule(Section 2).
  • Page 3 SERVICE INFORMATION...
  • Page 4 SERVICE INFORMATION...
  • Page 5 SERVICE INFORMATION...
  • Page 6 SERVICE INFORMATION...
  • Page 7 SERVICE INFORMATION...
  • Page 8 SERVICE INFORMATION...
  • Page 9 SERVICE INFORMATION...
  • Page 10 SERVICE INFORMATION...
  • Page 11 SERVICE INFORMATION...
  • Page 12 SERVICE INFORMATION 145kg 306.9kg 11.5 stroke SOHC ATDC 1-10...
  • Page 13 SERVICE INFORMATION , 30A 1-11...
  • Page 14 SERVICE INFORMATION 1-12...
  • Page 15 SERVICE INFORMATION 1-13...
  • Page 16 SERVICE INFORMATION 1-14...
  • Page 17 SERVICE INFORMATION 1-15...
  • Page 18 SERVICE INFORMATION 1-16...

  • Page 19: Service Information

    SERVICE INFORMATION BATTERY + CABLE BATTERY + CABLE START-MAGNET SW. ASS’Y. START-MAGNET SW. ASS’Y. START MOTOR CABLE START MOTOR CABLE TO. CARBULATOR TO. CARBULATOR TUBE CLIP TUBE CLIP FUEL PUMP FUEL PUMP TUBE CLIP TUBE CLIP TUBE CLIP TUBE CLIP TO.
  • Page 20 MEMO...
  • Page 21 INSPECTIONS/ADJUSTMENTS...
  • Page 22 INSPECTIONS/ADJUSTMENTS...
  • Page 23 INSPECTIONS/ADJUSTMENTS...
  • Page 24 INSPECTIONS/ADJUSTMENTS...
  • Page 25 INSPECTIONS/ADJUSTMENTS...
  • Page 26 INSPECTIONS/ADJUSTMENTS...
  • Page 27 INSPECTIONS/ADJUSTMENTS...
  • Page 28 INSPECTIONS/ADJUSTMENTS...
  • Page 29 INSPECTIONS/ADJUSTMENTS...
  • Page 30 INSPECTIONS/ADJUSTMENTS 2-10...
  • Page 31 EXTERNAL PARTS...
  • Page 32 EXTERNAL PARTS...
  • Page 33 EXTERNAL PARTS...
  • Page 34 EXTERNAL PARTS...
  • Page 35 EXTERNAL PARTS UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER UPPER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER HANDLE COVER UNDER...
  • Page 36 EXTERNAL PARTS FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER FRONT UNDER COVER A COVER A COVER A COVER A COVER A COVER A COVER A COVER A...
  • Page 37 EXTERNAL PARTS...
  • Page 38 EXTERNAL PARTS...

  • Page 39: Torque Values

    LUBRICATION SYSTEM...
  • Page 40 LUBRICATION SYSTEM...
  • Page 41 LUBRICATION SYSTEM...
  • Page 42 LUBRICATION SYSTEM...
  • Page 43 LUBRICATION SYSTEM SERVICE...
  • Page 44 LUBRICATION SYSTEM...
  • Page 45 LUBRICATION SYSTEM...
  • Page 46 LUBRICATION SYSTEM...
  • Page 47 LUBRICATION SYSTEM...
  • Page 48 MEMO...

  • Page 49: Table Of Contents

    EMS(Engine Management System) 5. EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS 2. THE COMPONENT PARTS OF THE EMS 3.TERMINAL ARRANGEMENT OF THE ECU 4. WIRING DIAGRAM OF THE ECU 5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - Self diagnostic function - Fail safe function - How to check the fault code - How to show the fault code...

  • Page 50: Caution When Repairing The Ems Parts

    EMS(Engine Management System) 1.CAUTION WHEN REPAIRING THE EMS PARTS. If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop. Do not touch the ECU terminal, because it may be damaged by the static.

  • Page 51: The Component Parts Of The Ems

    EMS(Engine Management System) 2.THE COMPONENT PARTS OF THE EMS EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM. 1) INTAKE SYSTEM As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc.

  • Page 52: Terminal Arrangement Of The Ecu

    EMS(Engine Management System) 3. TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected. 4. WIRING DIAGRAM OF THE ECU...
  • Page 53 EMS(Engine Management System) 5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp) SELF-DIAGNOSTIC FUNCTION The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL (malfunction indicator lamp).
  • Page 54 EMS(Engine Management System) FAIL-SAFE FUNCTION If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible. INTAKE : MIL on/off INTAKE...

  • Page 55: How To Check The Fault Code

    EMS(Engine Management System) HOW TO CHECK THE FAULT CODE There are two methods of checking the fault codes. 1) Use the MIL in the speedometer. 2) The diagnostic tool. First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic methods for each part) Second) The diagnostic tool (refer to scan user’s manual.) Turn off the ignition key...

  • Page 56: How To Show The Fault Code

    EMS(Engine Management System) HOW TO SHOW THE FAULT CODE There are two methods to show the Fault codes. First, the methods to show in engine operation In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the light on/off function of MIL in order for driver to acknowledge defect.

  • Page 57: Fault Codes Table

    EMS(Engine Management System) FAULT CODES TABLE No failure Injection valve failure(IV) Idle speed actuator failure (ISA) Electrical fuel pump failure (EFP) Intake Manifold absolute pressure signal failure (IMP) Throttle position signal failure (TPS) O2 sensor heater output failure (LSH) Lambda signal failure (VLS) Engine temperature signal failure (TENG) Breathing air temperature signal failure (TBA)

  • Page 58: How To Remove The Fault Code

    EMS(Engine Management System) HOW TO REMOVE THE FAULT CODE Remove the fault codes in two ways; First) Full warm up 1. Starting the engine. - The MIL blinks continuously because the ECU memorized the fault code yet. 2. Full warm up the engine (keep idling five minutes) 3.
  • Page 59 EMS(Engine Management System) 6.INJECTOR Remove Connector Connector bolt Injector and injector cap. Replace the injector CAUTION Before disassemble, the key is off. NOTICE Make sure that dust does not enter the throttle body insulator. 5-11...
  • Page 60 EMS(Engine Management System) CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit 40 : INJECTOR control 39 : FUEL PUMP control INJECTOR FUEL PUMP RELAY Coupler terminal is based on wire harness. Checking Procedure 1) Turn off the ignition key.
  • Page 61 EMS(Engine Management System) 7) If the measured voltage is normal, Check the ‘Blue/Yellow’ electric wire to see if they have been broken or have short-circuited or if the wire-harness coupler and the ECU coupler are a bad contact (ECU terminal No. 40) If there is no problem in the electric wires, ECU is broken Replace the ECU with new one, it rechecks 8) If the measured voltage is not normal,...
  • Page 62 EMS(Engine Management System) 7. MAPAT(Manifold Air pressure sensor, Temperature sensor) Located on the left- side of the throttle body CAUTION Before disassembly, the key is off. MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT Remove MAPAT connector (Push by hand and pull to the front-side)
  • Page 63 EMS(Engine Management System) Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit Fault code number is displayed by MIL The Fault code of intake pressure sensor The Fault code of intake temperature sensor Checking circuit MAPAT 3 : Intake pressure sensor ground 3 : Inhalation pressure 26 : 5V voltage sensor GROUND...
  • Page 64 EMS(Engine Management System) Checking of the intake pressure sensor 1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler 2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-32 ) 3) Turn on the ignition key.
  • Page 65 EMS(Engine Management System) Checking of intake temperature sensor 4) Turn on the ignition key. Start the engine and idling. 5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No.28(TBA) ECU No.3(IMP GROUND) - Measuring voltage: 0.1[V] ~ 4.9[V]...
  • Page 66 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number displayed by MIL Checking circuit 4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key .
  • Page 67 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ 7) If not problem, measure the resistance of TPS.
  • Page 68 EMS(Engine Management System) 9.ETS(ENGINE TEMPERATURE SENSOR) Situated on the Right-hand side of cylinder head CAUTION Before disassembly, the key is off. PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH PUSH Remove Rh.shroud comp Connector by hand Replace the ETS Install in reverse order of removal CAUTION...
  • Page 69 EMS(Engine Management System) 1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) Fault code number is displayed by MIL CHECKING CIRCUIT 4 : SENSOR GROUND 20 : ETS Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key . 2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad.
  • Page 70 EMS(Engine Management System) 6-1) If the measured value is not normal, Replace the ETS with the new one, recheck. If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if the ECU coupler is a bad contact ( No.4, No.
  • Page 71 EMS(Engine Management System) 10.ISA(IDLE SPEED ACTUATOR) It is located upwards on the throttle body CAUTION Before disassembly, the key is off. Remove SEAT Maintenance cover ISA connector O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring 5-23...
  • Page 72 EMS(Engine Management System) 1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT. Showing of defects codes by MIL CHECKING CIRCUIT 33 : ISA CONTROL 39:FUEL PUMP FUEL PUMP RELAY Coupler terminal is based on the side of the wire-harness CHECK PROCEDURE 1) Turn off ignition key . 2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad.
  • Page 73 EMS(Engine Management System) CHECK PROCEDURE 5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck. 6) If resistance and continuty is normal, connect the coupler of ISA. 7) Turn on ignition key 8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : 10~14[V]...
  • Page 74 EMS(Engine Management System) 11.O2(Oxygen) SENSOR Located on the exhaust pipe CAUTION Before disassembly, the key is off. Remove SEAT O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 Sensor O2 sensor connector Muffler...
  • Page 75 EMS(Engine Management System) 1) CHECKING OF OXYGEN(O ) SENSOR CIRCUIT Fault code number is displayed by MIL Fault code number is displayed by MIL of the oxygen(O )sensor lambda signal. CHECKING CIRCUIT OXYGEN SENSOR 2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER Coupler terminal is based on the side of Wire-Harness.
  • Page 76 EMS(Engine Management System) CHECKING FOR A FAULT CODE BY OXYGEN(O )SENSOR HEATER If the voltage value is abnormal, Check to see if the ECU coupler is loose or if there is bad contact. Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been broken or have short- circuited.
  • Page 77 EMS(Engine Management System) 12.CHECKING OF MIL(MALFUNCTION INDICATOR LAMP)CIRCUIT Fault code number is displayed by MIL CHECKING CIRCUIT 24 : MALFUNCTION INDICATOR LAMP OUTPUT MALFUNCTION INDICATOR LAMP(MIL) CHECK PROCEDURE 1) Turn off ignition key. 2) Check the ESS coupler is loose, or bad. If there is no problem.
  • Page 78 EMS(Engine Management System) 13.ECU(ELECTRONIC CONTROL UNIT) Located inside the LH. side cover CAUTION Make sure that the key is off before disassembly Remove Body cover Connector (A display portion is pulled behind) Flange bolt 4 EA Replace the ECU Install in the reverse order of removal. Replace the ECU CAUTION Be sure to assemble the ECU ground wire.

  • Page 79: Ignition Coil

    EMS(Engine Management System) 14.IGNITION COIL Locate on the RH.body cover CAUTION Be sure to check the engine is cooling. because a little gasoline remains, it is still hot. Remove SEAT Body cover Ignition coil -Connector -Spark plug cap -Ignition coil bolt 2EA -Ignition coil CAUTION Be sure to assemble the IG coil Ground wire.
  • Page 80 EMS(Engine Management System) 15.CRANK POSITION SENSOR :CPS ENG RH.crankcase cover CAUTION Before disassembly, the key is off. Remove Connector - CPS connector(BLUE, LIGHT GREEN) - ACG connector(YELLOW) RH.shroud Cooling fan Flywheel Stator CPS wire CPS wire CPS wire CPS wire CPS wire CPS wire CPS wire...

  • Page 81: Fuel Pump

    EMS(Engine Management System) 16.FUEL PUMP Located below the floor panel CAUTION Before disassembling, the key is off. Remove Fuel pump nut 4EA Replace the fuel pump injector cap NOTICE Do not push the fuel pump base under the fuel tank when the fuel tank is stored. Always replace the packing when the fuel pump is removed.
  • Page 82 EMS(Engine Management System) 16.FUEL PUMP The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump) 5-34...
  • Page 83 EMS(Engine Management System) CHECKING OF THE FUEL LEVEL GAUGE. Remove the fuel level gauge (19-10) Measure the resistance between terminals. The FLOAT position Terminals resistance [ ] F : 128.5[mm] 5[ ] 1/2 : 83.5[mm] 5[ ] E : 28.5[mm] 3[ ] The float position is based on the tank bottom plate after assemble.
  • Page 84 EMS(Engine Management System) 17.THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY MAPAT 5-36...
  • Page 85 EMS(Engine Management System) DISCONNECT THE THROTTLE BODY Disconnect: - Luggage box - TPS,ISA,MAPAT coupler - Throttle cable CAUTION Do not disconnect both the throttle adjust screw and adjusting nut DISASSEMBLE THE THROTTLE BODY - Disconnect the insulator and the connecting tube band 2ea at the air cleaner side.
  • Page 86 EMS(Engine Management System) DISASSEMBLE THE INSULATOR INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP Disconnect: - Injector cap bolt INJECTOR INJECTOR INJECTOR INJECTOR...
  • Page 87 EMS(Engine Management System) ASSEMBLY OF THE THROTTLE BODY Assembly is the reverse order of removal. Assemble the o-ring to the throttle body. CAUTION Replace the o-ring with new one. INSTALLATION OF INSULATOR AND THROTTLE BODY Installation of insulator and throttle body in the reverse order of removal Check the o-ring when the insulator assembly.
  • Page 88 EMS(Engine Management System) SUPPLEMENT ADJUSTMENT OF THROTTLE ADJUST SCREW A vehicle is assembled in the state which engine operation is possible. Loosen the maintenance cover and the adjust-screw is makes possible to adjust. The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool.
  • Page 89 EMS(Engine Management System) 18.HOW TO USE THE SCAN WHEN ECU IS INITIALIZED The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnostic tool. Press the enter button in the initial screen.
  • Page 90 EMS(Engine Management System) Press the enter button when it is ready When the ECU was initialized. turn off the lgnition key and then turn on the ignition key. 5-42...
  • Page 91 EMS(Engine Management System) 19.HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key on. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
  • Page 92 EMS(Engine Management System) 20.HOW TO USE THE SCAN WHEN THE IGNITION TIMING IS CHECKING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
  • Page 93 EMS(Engine Management System) 21.HOW TO USE THE SCAN WHEN ENGINE REVOLUTION IS CHECKING The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn the lgnition key. Start the engine. Press the power button of the diagnosis tool. Press the enter button on the initial screen.
  • Page 94 MEMO...
  • Page 95 FUEL SYSTEM / ENGINE...
  • Page 96 FUEL SYSTEM / ENGINE...
  • Page 97 FUEL SYSTEM / ENGINE...
  • Page 98 MEMO...
  • Page 99 ENGINE REMOVAL/INSTALLATION...
  • Page 100 ENGINE REMOVAL/INSTALLATION...
  • Page 101 ENGINE REMOVAL/INSTALLATION...
  • Page 102 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 103 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 104 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 105 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 106 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 107 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 108 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 109 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 110 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 111 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 112 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-10...
  • Page 113 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-11...
  • Page 114 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-12...
  • Page 115 LH.CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-13...
  • Page 116 A.C GENERATOR / STARTER CLUTCH...
  • Page 117 A.C GENERATOR / STARTER CLUTCH...
  • Page 118 A.C GENERATOR / STARTER CLUTCH...
  • Page 119 A.C GENERATOR / STARTER CLUTCH...
  • Page 120 A.C GENERATOR / STARTER CLUTCH...
  • Page 121 A.C GENERATOR / STARTER CLUTCH...
  • Page 122 A.C GENERATOR / STARTER CLUTCH...
  • Page 123 A.C GENERATOR / STARTER CLUTCH...
  • Page 124 A.C GENERATOR / STARTER CLUTCH...
  • Page 125 MEMO...
  • Page 126 CYLINDER HEAD / VALVE INJECTOR ASSY ENGINE TEMP.SENSOR 10-0...
  • Page 127 CYLINDER HEAD / VALVE 10-1 10-6 10-2 10-7 10-3 10-8 10-5 10-11 10-6 10-13 10-1...
  • Page 128 CYLINDER HEAD / VALVE 10-2...
  • Page 129 CYLINDER HEAD / VALVE 10-3...
  • Page 130 CYLINDER HEAD / VALVE 10-4...
  • Page 131 CYLINDER HEAD / VALVE 10-5...
  • Page 132 CYLINDER HEAD / VALVE 10-6...
  • Page 133 CYLINDER HEAD / VALVE 10-7...
  • Page 134 CYLINDER HEAD / VALVE 10-8...
  • Page 135 CYLINDER HEAD / VALVE 10-9...
  • Page 136 CYLINDER HEAD / VALVE 10-10...
  • Page 137 CYLINDER HEAD / VALVE 10-11...
  • Page 138 CYLINDER HEAD / VALVE 10-12...
  • Page 139 CYLINDER HEAD / VALVE 10-13...
  • Page 140 CYLINDER HEAD / VALVE 10-14...
  • Page 141 CYLINDER HEAD / VALVE throttle body 10-15...
  • Page 142 CYLINDER/PISTON 11-0...
  • Page 143 11-1 11-3 11-1 11-5 11-2 11-1...
  • Page 144 CYLINDER/PISTON 11-2...
  • Page 145 CYLINDER/PISTON 11-3...
  • Page 146 CYLINDER/PISTON 11-4...
  • Page 147 CYLINDER/PISTON 11-5...
  • Page 148 CYLINDER/PISTON 11-6...
  • Page 149 MEMO...
  • Page 150 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-0...
  • Page 151 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-1 12-7 12-2 12-8 12-3 12-9 12-6 12-10 12-1...
  • Page 152 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-2...
  • Page 153 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-3...
  • Page 154 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-4...
  • Page 155 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-5...
  • Page 156 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-6...
  • Page 157 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-7...
  • Page 158 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-8...
  • Page 159 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-9...
  • Page 160 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-10...
  • Page 161 MEMO...
  • Page 162 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-0...
  • Page 163 13-1 13-7 13-2 13-7 13-3 13-10 13-4 13-12 13-5 13-14 13-6 13-19 FRONT 33.914~33.935mm 33.87mm 34~34.039mm 34.01mm FRONT REAR 25.278~25.328mm 25.27mm REAR 25.44~25.41mm 25.42mm 24.914~24.935mm 25.27mm FRONT COMBI BRAKE CALIPER PISTON O.D 25~25.039mm 25.07mm FRONT COMBI BRAKE CALIPER CYLINDER I.D 13-1...
  • Page 164 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-2...
  • Page 165 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-3...
  • Page 166 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-4...
  • Page 167 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-5...
  • Page 168 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-6...
  • Page 169 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-7...
  • Page 170 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-8...
  • Page 171 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-9...
  • Page 172 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-10...
  • Page 173 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-11...
  • Page 174 FRONT WHEEL/FRONT FORK/STEERING/BRAKE BRAKE CALIPER REMOVAL First drain the baeke fluid from the h¥draulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. DISASSEMBLY REmove the two brake pads dowelpins and three bolts from the brake caliper.
  • Page 175 FRONT WHEEL/FRONT FORK/STEERING/BRAKE INSPECTION Check the piston for scratches or wear.. Measure the piston O.D. with a micrometer gauge. Top service limit : 26.91mm Under service limit:33.87mm Check the caliper cylider for scratches or wear and measure the cylinder bore. Top service limit : 27.05mm Under service limit:34.01mm ASSEMBLY...
  • Page 176 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-14...
  • Page 177 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-15...
  • Page 178 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-16...
  • Page 179 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-17...
  • Page 180 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-18...
  • Page 181 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-19...
  • Page 182 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-20...
  • Page 183 MEMO...
  • Page 184 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-0...
  • Page 185 14-1 14-5 14-2 14-7 14-3 14-7 14-1...
  • Page 186 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-2...
  • Page 187 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-3...
  • Page 188 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-4...
  • Page 189 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-5...
  • Page 190 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-6...
  • Page 191 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-7...
  • Page 192 REAR WHEEL/BRAKE/SUSPENSION/REAR SWING ARM 14-8...
  • Page 193 MEMO...
  • Page 194 CHARGING SYSTEM 15-0...
  • Page 195 15-1 15-3 15-2 15-4 15-2 15-5 15-1...
  • Page 196 CHARGING SYSTEM 13.5~15.5V 13.5V 15-2...
  • Page 197 CHARGING SYSTEM 15-3...
  • Page 198 CHARGING SYSTEM 15-4...
  • Page 199 CHARGING SYSTEM 15-5...
  • Page 200 MEMO...
  • Page 201 16-1 16-6 16-3 16-6 16-4 16-5 0.73±0.08Ω(23℃±5℃) (15KΩ) 80~150 16-1...
  • Page 202 IGNITION SYSTEM 16-2...
  • Page 203 IGNITION SYSTEM pulser pulser 16-3...
  • Page 204 IGNITION SYSTEM The secondary coil resistance might not measure cause by the high voltage diode inside the ignition coil. 16-4...
  • Page 205 IGNITION SYSTEM GREEN AND BLACK/WHITE GREEN AND BLACK/WHITE 16-5...
  • Page 206 STARTER SYSTEM 17-0...
  • Page 207 17-1 17-4 17-2 17-7 17-3 17-1...
  • Page 208 STARTER SYSTEM 17-2...
  • Page 209 STARTER SYSTEM 17-3...
  • Page 210 STARTER SYSTEM 17-4...
  • Page 211 STARTER SYSTEM 17-5...
  • Page 212 STARTER SYSTEM 17-6...
  • Page 213 STARTER SYSTEM 17-7...
  • Page 214 MEMO...
  • Page 215 18-1 18-4 18-1 18-2 18-2 18-3 18-3 18-4 18-4 18-1...
  • Page 216 LIGHTS/SWITCH/HORN BAT 1 BAT 2 COLOR GRAY 18-2...
  • Page 217 LIGHTS/SWITCH/HORN 18-3...
  • Page 218 LIGHTS/SWITCH/HORN 18-4...
  • Page 219 MEMO...
  • Page 220 MEMO...
  • Page 221 19. CIRCUIT DIAGRAM...
  • Page 222 19-1...

This manual is also suitable for:

Sq125S2-125 fi

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