DAELIM DAYSTAR Service Manual
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DAELIM DAYSTAR Service Manual

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SERVICE MANUAL

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  • Page 1 SERVICE MANUAL...

  • Page 2: Table Of Contents

    Seat / Exhaust Muffler DAELIM reserves the right to make changes at any Front Wheel / Front Fork time without notice and without incurring any / Steering obligation whatever.

  • Page 3: General Information

    Service Rules 1. Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents. 2. Use the special tools designed for this product. 3. Install new gaskets, o-ring, piston pins, clips, cotter pins, etc. When reassembling.
  • Page 4 General Information Model Identification Frame No Frame No Frame No Engine No Engine No Engine No Frame No Frame No Engine No Engine No Frame No Frame No Frame No Frame No Engine No Engine No Engine No Engine No Frame No Frame No Engine No...

  • Page 5: Specifications

    General Information Specifications Item Specifications Overall Length 2,240mm Overall Width 860mm Overall Height 1,140mm Dimensions Wheel Base 1,505mm Seat Height 720mm Ground clearance 135mm Dry Weight 147.5kgf Curb Weight 341kgf Type Double Cradle Front Suspension Stroke Telescopic fork 140mm Rear Suspension Stroke Swingarm 35mm Front Tire Size 90/90 - 18 (Tubeless)
  • Page 6 General Information Item Specifications Carburetor Type Piston Valve/24mm(0.94 in) Setting Mark VL125 B Main Jet #102 Carburetor Slow Jet Pilot Screw Initial Setting 2 1/4 Float level 19mm Idle Speed 1,400±100(rpm) Clutch Hydraulic, Multi-plate Transmission Type Constant Mesh Transmission Primary Reduction 3.650(73/20) Secondary Reduction 3,000(42/14)
  • Page 7 General Information Torque Values Engine Thread dia Torque Item Q’ty Remark (mm) kgf.m,(N.m) Oil Filter Screen Cap 1.5(15) Oil Filter Relief Valve Oval Screw 1.2(12) Oil Filter Cover Socket Bolt 1.1(11) Oil Pump Mounting Bolt 1.1(11) Valve Adjusting Screw Lock Nut 1.1(11) Drive Sprocket 1.2(12)
  • Page 8 General Information Thread dia Torque Item Q’ty Remark (mm) kgf.m,(N,m) Brake Caliper Bracket Bolt 3.0(30) Brake Caliper Bleed Valve 0.6(6) Brake Pad pin Bolt (1.8, 13) Master Cylinder Reservoir Cap Screw 0.13(1.3) Brake Hose Bolt 3.4(34) Brake Lever Pivot Bolt 1.0(10, 7) Brake Lever Pivot Lock Nut 1.0(10, 7)
  • Page 9 General Information Safety Notices Following marks indicate some warnings and caution against some specific service methods. Mark Meaning Mark Meaning Indicates a possibility of △ Indicates a strong possibility of WARNING personal injury or equipment △ severe personal injury or loss of CAUTION damage if instructions are not life if instructions are not...
  • Page 10 General Information Tools Special Common Description Reference section Description Reference section Clutch Center Holder Wrench, 8 9mm Flywheel Puller Adjusting Wrench, B Lock Pin Puller Set Float Level Gauge Sliding shaft Lock Nut Wrench, 20 24mm Sliding Weight Extension Bar 6, 13 Valve Guide Reamer Fly Wheel Holder...
  • Page 11 General Information Tester, Gauge Description Reference section Remark Compression Gauge Digital Circuit Tester 16, 17 Circuit Tester 16, 17 Inspecion Adapter Spark Adapter Valve Seat Cut Description Reference section Remark 24.5mm IN, EX Valve Seat Cutter 45 23mm IN Valve Seat Cutter 35 20mm EX Valve Seat Cutter 35 22mm IN, EX...
  • Page 12 General Information Cable & Harness Routing Note the following when routing cables and wire harnesses: ● A loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. ● Do not squeeze wires against the weld or its clamp.
  • Page 13 General Information Fuel Meter Code R. Front Winker Cord Horn Sub Harness Clutch Cable L. Front Winker Cord Engine Stop Switch Cord (Starter Kill Switch Cord) Winker Switch Cord Head Light Cord Horn(Low) Horn(High) L. Front Winker Cord R. Front Winker Cord L.
  • Page 14 General Information Throttle Cable Front Brake Hose Throttle Cable Cable Guide Starter Kill Switch Cord Front Brake Hose Wire Harness Fuel Tube Starter Kill Switch Cord Throttle Cable Clutch Cable High Tension Cord Fuel Unit cord Noise Supperssor Clutch Cable Battery Earth Cable Engine breather tube Battery Breather Tube...

  • Page 15: Lubrication

    Lubrication 2. Lubrication Service Information …………………2-1 Engine Oil Change …………………2-3 Specifications ………………………2-1 Engine Oil Filter Element Change …2-4 Troubleshooting ……………………2-2 Oil Pump ………………………………2-4 Engine Oil Level Check ……………2-3 Lubrication Points …………………2-7 Service Information △ WARNING 1. If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area.
  • Page 16 Lubrication Troubleshooting Low oil pressure ● Oil level low ● Pressure relief valve stuck open ● Plugged oil pick-up screen ● Oil pump worm ● External oil leaks High oil pressure ● Pressure relief valve stuck closed ● Plugged oil filter, gallery, or metering orifice ●...

  • Page 17: Engine Oil Level Check/Oil Change

    Filter Screen Filter Screen Filter Screen Filter Screen DAELIM genuine oil API service classification : SE or SH Viscosity : SAE 10W-30 ● Install the oil level gauge. ● Start the engine and let it idle for a few minutes.
  • Page 18 Lubrication Engine Oil Filter Element Change Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover ●...
  • Page 19 Lubrication ● Measure the rotor end clearance. Service Limit : 0.20mm(0.008 in) ● Measure the pump side clearance. Service Limit : 0.12mm(0.005 in) Disassembly / Assembly Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring Setting Ring...
  • Page 20 Lubrication ● Remove the oval screw, sealing washer, spring and relief valve from oil filter cover. ● Remove the oil filter element from R. crank case cover. ● Blow the oil path way of crank case cover with compressed air, and clean. Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw: 1.2kgf-m(12N.m)
  • Page 21 Lubrication Lubrication points if there is no specific indication of oil, use general grease to lubricate the lubrication parts. Lubricate the other operation parts which are not shown below with oil or grease. Control Cable Lubrication Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil.
  • Page 22 MEMO...

  • Page 23: Maintenance

    Maintenance 3. Maintenance Service Information …………………3-1 Brake Fluid ……………………………3-10 Maintenance Schedule ………………3-3 Brake Pad / Shoe………………………3-10 Fuel Line ………………………………3-4 Brake System …………………………3-11 Throttle Grip Operation ………………3-4 Brake Stop Switch ……………………3-12 Carburetor Choke ……………………3-5 Headlight Adjustment ………………3-12 Air Cleaner ……………………………3-5 Clutch……………………………………3-12 Spark Plug ……………………………3-6 Side Stand………………………………3-13 Valve Clearance ………………………3-6...
  • Page 24 Maintenance Torque Values Spark Plug 1.1 kgf-m( 11N.m) Cylinder Head Cover Bolt 1.0 kgf-m( 10N.m) Valve Adjusting Nut 1.1 kgf-m( 11N.m) Timing Hole Cap 0.6 kgf-m( 6N.m) Crankshaft Hole Cap 0.8 kgf-m( 8N.m) Rear Axle Nut 8.8kgf-m(88N.m) Tools Common Tool Wrench, 8×9 mm Adjuster Wrench Compression Gauge...
  • Page 25 Steering Head Bearing 3-15 ＊Should serviced by an authorized DAELIM dealer, unless the owner has proper tools and service date and is mechanically qualified. In the interest of safety, we recommended these items be serviced only by an authorized DAELIM dealer.

  • Page 26: Fuel Line

    Maintenance Fuel Line Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Tube Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Cock Fuel Tube Fuel Tube Fuel Tube...

  • Page 27: Carburetor Choke

    Maintenance Carburetor Choke Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever ● Make sure if there is no deterioration, damage or kinking in the choke cable. Check for smooth chock lever operation at any adjusting position.

  • Page 28: Spark Plug

    Maintenance ● Make sure if there is no deterioration and Element Element Element Element Element Element Element Element Element Element Element Element Element damage in the air cleaner element. Replace damaged parts. NOTE •The element is a viscous type which contains oil.

  • Page 29: Valve Clearance

    Maintenance ● Measure the valve clearance with filler gauge. Valve Clearance: Intake: 0.12±0.02mm(0.05±0.001in) Exhaust: 0.12±0.02mm(0.05±0.001in) ● Loosen the lock nut with a valve wrench, and adjust the adjuster screw to the standard clearance using a valve adjusting wrench. When the standard clearance is done, hold the adjuster screw with a valve adjusting wrench.

  • Page 30: Carburetor Idle Speed

    Maintenance Carburetor Idle 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 Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw NOTE •Inspect all other engine adjustments are within...
  • Page 31 Maintenance ● Inspect the drive chain for adherence and damaging. ● Remove the contamination with a cleaner. After drying completely, coat the chain with #80-90 gear oil. Wipe any excessive oil off Gear Oil(#80-90) the chain, check the drive chain for wear and damage, replace it if necessary.

  • Page 32: Battery

    Maintenance Battery ● Remove the right side cover. ● Inspect the battery electrolyte level. When the level nears the lower level, add distilled water to the upper level. NOTE • Add only distilled water. • Avoid spilling the fluid of battery on other parts. △...

  • Page 33: Brake System

    Maintenance Brake Shoe Replacement ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ▵ Mark ● Replace the brake shoes if the arrow on the brake arm aligns with the reference mark “△”...

  • Page 34: Brake Stop Switch

    Maintenance Height Adjustment ● Adjust the brake pedal height to 10-20mm. △ CAUTION • The adjustment faulty of height may caused that the brake runs in state of operation. Loosen the lock nut, and then adjust the height by turning the brake pedal stoper bolt. After adjusting, tighten the lock nut securely.

  • Page 35: Side Stand

    Maintenance ● Perform the light adjustment by loosening the Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster Adjuster lock nut from the handle and turning the adjuster. Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut Lock Nut...

  • Page 36: Bolts, Nuts Fasteners

    Maintenance Rear ● Check the action of the rear cushion by compressing them several times. Check the rear cushion for leaks, damage, or looseness. ● Support the motorcycle with a main stand. ● Check for worn rear fork bush by attempting to move the wheel side to side.

  • Page 37: Steering Head Bearings

    Maintenance ● Measure the tread depth at the center of the tire. ● Replace the tire when the tread depth reaches the following limits: Minimum Tread Depth: 4mm (0.16 in) 8.5mm (0.3 in) Steering Head Bearings NOTE ● Check that the control cables do not interfere with handle bar rotation.
  • Page 38 Fuel System...

  • Page 39: Fuel System

    Fuel System 4. Fuel System Service Information …………………4-1 Throttle Valve …………………………4-5 Troubleshooting ………………………4-2 Carburetor………………………………4-6 Fuel Tank ………………………………4-3 Accelerator Adjustment ……………4-11 Air Cleaner Case ………………………4-4 Service Information General △ WARNING 1. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.

  • Page 40: Troubleshooting

    Fuel System Torque Air cleaner case cover screw 0.43kg-m (4.3N.m, 3.1ft-lb) Tools Float level gauge Troubleshooting won’ ’ t start Engine cranks but ● No fuel in tank ● No fuel to carburetor ● Engine flooded with fuel ● Clogged air cleaner ●...

  • Page 41: Fuel Tank

    Fuel System Fuel Tank Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Cock Fuel Cock Fuel Cock...

  • Page 42: Air Cleaner Case

    Fuel System Air Cleaner Case Removal ● Remove the L. side cover. ● Remove the air cleaner connecting tube band out of the air cleaner side. Remove the battery. ● Remove the air cleaner mounting bolt. ● Remove the air cleaner case. Installation ●...

  • Page 43: Throttle Valve

    Fuel System Throttle Valve Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Removal ● Remove the R. side cover. ● Remove the seat and the fuel tank. Loosen the carburetor top slowly and remove the throttle valve.

  • Page 44: Carburetor

    Fuel System Installation Lean Mixture ● Install the jet needle, retainer clip into the First Level throttle valve. ● Needle clip standard position: 2nd Level Standard ● Install the carburetor top, spring into the 2nd Level throttle cable. ● Install the throttle cable into throttle valve. 3rd Level Rich Mixture ●...
  • Page 45 Fuel System ● Remove the throttle cable. ● Loosen the carburetor mounting nut, and remove the carburetor. Disassembly Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube Fuel Tube ●...
  • Page 46 Fuel System ● Align the diaphragm projecting part with float Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part Projecting Part chamber groove. Install the spring to diaphragm cover, and install the cover to the float chamber preventing the diaphragm form damaging.
  • Page 47 Fuel System Main Jet Main Jet Main Jet Main Jet Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Main Jet Main Jet Needle Jet Holder Needle Jet Holder Main Jet Main Jet Main Jet Main Jet Needle Jet Holder Needle Jet Holder Needle Jet Holder...
  • Page 48 Fuel System ● Blow each jet and body pathway with compressed air, and clean the clogged place. ● Install the needle jet, needle jet holder, main jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet...

  • Page 49: Accelerator Adjustment

    Fuel System ● Install the new o-ring to the float chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber Float Level Chamber...
  • Page 50 Fuel System Pilot Screw Adjustment Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw Pilot Screw 1. Turn each pilot screw clockwise until it seats lightly and back it out to the specification given.

  • Page 51: Engine Removal/Installation

    Engine Removal/Installation 5. Engine Removal/Installation Service Information …………………5-2 Engine Installation………………………5-4 Engine Removal ………………………5-3...
  • Page 52 Engine Removal / Installation Service Information General ● A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the frame, engine body, cables, wire system. ● The following parts or components can not be served with the engine installed in the frame. ●...
  • Page 53 Engine Removal / Installation Engine Removal ● Drain the engine oil.(⇨2-3) ● Remove the following - Side cover(⇨ 12-2) - Seat(⇨ 12-2) - Fuel tank(⇨ 4-3) - Mufflers(⇨ 12-3) ● Disconnect the connector of the starter motor cable, AC generator wire, gear change switch Screw Screw Screw...
  • Page 54 Engine Removal / Installation Engine Installation Engine installation is essentially the reverse order of removal. NOTE • Carefully align mounting points with the jack to prevent damage from mounting bolt threads and wire harness and cables. • Be careful not to damage any part of the frame and bolt nuts.
  • Page 55 MEMO...
  • Page 56 Clutch, Gearshift...

  • Page 57: Clutch / Gearshift

    Clutch, Gearshift 6. Clutch / Gearshift …………………6-1 Service Information Gearshift Linkage……………………6- 7 Troubleshooting ……………………6-2 Clutch Installation …………………6- 9 R. Crankcase Cover Dissembly …6-3 Primary Drive Gear …………………6-10 R. Crank Case Cover ………………6-11 Clutch Disassembly…………………6-4 Service Information ● The clutch, gearshift linkage can be serviced with the engine in the frame. ●...
  • Page 58 Clutch, Gearshift Troubleshooting Clutch operation problem can be corrected by adjusting a cable free play. Clutch lever pull too hard ● Damaged, clogged or sticking clutch cable ● Damaged lifter mechanism ● Damaged clutch lifter plate bearing ● Incorrect wiring of clutch cable Clutch slips ●...
  • Page 59 Clutch, Gearshift R. Crankcase Cover Disassembly ● Drain the engine oil(⇨ 2-3) ● Remove the kick starter pedal. ● Remove the clutch adjusting lock nut and adjusting nut. Separate the clutch cable from the clutch arm. ● Remove the cable out of the cable holder. Kick Starter Pedal Kick Starter Pedal Kick Starter Pedal...
  • Page 60 Clutch, Gearshift ● Separate the clutch arm spring and o-ring from 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 the clutch arm/lift shaft. ● Inspect the wear and damage of the lifter rod and clutch arm/lift shaft. ●...
  • Page 61 Clutch, Gearshift ● Press the clutch center using the clutch center Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Extension Bar Extension Bar...
  • Page 62 Clutch, Gearshift Inspection Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate ● Inspect the lifter plate bearing for scoring and Lifter Plate other damage. ●...
  • Page 63 Clutch, Gearshift ● Check the slots in the clutch outer for nicks or indentations made by the clutch discs. If necessary replace them. ● Measure the clutch outer inside diameter. Service Limit:28.030mm(1.1035in) ● Measure the clutch outer guide outsider diameter. Service Limit:27.950mm(1.1004in) Installation ●...
  • Page 64 Clutch, Gearshift Inspection Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate Gear Shift Plate ●...
  • Page 65 Clutch, Gearshift ● Install the following: - Clutch assy. - R. crank case cover ● Install the gear shift arm into the gear shift spindle Clutch Assembly Thrust Washer Thrust Washer Clutch Outer Guide Clutch Outer Guide Thrust Washer Thrust Washer Clutch Outer Guide Clutch Outer Guide Thrust Washer...
  • Page 66 Clutch, Gearshift ● Install the pressure plate, disk, plate and clutch center into the clutch outer. ● Coat the nut parts with clean engine oil, and tighten the lock nut. ● Install the lock nut by pressing clutch center Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench...
  • Page 67 Clutch, Gearshift ● When replacing the primary drive gear, select the gear which the paint mark, same colar of R.crank case paint mark, is indicated. Paint mark of crank case Paint mark of primary drive gear White White(Primary drive gear A) Blue Blue(Primary drive gear B) Yellow...
  • Page 68 Clutch, Gearshift R. Crankcase Cover 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 Installation ● Remove the gasket from the crank case surface.
  • Page 69 A.C Generator / Starter Clutch...

  • Page 70: Generator / Starter Clutch

    A.C Generator / Starter Clutch 7. A.C Generator / Starter Clutch Service Information …………………7-1 Starter Clutch ………………………7-7 A.C Generator ………………………7-2 Service Information General ● This section covers removal and installation of the A.C. generator. ● Refer to section 16 for inspection of the A.C. generator. ●...
  • Page 71 A.C Generator / Starter Clutch A.C Generator Removal ● Remove the gear change pedal. ● Remove the L. lower cover. L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L. Rear Cover L.
  • Page 72 A.C Generator / Starter Clutch ● Remove the starter reduction gear shaft and Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear Starter Reduction Gear...
  • Page 73 A.C Generator / Starter Clutch ● After installing the flywheel puller on the rotor, remove the rotor. Tool: Flywheel puller Flywheel Puller ● Remove the woodruff key from the crank Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar...
  • Page 74 A.C Generator / Starter Clutch Starter Idle Gear Inspection Gear Shaft ● Inspect the wear and damage of starter ldle gear. ● Measure the gear inside diameter. Service Limit : 10.100mm(0.393in) ● Measure the gear shaft inside diameter. Service Limit : 9.97mm(0.393in) Starter Idle Gear Reduction Gear Inspection Reduction Gear...
  • Page 75 A.C Generator / Starter Clutch ● Install the starter idle gear and shaft. Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear Starter Idle Gear...
  • Page 76 A.C Generator / Starter Clutch ● Connect the AC generator wire and gear position light switch wire coupler, and install the wire clamp. ● Install the L. Lower cover and gear change Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal...
  • Page 77 A.C Generator / Starter Clutch ● Check the starter driven gear for damage and wear. ● Measure the driven gear I.D. and O.D. Service Limit: O.D. : 42.180mm(1.658in) I.D. : 22.100mm(0.870in) Assembly Clutch Outer Flange Part ● Inspect the one way clutch for wear and damage.
  • Page 78 MEMO...

  • Page 79: Cylinder Head / Valve

    Cylinder Head / Valve...
  • Page 80 Cylinder Head / Valve 8. Cylinder Head / Valve Service Information …………………8-1 Valve Guide Replacement……………8-8 Troubleshooting ………………………8-2 Valve Seat Inspection ………………8-9 Camshaft Removal ……………………8-3 Cylinder Head Assembly ……………8-11 Cylinder head Removal ………………8-5 Cylinder Head Assembly ……………8-13 Cylinder Heand Installation …………8-13 Cylinder Head Disassembly…………8-6 Service Information General...

  • Page 81: Cylinder Head / Valve

    Cylinder Head / Valve Torque Values Cam Chain Tensioner Pivot Bolt 1.1kgf-m(11N.m) Spark Plug 1.1kgf-m(11N.m)-Apply engine oil Camshaft Holder 8mm nut 2.0kgf-m(20N.m)-Apply engine oil Cam Chain Tensioner Mounting Bolt 1.2kgf-m(12N.m) Cam Chain Tensioner Sealing Screw 0.4kgf-m(4N.m) Cylinder Head Cover Bolt 1.0kgf-m(10N.m) Crank Shaft Hole Cap 0.8kgf-m(8N.m)

  • Page 82: Camshaft Removal

    Cylinder Head / Valve Camshaft Removal ● Remove the fuel tank(⇨ 4-3) ● Remove the cylinder head cover bolts and cover. ● Remove the timing hole cap and crank shaft Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap...
  • Page 83 Cylinder Head / Valve ● Remove the cam chain from camshaft. 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 Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins...

  • Page 84: Cylinder Head Removal

    Cylinder Head / Valve Inspection ● Inspect the rocker arm and rocker arm shaft for wear and damage. ● Measure the rocker arm I.D. Service Limit : 12.060mm(0.4748in) ● Measure the rocker arm O.D. Service Limit : 11.950mm(0.4505in) ● Inspect the cam lobe of the camshaft for wear and damage.

  • Page 85: Cylinder Head Disassembly

    Cylinder Head / Valve ● Remove the gasket, dowel pins, and cam chain Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide...
  • Page 86 Cylinder Head / Valve ● Inspect the spark plug assembly hole and the crack of near valve seat. Check for the warp of the cylinder head with a square and filler gauge. Service Limit : 0.1mm(0.004in) Valve Spring ● Measure the free field of valve spring. Service Limit : 40.0mm(1.57in) △...

  • Page 87: Valve Guide Replacement

    Cylinder Head / Valve Valve Guide Replacement △ CAUTION • When replacing the valve guide, valve seat must be amended. ● Heat the cylinder head equally to 130-140℃. ● Avoid heating over 150℃ △ CAUTION • Avoid performing the unskilled work. It is caused a burn.

  • Page 88: Valve Seat Inspection

    Cylinder Head / Valve △ CAUTION • Trim the reamer not to lean. If cutting the reamer by leaning, the valve hole is inclined, the step seal is leaked, and the around of valve seat is enlarged. So the around of seat is not amended.
  • Page 89 Cylinder Head / Valve Valve Seat Amendment Damaged or Rough ● If the Seat part is damaged or rough, cut them using 45。 cutter. △ CAUTION • After replacing the valve guide, cut the seat Valve part. Seat 45。 ● Amend the flat using a 35。 cutter side by side. Cut The Seat Part 35。...

  • Page 90: Cylinder Head Assembly

    Cylinder Head / Valve ● Coat the valve seat with the compound. ● Use the valve guide reamer without turning the Contact Part is Hight Valve, check the attached state by hitting against lightly. Seat Width Before ● If the position of contacting side is high, cut it Cutting using a 35。...
  • Page 91 Cylinder Head / Valve ● Install the valve springs. The springs tightly would coils should face toward the cylinder head. For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head...

  • Page 92: Cylinder Heand Installation

    Cylinder Head / Valve Cylinder Head Installation 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 Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede...
  • Page 93 Cylinder Head / Valve ● Insert the dowel pins into the camshaft holder thoroughly. Align the teeth of the rocker arm spring with the dowel pins as shown. ● Check the camshaft ass’ y for wear or damage, and Install the Cylinder head ●...
  • Page 94 Cylinder Head / Valve ● Install the dowel pin into the cylinder Head. ● Install the camshaft holder. ● Apply engine oil to the nut part, install and tighten the cam shaft holder nut and bolt in two or three steps as shown Torque : 2.0kgf-m(29N.m) ●...
  • Page 95 Cylinder Head / Valve ● Hold the tensioner shaft with the light clip as shown Install a new gasket into the tensioner lifter, then install the tensioner lifter into the Tensioner Lifter cylinder. ● Install the tensioner mounting bolt. Torque:1.2kgf-m(12N.m) ●...
  • Page 96 MEMO...

  • Page 97: Cylinder / Piston

    Cylinder / Piston...
  • Page 98 Cylinder / Piston 9. Cylinder / Piston Service Information …………………9-1 Piston …………………………………9-3 Troubleshootint ……………………9-1 Piston/Cylinder Installation ………9-5 Cylinder ………………………………9-2 Service Information Geaneral ●When removing the cylinder, avoid damaging the cylinder joint part with a driver or cooling pin by hitting the cylinder strongly. ●Avoid damaging the inside of the cylinder and piston surface.
  • Page 99 Cylinder / Piston Cylinder Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Removal ●...
  • Page 100 Cylinder / Piston ● Inspect the twist of cylinder. Ruller Service Limit:0.1mm(0.004in) Filter Gauge Piston Piston Pin Clip Piston Removal ● Remove the piston pin clips. ＊ ＊ NOTE • Do not let the clips fall into the crankcase. • Push the piston pin out and remove the piston. ●...
  • Page 101 Cylinder / Piston ● Insert the piston ring into the cylinder inside, Filter Gauge and inspect the piston ring clearance. ＊ ＊ NOTE ● Insert the piston ring horizontally using a piston head. Service Limit: Top/Second:0.5mm(0.02in) Oil(Side rail):1.1mm(0.04in) Piston Pin ●...
  • Page 102 Cylinder / Piston Piston/Cylinder Installation Piston Ring Installation ● Clean the piston domes, ring lands and skirts and install the piston ring. ＊ ＊ NOTE • Be careful not to damage the piston and piston rings during assembly. • Carefully install the piston rings onto the piston with the markings facing up.
  • Page 103 Cylinder / Piston ● Install the piston, piston pin on the connecting Piston Pin Clip Piston rod. ● Install new piston pin clips. ＊ ＊ NOTE • Install the piston with the “IN” mark facing towards the intake side. • Place a shop towel over the opening to prevent piston pin clips from falling into the crankcase.
  • Page 104 Cylinder / Piston ● Install the lower part of the cam chain into the Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide...
  • Page 105 Crank Case / Transmission / Crankshaft 1.2kgf-m(12N-m) 1.1kgf-m(11N-m) 10-0...
  • Page 106 Crank Case / Transmission / Crankshaft / Kick Starter 10. Crank Case/Transmission/Crankshaft/Kick Starter Service Information ………………10-1 Crank Case Bearing ………………10-7 Troubleshooting ……………………10-2 Crankshaft Installation ……………10-8 Crank Case Disassembly …………10-3 Transmission Assembly …………10-9 Transmission Disassembly ………10-4 Kick Starter …………………………10-10 Crankshaft Disassembly …………10-6 Crank Case Assembly ……………10-12 Service Information General...

  • Page 107: Crankcase / Transmission Crankshaft / Kick-Starter

    Crank Case / Transmission / Crankshaft / Kick Starter Item Standard Service Limit 0.20-0.062(0.0008-0.0024) 0.10(0.004) Transmissin Bush-to-shaft clearance 0.016-0.052(0.0006-0.0020) 0.09(0.004) 0.013-0.047(0.0005-0.0019) 0.09(0.004) Connecting rod big end side 0.05-0.3(0.002-0.012) 0.6(0.02) clearance Connecting rod bid end Crankshaft 0-0.008(0-0.0003) 0.05(0.002) vertical direction clearance Right 0.1(0.004) Crankshaft runout...

  • Page 108: Crankcase Disassembly

    Crank Case / Transmission / Crankshaft / Kick Starter Crankcase Disassembly Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain Cam Chain ● The engine must be separated from the frame (⇨...

  • Page 109: Transmission Disassembly

    Crank Case / Transmission / Crankshaft / Kick Starter Transmission Disassembly Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft Shift Fork Shaft...
  • Page 110 Crank Case / Transmission / Crankshaft / Kick Starter ● Inspect the shift drum for wear and damaging. ● Inspect the shift drum guide groove for partial wear and damaging. ● Measure the main shaft and counter shaft outside diameter. Service Limit: M3, M5:19.930mm(0.7486in) C1:16.440mm(0.6472in) C2:19.940mm(0.7850in)

  • Page 111: Crankshaft Disassembly

    Crank Case / Transmission / Crankshaft / Kick Starter Crankshaft Disassembly Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft ● Disassemble the transmission. ● Remove the crankshaft from the left crankcase using a crankshaft separating tool. Remove the remaining bearings in the left crankcase with a driver handle and outer driver.

  • Page 112: Crankcase Bearing

    Crank Case / Transmission / Crankshaft / Kick Starter ● Measure the state of vertical flux of the Connecting Rod end by X and Y direction. Service Limit:0.05mm(0.002in) Crankcase Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing...

  • Page 113: Crankshaft Installation

    Crank Case / Transmission / Crankshaft / Kick Starter R. Crank Case Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet Cooling Jet ● Remove the main shaft bearing set plate. ●...

  • Page 114: Transmission Assembly

    Crank Case / Transmission / Crankshaft / Kick Starter Transmission Assembly ● Coat the gear and gear bush with clean engine Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft...

  • Page 115: Kick Starter

    Crank Case / Transmission / Crankshaft / Kick Starter ● Check the marks on the shift forks. - Left fork: L. mark - Center fork: C. mark - Right fork: R. mark Center Fork Center Fork Center Fork Center Fork Right Fork Right Fork Left Fork...
  • Page 116 Crank Case / Transmission / Crankshaft / Kick Starter ● Remove the 12mm thrust washer, snap ring, Snap Ring Snap Ring Snap Ring Snap Ring Spring Spring Snap Ring Snap Ring Spring Spring Snap Ring Snap Ring Snap Ring Snap Ring Spring Spring Spring...

  • Page 117: Crankcase Assembly

    Crank Case / Transmission / Crankshaft / Kick Starter Installation ● Coat the pinion gear with clean engine oil. Install the gear into the 20mm thrust washer and tighten them with the snap ring. ● Install the kick starter ratchet into the spindle, aligning the punch mark.
  • Page 118 Crank Case / Transmission / Crankshaft / Kick Starter ● Install the kick starter into the right crankcase, hanger the end of the kick starter spring on the case hole. ● Turn the ratchet and ratchet guide plate to the Guide Plate Guide Plate Guide Plate...
  • Page 119 Crank Case / Transmission / Crankshaft / Kick Starter ● Tighten the left crankcase bolt ina crisscross Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube pattern in 2-3 steps.

  • Page 120: Cooling System

    Cooling System 11. Cooling System Service Information ………………11-1 Radiator ………………………………11-2 Service Information General The engine must be cool before servicing the cooling system. 11-1...
  • Page 121 Cooling System Radiator Removal ● Remove the radiator grill ● Remove the radiator from the frame. ● Loosen the oil through bolt from the cylinder, and remove the radiator hose R.L ● Loosen the oil through bolt from the radiator, and remove the radiator hose R.L Radiator Grill Radiator Grill...

  • Page 122: Seat/Exhaust Muffler

    Seat/Exhaust Muffler 12. Seat/Exhaust Muffler ………………12-1 Rear Fender …………………………12-3 Service Information Side Cover, Seat ……………………12-2 Muffler ………………………………12-3 Grab Rail ……………………………12-2 Tool Box………………………………12-4 Service Information △ CAUTION ● Muffler is very hot after engine stops. Avoid inspection right after engine stop. 12-1...

  • Page 123: Side Cover/Seat

    Seat/Exhaust Muffler Side Cover/Seat Side Cover Removal ● Remove the R.side cover. (Removing with a lock key) ● Loosen the screw with a “+” driver ● Separate the side cover hook from grommet of frame. (When removing, remove the side cover with pushing toward the down.) Screw Screw...

  • Page 124: Rear Fender

    Seat/Exhaust Muffler Rear Fender R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R. Grab Rail R.

  • Page 125: Tool Box

    Seat/Exhaust Muffler Muffler Removal/Assembly ● Loosen the 3 pan screw of muffler protector and remove the protector. ● Loosen the upper/low muffler band. ● Loosen the 2 flange nut of upper muffler stay and remove the muffler comp Pan Screw Pan Screw Pan Screw Pan Screw...
  • Page 126 MEMO 12-5...
  • Page 127 Front Wheel/Front Fork/Steering 13-0...

  • Page 128: Front Wheel/Front Fork/Steering

    Front Wheel/Front Fork/Steering 13. Front Wheel/Front Fork/Steering Front Wheel …………………………13-6 Service Information ………………13-1 Front Fork ……………………………13-11 Troubleshooting ……………………13-2 Handle Bar …………………………13-3 Steering Stem ………………………13-18 Service Information General △ CAUTION ● Contaminated brake disk and pad reduce stopping power. keep grease off the brake disk and pad. Wipe any excess grease off the disk.
  • Page 129 Front Wheel/Front Fork/Steering Tools Special Ball Race Driver Steering Stem Driver Fork Seal Driver Steering Stem Socket Common Extension Bar Driver Fork Seal Driver Body Lock Nut Wrench 30×32mm Bearing Remover shaft Remover Head Attachment 42×47mm Attachment 37×40mm Pilot 12mm Troubleshooting Hard steering Soft suspension...
  • Page 130 Front Wheel/Front Fork/Steering handle Bar Removal ● Loosen the cable guide bolt and remove the guide. Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt ● Remove the starter kick switch, Throttle cable Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder...
  • Page 131 Front Wheel/Front Fork/Steering Assembly ● Install the handle into the top bridge connecting hole. Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole...
  • Page 132 Front Wheel/Front Fork/Steering ● Apply grease to the ends of the throttle cable. Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable ● Install the throttle cable into the throttle pipe. ●...
  • Page 133 Front Wheel/Front Fork/Steering ● Tighten the forward screws first, then tighten the rear screws. Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw ● After installing the brake hose, kill switch cable, winker switch code and chock cable into the cable guide, tighten the guide.
  • Page 134 Front Wheel/Front Fork/Steering ● Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Service Limit: Radial Runout: 2.0mm(0.08in) Axial Runout: 2.0mm(0.08in) Wheel Bearing Inspection ● Turn the inner race of each bearing with your finger.
  • Page 135 Front Wheel/Front Fork/Steering ● Remove the bust seal of R. side. Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk ● Remove the brake disc of L. side. NOTE •...
  • Page 136 Front Wheel/Front Fork/Steering Assembly ● Apply grease to the dust seal rim. ● Install the dust seal, brake disk. ● Install the brake disk. Torque: 4.2kgf-m(42N.m) Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal...
  • Page 137 Front Wheel/Front Fork/Steering ● Loosen the brake disc by the disk bolt. ● Align the speedometer gear retainer hole with the slot of the wheel hub. Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer...
  • Page 138 Front Wheel/Front Fork/Steering Front Fork Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Removal ● Remove the following - Front wheel (⇨13-6) - Brake caliper - Front fender ●...
  • Page 139 Front Wheel/Front Fork/Steering ● Cover the bottom case with cloth, and remove the socket bolt. △ CAUTION • If nto removing the socket bolt with turning, assemble temporarily the spring and fork tube cap bolt. • Support the bottom case by vise strongly, preventing it from transformation or damaging.
  • Page 140 Front Wheel/Front Fork/Steering ● Remove the set ring. Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring Set Ring ● Remove the oil seal. △ CAUTION •...
  • Page 141 Front Wheel/Front Fork/Steering ● Install the fork tube into V-block, and measure the bent with a dial gauge. Service Limit: replacement if over 0.2mm ● Inspect the contacted part of slider bush. Bottom case must be replaced if the copper Slider Bush portion is shown over three of quarter in teflon coating part or remarkably damaging.
  • Page 142 Front Wheel/Front Fork/Steering ● Connect the rebound spring and fork piston Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube into the fork tube. ●...
  • Page 143 Front Wheel/Front Fork/Steering ● Install the set ring. Set Ring ● Install the set ring to bottom case exactly. ● Install 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...
  • Page 144 Front Wheel/Front Fork/Steering ● Install the new O-ring to frok tube cap bolt. Fork Tube Cap Bolt Fork Tube Cap Bolt O-Ring O-Ring O-Ring O-Ring Fork Tube Cap Bolt Fork Tube Cap Bolt O-Ring O-Ring O-Ring O-Ring Fork Tube Cap Bolt Fork Tube Cap Bolt Fork Tube Cap Bolt Fork Tube Cap Bolt...
  • Page 145 Front Wheel/Front Fork/Steering ● Install the following: Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender - Brake Caliper Torque: 3.0kgf-m - Front fender - Front wheel (⇨13-6) Steering Stem Removal...
  • Page 146 Front Wheel/Front Fork/Steering ● Remove the steering head top thread. Tools: Steering stem socket Extension bar Steering Stem Socket ● Remove the steering upper bearing. NOTE Bearing Replacement NOTE • Always replace the bearing and races as a set. Tool: Ball race driver ●...
  • Page 147 Front Wheel/Front Fork/Steering NOTE • If the motorcycle had caused an accident, check the steering head pipe for crack of damage. ● Tighten the top thread. Torque: 1.8kgf Tools: Steering stem socket Steering Extension bar Stem Socket ● Move the steering stem from side to side 4-5 times, and allow the steel ball to operate.
  • Page 148 Front Wheel/Front Fork/Steering ● After arranging the cable, install the cable guide. ● Install the front fork. (⇨13-11) Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide ●...
  • Page 149 Rear Wheel/Rear Brake/Suspension 14-0...

  • Page 150: Rear Wheel/Rear Brake/Suspension

    Rear Wheel/Rear Brake/Suspension 14. Rear Wheel/Rear Brake/Suspension Service Information ………………14-1 Rear Brake Pedal……………………14-8 Troubleshooting ……………………14-2 Rear Cushion ………………………14-8 Rear Wheel …………………………14-3 Rear Fork ……………………………14-10 Rear Brake …………………………14-6 Service Information General ● Note the assembling direction of the bolts. Specifications Unit: mm(in) Item Standard Service Limit...

  • Page 151: Troubleshooting

    Rear Wheel/Rear Brake/Suspension Tools Common Rear Cushion Compressor Rear Cushion Compressor Attachment Attachment, 32×35mm Attatchment, 42×47mm Pilot, 15mm Driver Bearing Remover Shaft Remover Head, 15mm Troubleshooting Wobble or vibration in motorcycle Rear cushion noise ● Bent rim ● Binding shock case ●...

  • Page 152: Rear Wheel

    Rear Wheel/Rear Brake/Suspension Rear Wheel Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Chain Adjuster Removal ● Raise and support the motorcycle with main stand.
  • Page 153 Rear Wheel/Rear Brake/Suspension ● Check the teeth of the final driven sprocket. ● Replace the worn, damaged final driven sprocket. 불량 △ 양호 Good WARNING • Check the drive chain and drive sprocket at the same time. Disassembly Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket...
  • Page 154 Rear Wheel/Rear Brake/Suspension ● Coat the bearing with the grease. ● Insert the new bearing in parallel with the seal side facing outside. After inserting the distance collar, insert the bearing of the right side with the seal side facing outside. Tools: Driver Attachment...

  • Page 155: Rear Brake

    Rear Wheel/Rear Brake/Suspension ● Install the chain adjuster, insert the axle shaft Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut Chain Adjust Nut...
  • Page 156 Rear Wheel/Rear Brake/Suspension Assembly Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam ● Apply Grease a little to the anchor pins and brake cam.

  • Page 157: Rear Brake Pedal

    Rear Wheel/Rear Brake/Suspension Rear Brake Pedal Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Disassembly ● Remove the bolts and brake pedal. ●...
  • Page 158 Rear Wheel/Rear Brake/Suspension Disassembly Attachment ● Install the rear cushion compressor and attachment. Tools: Rear cushion compressor Rear cushion attachment △ CAUTION • Avoid the upper joint from damage. Rear Cushion Compressor ● Fix the upper joint, and remove the upper joint Attachment by loosening the lock nut.
  • Page 159 Rear Wheel/Rear Brake/Suspension ● Coat the lock nut with oil to the thread, and install the rear cushion compressor attachment into the damper rod. ● Coat the upper joint with oil to the thread and install it into the damper rod. ●...
  • Page 160 Rear Wheel/Rear Brake/Suspension Disassembly ● Disassemble the rear sub fender. ● Disassemble the chain slider. ● Disassemble the rear fork pivot bearing. ● Disassemble the dust seal and center collar. ● Disassemble the pivot bush. Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider Chain Slider...
  • Page 161 Hydraulic Brake 15-0...

  • Page 162: Hydraulic Brake

    Hydraulic Brake 15. Hydraulic Brake ………………15-1 Service Information Brake Disk……………………………15-6 Troubleshooting ……………………15-2 Brake Caliper ………………………15-7 Brake Fluid/Bleeding ………………15-3 Master Cylinder ……………………15-9 Brake Pad ……………………………15-4 Service Information General Do not allow foreign material to enter the system when filling the reservoir. Do not mix different types of brake fluid.

  • Page 163: Troubleshooting

    Hydraulic Brake Tools Special Snap Ring Pliers Troubleshooting Brake lever soft or too hard Air bubbles in hydraulic system. Moisture in brake fluid. Brake pad and disk contaminated. Caliper piston worn. Master cylinder piston worn. Brake pad worn. Contaminated caliper inner part. Incorrectly installed caliper.

  • Page 164: Brake Fluid/Bleeding

    Hydraulic Brake Brake Fluid / Bleeding Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Master Cylinder Master Cylinder...

  • Page 165: Brake Pad

    Hydraulic Brake If the brake bleeder is not available, use the following procedure. Fill the master cylinder reservoir to the upper level mark. Connect the bleeder hose to the bleed valve and bleed the system as follows. 1. Squeeze the brake lever, open the bleed valve 1/2 turn and then close the bleed valve.
  • Page 166 Hydraulic Brake Remove the brake caliper from the left front Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper fork. Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...

  • Page 167: Brake Disk

    Hydraulic Brake Install the brake caliper into the left front fork. Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose NOTE • Be careful not to damage the brake pad. Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...

  • Page 168: Brake Caliper

    Hydraulic Brake Brake Caliper Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Removal Remove the brake hose bolt and brake hose from the brake caliper. Remove the caliper from the front fork, then remove the pad pin bolt, brake pad.
  • Page 169 Hydraulic Brake Inspection Caliper Inspect the caliper friction surface for damaging or crack. Measure the caliper inside diameter. Service Limit: 34.02mm (1.339in) Inspect the piston outside for damaging or Caliper Piston crack. Measure the piston outside diameter. Service Limit: 33.87mm (1.333in) Micro Meter Assembly Bush...

  • Page 170: Master Cylinder

    Hydraulic Brake Installation Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Brake Hose Connect the brake hose to the caliper, and install the 2 sheets of sealing washer and brake hose bolt.
  • Page 171 Hydraulic Brake Remove the washer, piston, spring from the Secondary Cope Secondary Cope Master Piston Master Piston Master Piston Master Piston Spring Spring Secondary Cope Secondary Cope Master Piston Master Piston Master Piston Master Piston Spring Spring Secondary Cope Secondary Cope Secondary Cope Secondary Cope Master Piston...
  • Page 172 Hydraulic Brake Install the boot into master cylinder. Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Brake Lever Install the rear mirror, brake lever and stop switch.
  • Page 173 Charging System/Battery Regulator Rectifier Fuse AC Generator Battery 16-0...

  • Page 174: Charging System / Battery

    Charging System/Battery 16. Charging System / Battery Service Information ………………16-1 Charging System Inspection ……16-5 Troubleshooting ……………………16-2 Regulator/Rectifier …………………16-6 Battery ………………………………16-3 A.C Generator Inspection …………16-7 Service Information General △ CAUTION The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. - If Electrolyte gets on your skin, flush with water.
  • Page 175 Charging System/Battery Troubleshooting No power (Main switch turned “ON”) Dead battery - Low fluid level - Low specified gravity - Charging system failure Disconnected battery cable Main fuse burned out Faulty ignition switch Low power (Main switch turned “ON”) Weak battery - Low fluid level - Low specific gravity - Charging system failure...
  • Page 176 Charging System/Battery Battery + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal + Terminal Removal Remove the right side cover. Disassemble the battery holder. Remove the battery cable from the battery terminal.
  • Page 177 Charging System/Battery Charging Remove the battery caps. Fill the cells with distilled water to the upper level, if necessary. Connect the charger positive cable to the battery positive terminal. Connect the charger negative cable to the battery negative terminal. Battery Charger Charge the battery until specific gravity is 1.270~1.290{20 (68 )}.
  • Page 178 Charging System/Battery Charging System Inspection Amperetmeter Leakage Inspection Turn the ignition switch OFF. Remove the negative cable from the battery. Connect the voltmeters between the negative cable and battery negative terminal. Measure the leakage voltage with the main switch OFF. △...
  • Page 179 • Must inspect using the defined tester as the below. If being inspected by different tester, can not be inspected exactly because strange resistance value is indicated. • Measure the resistance using the DAELIM PVA multi-tester. - PVA multi-tester 16-6...
  • Page 180 Charging System/Battery Replace the regulator / rectifier if the resistance is out of specification. Unit: k ( - ) ( + ) Black Yellow Yellow Green ∞ ∞ ∞ ∞ Black 1-30 0.05-20 0.5-20 0.2-1 ∞ ∞ ∞ Yellow 0.5-10 ∞...
  • Page 181 Ignition System Ignition Coil CDI-Unit Spark Plug A.C Generator 17-0...

  • Page 182: Ignition System

    Ignition System 17. Ignition System Service Information ………………17-1 Pulse Generator ……………………17-5 Troubleshooting ……………………17-2 A.C. Generator Inspection ………17-5 C.D.I Unit ……………………………17-3 Ignition Timing Inspection ………17-6 Ignition Coil Inspection ……………17-4 Service Information General Inspect the ignition system in proper sequence based on the troubleshooting. Dropping or giving a shock to the C.D.I unit causes a trouble.

  • Page 183: Troubleshooting

    Ignition System Troubleshooting No spark at plug Poorly connected, broken or shorted wires - Between A.C. generator and C.D.I unit - Between C.D.I unit and ignition coil - Between ignition coil and plug Faulty main switch Faulty ignition coil Faulty C.D.I unit Faulty A.C.

  • Page 184: Unit

    Black/White (+) & Ground ( - ) When the main switch is ON Wire Stator Ground Green & Ground ( - ) Continuity Inspection by CDI Tester Measure the resistance using the DAELIM PVA Adapter PVA multi-tester - PVA multi-tester △ CAUTION •...

  • Page 185: Ignition Coil Inspection

    Ignition System Ignition Coil Inspection Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Remove the seat Remove the Fuel Tank Disconnect the primary circuit. Measure the ignition coil primary coil resistance between the ignition coil terminal and ground.

  • Page 186: Pulse Generator

    Ignition System Performance Test Measure it using the DAELIM PVA multi- PVA Adapter tester. - PVA multi-tester △ CAUTION • Well read the instruction manual of tester and handle it. Pulse Generator Disconnect the AC generator 3P coupler blue/yellow wire connector.

  • Page 187: Ignition Timing Inspection

    Ignition System Ignition Timing Inspection NOTE • A CDI ignition system is used and it can not be adjusted. Inspect the ignition system if ignition timing is incorrect. Start the engine and warm it up. Remove the timing hole cap. Install the timing light into the high tension Timing Light Timing Light...
  • Page 188 MEMO...
  • Page 189 Electric Starter Starter Magnetic Switch Starter Motor Battery 18-0...

  • Page 190: Electric Starter

    Electric Starter 18. Electric Starter Service Information ………………18-1 Starter Motor ………………………18-2 Troubleshooting ……………………18-1 Starter Magnetic Switch …………18-5 Service Information General The Starter motor can be serviced with the engine in the frame. Specification Unit: mm(in) Item Standard Service Limit Starter Motor Brush Length 12.5-13.0(0.49-0.51) 8.5(0.33) Starter Motor Brush Spring Tension...
  • Page 191 Electric Starter Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Starter Motor Removal △ CAUTION • Turn the main switch OFF before servicing the starter motor.
  • Page 192 Electric Starter Inspect the continuity between cable terminal and case. Inspect the continuity between the terminal and brush. If it doesn’t have continuity between cable terminal and case, it is OK. If it doesn’t have continuity between the cable terminal and Brush (Case side), it is OK. Replace or repair them if necessary.
  • Page 193 Electric Starter Assembly Rear Cover Armature Brush Brush Holder Shim Front Cover Shim O-Ring Motor Case Brush Spring Lock Washer Insert the armature into the brush holder center with driving each brush into the brush holder inside. Install the holder into the case aligning the projecting part of brush holder with the part of case.
  • Page 194 Electric Starter Align the rear cover with the case mark and Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover Rear Cover install the 2 setting bolts. Tighten the setting bolts exactly.
  • Page 195 Electric Starter Voltage Inspection Measure the voltage between the yellow/red wire ⊕ of the starter magnetic switch and Yellow/Red Wire ground. Turn the main switch “ON”. There should be battery voltage while the starter switch is depressed. Ground Circuit Inspection Disconnect the green/red wire connector of the Green/Red Wire starter magnetic switch.
  • Page 196 MEMO...
  • Page 197 Lights/Switches/Horn 19-0...

  • Page 198: Lights/Switches/Horn

    Lights/Switches/Horn 19. Lights/Switches/Horn Service Information ………………19-1 Main Switch …………………………19-7 Troubleshooting ……………………19-1 Handle Switch ………………………19-8 Headlight ……………………………19-2 Gear Change Switch ………………19-9 Brake Light Switch …………………19-9 Speedometer/Tachometer/Fuel Meter 19-2 Tail/Brake Light ……………………19-4 Horn …………………………………19-9 Winker Bulb …………………………19-5 Fuel Unit ……………………………19-10 Winker Ass y Removal ……………19-6 Service Information General Some wires have different colored bands around the near the connector.

  • Page 199: Headlight

    Lights/Switches/Horn Headlight Removal Remove the two headlight mounting bolts and remove the headlight from the bracket. Remove the individual code from the wire. Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Bulb Replacement Remove the headlight rim and unit. Headlight Socket Headlight Socket Headlight Socket...
  • Page 200 Lights/Switches/Horn Remove the combination switch upper/ Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover Combination S/W Upper Cover...

  • Page 201: Tail/Brake Light

    Lights/Switches/Horn Fuel Meter Bulb Replacement Remove the hax socket bolt(3) of fuel meter. Take off the bulb socket, and replace the bulb Fuel Mete Removal Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Screw Remove the headlight and remove the individual code from the case.

  • Page 202: Winker Bulb

    Lights/Switches/Horn Take off the bulb by turning toward anti- clockwise, and replace it. Assembly is done in the reverse order of disassembly. Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Bulb Winker Bulb Loosen the screw and remove the winker unit. Remove the bulb in bulb socket by turning toward anti-clockwise Screw...

  • Page 203: Winker Ass Y Removal

    Lights/Switches/Horn Winker Ass’y Removal Front Loosen the head light case screw (2 screws) Remove the winker connector connection in state of inclining for ward the head light lens. Remove the winker. NOTE • Place the wiring and cables exactly according to a wiring diagram.

  • Page 204: Main Switch

    Lights/Switches/Horn Main Switch Inspection Remove the fuel tank. Disconnect the main switch code coupler connection. Check for continuity between terminals in each switch position. There should be a continuity between ○) the colour coded wire. (○ Color Code Black/White Green Black Cable Guide Cable Guide...

  • Page 205: Handle Switch

    Lights/Switches/Horn Handle Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Light Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch...

  • Page 206: Gear Change Switch

    Lights/Switches/Horn Gear Chain Switch Disconnect the gear change switch wire coupler. Check for the continuity between the terminal and engine ground. Gear Position Terminal Neutral Light green/Red Brake Light Switch Front Remove the headlight case. Disconnect the front brake light switch wire connectors and check for continuity between the connector terminals.

  • Page 207: Fuel Unit

    Lights/Switches/Horn The horn should sound when a fully charge 12V battery is connected across he horn terminals. Fuel Unit Remove the fuel tank. Drain fuel out of tank at clean container. Loosen the 4 nuts and remove the fuel unit from tank.

  • Page 208: Wiring Diagram

    Wiring Diagram 20. Wiring Diagram 20-1...
  • Page 209 MEMO...

  • Page 210: Troubleshooting

    Troubleshooting 21. Troubleshooting Engine Does Not Starter is Hard to Start ………………………………………………21-1 Engine Lacks Power ………………………………………………………………………21-2 Poor Performance(At Low and Idle Speeds)……………………………………………21-3 Poor Performance (At High speed) ………………………………………………………21-4 Poor Handling ………………………………………………………………………………21-4 Engine Doesn’t Start or is Hard to Start 1. Check fuel flow to carburetor. Not reaching Fuel tank empty.
  • Page 211 Troubleshooting Engine Lacks Power 1. Raise wheels off ground Wheel don’t Brake dragging and spin by hands. spin freely. Worn or damaged wheel bearings Wheel bearings need lubrication Wheels spin freely. Wheels spin freely. 2. Check tire pressure. Pressure low. Punctured tire Faulty tire valve Pressure normal.
  • Page 212 Troubleshooting 10. Check oil level. Incorrect. Oil level too high. Oil level too low. Correct. Contaminated oil. 11. Remove cylinder head cover Valve train Clogged oil passage. and inspect lubrication. lubricated Clogged oil filter element. properly. Valve train lubricated properly. 12.
  • Page 213 Troubleshooting Poor Performance(At High Speed) 1. Check the ignition timing and Incorrect. Faulty valve clearance adjustment. valve clearance. Faulty CDI unit. Faulty pulse generator. Correct. Flywheel not installed properly. 2. Disconnect fuel tube at Fuel flows Carburetor choke closed. carburetor. restricted.
  • Page 214 ■HEAD OFFICE:#16-6 PIL-DONG 2KA, CHUNG-KU, SEOUL, KOREA TEL:(82-2) 2267-6111 / FAX:(82-2) 2269-7997 ■FACTORY:#58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL:(82-551) 279-1000 / FAX:(82-551) 263-9761 SM38-9911-01E...

This manual is also suitable for:

Daystar vl125e

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