DAELIM S2-250 Service Manual
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DAELIM S2-250 Service Manual

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Summary of Contents for DAELIM S2-250

  • Page 2: Table Of Contents

    HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for the S2-250 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the SERVICE INFORMATION maintenance schedule (Section 2).
  • Page 4 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 5 SERVICE INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.
  • Page 6 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball be performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.
  • Page 7 SERVICE INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.
  • Page 8 SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
  • Page 9 SERVICE INFORMATION •Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire •Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.
  • Page 10 SERVICE INFORMATION •Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. •The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.
  • Page 11 SERVICE INFORMATION •In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.
  • Page 12 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

  • Page 13: Specifications

    SERVICE INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS OVERALL LENGTH 2,110 mm OVERALL WIDTH 745 mm OVERALL HEIGHT 1,356 mm WHEEL BASE 1,481 mm DIMENSIONS SEAT HEIGHT 760 mm GROUND CLEARANCE 121 mm DRY WEIGHT 164 kg GROSS WEIGHT 294 kg TYPE Underbone FRONT SUSPENSION / STROKE Telescopic REAR SUSPENSION / STROKE...
  • Page 14 SERVICE INFORMATION ITEM SPECIFICATIONS TYPE / VENTURI BORE CVK type/30 mm CHOKE TYPE Butterfly MAIN JET # 102 CARBURETOR 2 ½ PILOT SCREW INITIAL SETTING FLOAT LEVEL 18.5 mm IDLE SPEED 1,700±100 rpm CLUTCH TYPE Automatic Transmission PRIMARY REDUCTION 2.8 (42/15) DRIVE TRAIN SECONDARY REDUCTION 2.79 (39/14)
  • Page 15 SERVICE INFORMATION TORQUE VALUES ENGINE THREAD DIA ITEM Q’TY TORQUE VALUE REFERENCE (mm) CYLINDER HEAD BOLT A 3.0 kgf·m CYLINDER HEAD BOLT B 3.0 kgf·m OIL FILTER SCREEN CAP 1.47 kgf·m EXHAUST MUFFLER JOINT LOCK NUT 2.2 kgf·m CYLINDER HEAD CAP NUT 2.45 kgf·m VALVE ADJUST LOCK NUT 1.1 kgf·m...
  • Page 16 SERVICE INFORMATION STANDARD TORQUE VALUES ITEM TORQUE VALUE ITEM TORQUE VALUE 5mm BOLT, NUT 5mm SCREW 0.5 kgf·m 0.4 kgf·m 6mm BOLT, NUT 6mm SCREW 1.0 kgf·m 0.9 kgf·m 8mm BOLT, NUT 6mm FLANGE BOLT, NUT 2.2 kgf·m 1.2 kgf·m 10mm BOLT, NUT 8mm FLANGE BOLT, NUT 3.5 kgf·m...
  • Page 17 SERVICE INFORMATION LUBRICATION OIL ENGINE LUBRICATION POINTS REFERENCE VALVE GUIDE/VALVE STEM OPERATING PARTS SAE15W-40 or SAE10W 30# API SE, SF or SG CAM SHAFT CONTACT AREA CAM SHAFT DRIVE CHAIN CYLINDER LOCK BOLT AND NUT PISTON AROUND AND PISTON RING GROOVE PISTON PIN AROUND CONNECTING ROD, PISTON PIN HOLE CONNECTING ROD BIG END...
  • Page 18 SERVICE INFORMATION WIRING DIAGRAM WATER PASS TUBE A HOSE CLIP WATER PASS TUBE C E.M.I. UNIT COMP. RADIATOR HOSE A BATTERY (12V 10AH) RESISTER COMP. HORN HEATER CONTROLLER FUEL NECK EARTH WIRE IGNITION UNIT COMP. WATER PASS TUBE A L. SEAT LOCK CABLE E.M.I.
  • Page 19 SERVICE INFORMATION E.M.I. UNIT COMP. HORN WIRE WATER PASS TUBE B E.M.I. CORD(WIRE HARNESS) THROTTLE CABLE WATER PASS TUBE A WATER PASS TUBE A E.M.I. CORD(FAN MOTOR) RADIATOR CAP HOSE RADIATOR HOSE A THERMO SWITCH WIRE SEAT LOCK CABLE SEAT LOCK CABLE COMB METER COUPLER THERMO SWITCH WIRE RADIATOR HOSE B...
  • Page 20 SERVICE INFORMATION HEAD LIGHT RELAY THERMO SWITCH RELAY WINKER RELAY EARTH CABLE BATTERY BOX COUPLER *NOTE - WHITE COLOR : EXPORT USE ONLY - BLACK COLOR : DOMESTIC USE ONLY HEAD LIGHT CONTROLLER REGULATOR RECTIFIER START MAGNETIC SWITCH REGULATOR COUPLER 2EA BATTERY EARTH CABLE HEADLIGHT CONTROLLER CODE 1-17...
  • Page 21 SERVICE INFORMATION WINKER RELAY THERMO SWITCH RELAY HEADLIGHT RELAY FUSE BOX ASS'Y BATTERY BOX HEADLIGHT RELAY BATTERY EARTH CABLE RESERVE FUSE BATTERY BOX FUSE BOX 1-18...
  • Page 22 SERVICE INFORMATION FUEL TUBE (INSULATOR) FUEL TUBE (FUEL TANK) FUEL TUBE (CARBURETOR) TRUNK LAMP WIRE RR. BRAKE HOSE WATER HOSE B THERMO SENSOR WIRE WATER HOSE A NOISE SUPPRESSOR CAP AIR CLEANER BREATHER TUBE (AIR CLEANER) CARBURETOR DRAIN TUBE AUTO CHOCK CORD CARBURETOR BREATHER TUBE I.G.
  • Page 23 MEMO...
  • Page 24 2. INSPECTIONS/ADJUSTMENTS · · · · · · 2-1 DRIVE BELT· · · · · · · · · · · · · · · · · · · · 2-7 SERVICE INFORMATION MAINTENANCE SCHEDULE· · · · 2-3 COOLING LEVEL INSPECTION · · 2-8 FUEL LINE·...

  • Page 25: Inspections/Adjustments

    INSPECTIONS / ADJUSTMENTS TIRES FRONT TIRE 2.00kgf/㎠ ㎠ DRIVER ONLY COLD TIRE REAR TIRE 2.00kgf/㎠ ㎠ PRESSURE DRIVER AND A FRONT TIRE 2.00kgf/㎠ ㎠ PASSENGER REAR TIRE 2.25kgf/㎠ ㎠ FRONT TIRE 120/70 - 12 (Tubeless) TIRE SIZE REAR TIRE 140/60 - 13 (Tubeless)

  • Page 26: Inspections/Adjustments

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

  • Page 27: Fuel Line

    INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) ● Remove the luggage box. ● Check the fuel tube of the fuel auto cock connected to the fuel tank and carburetor. If the fuel tube is cranked, damaged or leaks, replace it. THROTTLE GRIP OPERATION ●...

  • Page 28: Air Cleaner

    INSPECTIONS / ADJUSTMENTS AIR CLEANER ● Loosen the 6 screws securing the air cleaner case cover, remove it. ● Loosen the 2 screws securing the air cleaner element holder, remove it. ● Remove the air cleaner element. ● Wash away any accumulated dust or dirt, by gently squeezing it in non flammable or high flash point solvent.

  • Page 29: Cylinder Compression Pressure

    INSPECTIONS / ADJUSTMENTS •Inspect and adjust the valve clearance when the engine is cool. (under 35 ° C / 95 ° F) •Remove the cylinder head cover. •Turn the flywheel counterclockwise, and align the “T” mark on the flywheel with the index mark on the RH.

  • Page 30: Final Reduction Gear Oil

    INSPECTIONS / ADJUSTMENTS CARBURETOR IDLE SPEED ● Remove the plug maintenance cover. •Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. •Heat the engine to make accurate idling inspection and adjustment. Stand the vehicle on the main stand. •Turn the throttle stop screw and make adjustments to prescribed idling speed.

  • Page 31: Cooling Level Inspection

    INSPECTIONS / ADJUSTMENTS COOLANT LEVEL INSPECTION ● Erect the main stand prior to beginning work. ● Check the coolant level of the reserve tank. ● The level should be between the “UPPER” and “LOWER” level lines. ● Fill the coolant with the reserve tank up to the “F”...

  • Page 32: Brake Fluid

    INSPECTIONS / ADJUSTMENTS BRAKE FLUID ● Remove the brake fluid cover. ● Check the oil level inside the front brake reservoir. If the oil level is near the lower limit line, remove the reservoir diaphragm and fill DOT 3 and DOT 4 brake fluid to the top limit line.

  • Page 33: Side Stand

    INSPECTIONS / ADJUSTMENTS SIDE STAND ● Erect the main stand. ● Pull the lower end of the side stand, and see if it moves freely. ● If the side stand does not move smoothly, apply grease to the pivot area. ●...

  • Page 34: Bolts, Nuts, Fasteners

    INSPECTIONS / ADJUSTMENTS BOLTS, NUTS, FASTENERS ● Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value. ● Check all pins, clips, hose clamps and cable stays. WHEELS/TIRES •Check the tire pressure when the tires have been cooled off.
  • Page 35 MEMO...

  • Page 36: External Parts

    3. EXTERNAL PARTS SERVICE INFORMATION· · · · · · 3-1 UNDER COVER· · · · · · · · · · · · · · · · 3-5 SEAT· · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-2 HANDLE COVER·...

  • Page 37: Seat

    EXTERNAL PARTS SEAT ● Release the seat lock by turning the main switch key to open the seat. ● Loosen the flange nuts and remove the seat. ● Install in the reverse order of removal. PILLION SEAT ● Release the seat lock by turning the main switch key to open seat.

  • Page 38: Luggage Box

    EXTERNAL PARTS LUGGAGE BOX ● Remove the seat. ● Remove the pillion seat. ● Remove the luggage box top cover. ● Loosen the screws on the seat catch. ● Loosen the open stay nuts. ● Loosen the washer bolts. ● Remove the wire for the trunk lamp. ●...

  • Page 39: Body Cover

    EXTERNAL PARTS BODY COVER ● Remove the Rr. Grip R/L ● Remove the following parts - Seat - Luggage box - Center cover - Body side cover ● Loosen the special screw ● Loosen the body cover clip (R/L) ● Remove the wire for the tail light and pull the body cover backward.

  • Page 40: Under Cover

    EXTERNAL PARTS UNDER COVER ● Loosen the 4 special screws (R/L, 2Ea for each) to remove the under cover ● Install in the reverse order of removal HANDLE COVER ● Loosen the washer screw and tapping screw securing the under handle cover ●...

  • Page 41: Windscreen

    EXTERNAL PARTS WINDSCREEN ● Remove the front cover ● Loosen the 4 washer bolts and remove the windscreen ● Install in the reverse order of removal FRONT UNDER COVER A ● Remove the front cover and windscreen ● Loosen the 7 tapping screws securing the inner cover ●...

  • Page 42: Inner Cover

    EXTERNAL PARTS ● Loosen the 4 tapping screws securing the inner cover INNER COVER ● Remove the front cover and windscreen ● Remove the coolant reserve tank ● Remove the fuel tube clip ● Remove the breather tube ● Loosen the 3 screws securing the inner cover ●...

  • Page 43: Front Fender

    EXTERNAL PARTS FRONT FENDER ● Loosen the 4 screws (R/L, 2Ea for each) ● Install in the reverse order of removal REAL WHEEL MUDGUARD ● Loosen the 2 flange bolts of RH. ● Loosen the flange bolt securing the air cleaner and mudguard ●...
  • Page 44 MEMO...
  • Page 45 LUBRICATION SYSTEM ROCKER ARM SHAFT CRANK SHAFT OIL FILTER SCREEN OIL PUMP...

  • Page 46: Lubrication System

    4. LUBRICATION SYSTEM SERVICE INFORMATION · · · · · · · · 4-1 ENGINE OIL CHANGE· · · · · · · · · · 4-3 TROUBLESHOOTING· · · · · · · · · · 4-2 OIL PUMP · · · · · · · · · · · · · · · · · · · · · · 4-4 ENGINE OIL LEVEL INSPECTION ·...
  • Page 47 LUBRICATION SYSTEM TROUBLESHOOTING Oil level low •Oil consumption. •External oil leaks. •Worn piston ring or incorrect piston ring installation. •Worn valve guide or seal. Oil contamination •Oil or filter not changed often enough. •Faulty head gasket. •Worn piston rings. Low or no oil pressure •Clogged oil orifice.
  • Page 48 LUBRICATION SYSTEM ENGINE OIL LEVEL INSPECTION OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE...
  • Page 49 LUBRICATION SYSTEM OIL PUMP REMOVAL ● Drain cooling water. ● Remove the following parts. - RH. crank case cover - A.C generator - Starting clutch gear comp - Oil seperator cover and attaching bolt OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER...
  • Page 50 LUBRICATION SYSTEM OIL PUMP INSPECTION ●Assemble the inner and outer rotors to the oil pump body. ●Measure the pump body clearance. SERVICE LIMIT : 0.25mm TOOL : FEELER GAUGE ●Measure the rotor tip clearance. SERVICE LIMIT : 0.20mm ●Measure the pump side clearance. SERVICE LIMIT : 0.12mm OIL PUMP ASSEMBLY ●Clean all parts with fresh cleaning oil.
  • Page 51 LUBRICATION SYSTEM ● Install in accordance with the hole of the dowel pin and pump cover. ● Tighten the pan screw. •After installing, check the oil pump to operate smoothly. OIL PUMP INSTALLATION ARROW MARK ARROW MARK ARROW MARK ARROW MARK ARROW MARK ARROW MARK ARROW MARK...
  • Page 52 MEMO...
  • Page 53 FUEL SYSTEM...

  • Page 54: Fuel System

    5. FUEL SYSTEM SERVICE INFORMATION · · · · 5-1 JETS/SCREW REMOVAL· · · · 5-6 TROUBLESHOOTING · · · · · · · · · · 5-2 AUTO BYSTARTER INSPECTION /REMOVAL· · · · · · · · · · · · · · · · · · 5-7 FUEL TANK·...

  • Page 55: Troubleshooting

    FUEL SYSTEM TROUBLESHOOTING Back firing The vehicle does not start. ● Ignition system is damaged. ● No gasoline in fuel tank. ● Mixture is too lean. ● Fuel is not coming out of carburetor. ● Too much fuel is flowing into cylinder. ●...

  • Page 56: Fuel Tank

    FUEL SYSTEM FUEL TANK REMOVAL •Gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthemore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. ● Release the seat lock by turning the main switch key to FUEL TANK FUEL TANK FUEL TANK...
  • Page 57 FUEL SYSTEM ● Loosen the throttle cable lock nut, and remove the throttle cable from the carburetor. ● Loosen the air cleaner connecting tube band and the carburetor intake manifold band. ● Remove the carburetor VACUUM CHAMBER REMOVAL ● Loosen the drain screw and drain the fuel from the float chamber.
  • Page 58 FUEL SYSTEM ● Remove the needle holder, spring and jet needle from the piston. •Be careful not to damage the vacuum piston diaphragm. VACUUM PISTON INSPECTION DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM...

  • Page 59: Float Valve Inspection

    FUEL SYSTEM FLOAT VALVE INSPECTION FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE ●...

  • Page 60: Auto Bystarter Inspection

    FUEL SYSTEM AUTO BYSTARTER INSPECTION/REMOVAL AUTO BYSTARTER INSPECTION ● Measure the resistance between the auto bystarter wire terminals. Resistance : 10Ω(minutes minimum after stopping the engine) •If the reading is not within the limit, replace the auto bystarter with a new one. ●...

  • Page 61: Removal

    FUEL SYSTEM AIR CUT-OFF VALVE (A.C.V) AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER AIR CUT-OFF VALVE COVER...
  • Page 62 FUEL SYSTEM ● Install and tighten the two screws attaching the air cut- off valve cover. ● Connect the hose. SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS ACCELERATING PUMP DISASSEMBLY ●...
  • Page 63 FUEL SYSTEM FLOAT LEVEL INSPECTION ● Install the float valve, float and float fin. ● Measure the float level at the location of the main jet (just contacting the float valve) ±1.0mm Float Level : 18.5 ● Replace the float if the level is incorrect. ●...

  • Page 64: Fuel Pump

    FUEL SYSTEM CARBURETOR INSTALLATION AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING AIR CLEANER CONNECTING...
  • Page 65 FUEL SYSTEM ● Disassemble the fuel pump. ● Inspect the fuel pump diaphragms A and B for damage. ● Inspect each gasket for damage. ● Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.
  • Page 66 MEMO...

  • Page 67: Cooling System

    COOLING SYSTEM...
  • Page 68 6. COOLING SYSTEM INFORMATION· · · · 6-1 RADIATOR DISASSEMBLY· · 6-5 SERVICE TROUBLESHOOTING· · · · · · · · 6-2 THERMOSTATIC SWITCH INSPECTION· · 6-6 COOLANT· · · · · · · · · · · · · · · · · · · · 6-3 RADIATOR ASSEMBLY·...

  • Page 69: Cooling System

    COOLING SYSTEM TROUBLESHOOTING Engine temperature too high ● Faulty temperature gauge or thermo sensor ● Air in cooling system ● Faulty thermostat stuck (Thermostat stuck closed) ● Passages blocked in radiator, hoses or water jacket ● Faulty fan motor switch ●...

  • Page 70: Coolant

    COOLING SYSTEM COOLANT COOLANT INSPECTION RADIATOR ● Radiator coolant mixes the distilled water. WATER •Coolant mixes the distilled water and radiator coolant base solution with about 5°C of tolerance in COOLANT respect to the minimum temperature. RADIATOR COOLANT MIXTURE CHART (ANTICORROSIVE AND ANTIFREEZE) •Radiator coolant is toxic.
  • Page 71 COOLING SYSTEM COOLING SYSTEM TEST ● Install the redicator cap onto the radiator tester. RADIATOR CAP ● Press it with specified pressure and it must keep the pressure for at least six seconds. RADIATOR TESTER ·Apply water to the cap sealing surface before the test.
  • Page 72 COOLING SYSTEM ● Loosen the hose band and disconnect the upper hose and lower hose from the radiator. UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE UPPER HOSE...

  • Page 73: Thermostatic Switch Inspection

    COOLING SYSTEM CHECK THERMOSTATIC SWITCH ● When coolant temperature lower then 83~87° C the thermostatic switch OFF. ● When coolant temperature over 88~92° C the thermostatic switch ON. ● Install the fan shroud on the radiator with the 3 bolts. FAN BOLT FAN BOLT FAN BOLT...

  • Page 74: Water Pump

    COOLING SYSTEM ● Connect the overflow tube and secure with the tube clamp. ● Fill the radiator with coolant. ● Connect the vent tube to the radiator filler. ● After installation, check for coolant leaks. ·If you want to refill the coolant, the following procedure must be checked.
  • Page 75 COOLING SYSTEM ● Remove the 4 bolts and the water pump cover. ● Remove the gasket and 2 dowel pins. BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS...
  • Page 76 COOLING SYSTEM ● Remove the water pump bearing snap ring from the water pump assembly. WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT ●...
  • Page 77 COOLING SYSTEM WATER PUMP SHAFT INSTALLATION SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING SNAP RING ●...

  • Page 78: Thermosensor

    COOLING SYSTEM ● Install the impeller onto the water pump shaft. TORQUE VALUE : 0.98~1.37kgf·m ·The impeller has left hand thread. ● Install the 2 dowel pins and a new gasket. DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN...
  • Page 79 COOLING SYSTEM INSPECTION THERMOSENSOR ● Suspen the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up. Temperature(° C) Ω Resistance( THERMOMETER INSTALLATION ● Apply a sealant to the themosensor threads and install it into the thermostat housing.
  • Page 80 COOLING SYSTEM INSPECTION ● Suspend the thermostat in a pan of water over a burner THERMOSTAT and gradually raise the water temperature to check its operation. Technical Data THERMOMETER Begins to open 80 2 C Full-open 90 C Valve lift 3.5~4.5mm ·Do not let the thermostat touch the pan as it will give a false reading.
  • Page 81 MEMO...

  • Page 82: Engine Removal/Installation

    7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION· · · · · · · · · · · · · · · · · · · · · · · · · · 7-1 ENGINE REMOVAL· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 7-2 ENGINE INSTALLATION ·...
  • Page 83 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ● Disconnect the battery ⊖ cable. ● Remove the frame body cover. ● Disconnect the engine ⊖ cable. ● Disconnect the A.C generator, auto bystarter, spark plug, thermosensor wire couplers and connectors. ● Disconnect the engine fuel tube. ●...
  • Page 84 ENGINE REMOVAL/INSTALLATION ● Remove the R/L rear shock absorber upper mount bolts. REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS...
  • Page 85 ENGINE REMOVAL/INSTALLATION ● Tighten the rear shock absorber upper mount bolts. TORQUE VALUE : 3.92kgf·m After installation, inspect and adjust the following: ● Throttle grip free play. ● Fill the rear brake reservoir with brake fluid and bleed air from the rear brake. ●...
  • Page 86 MEMO...
  • Page 87 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION...
  • Page 88 8. LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION SERVICE INFORMATION· · · · · · 8-1 DRIVE PULLY· · · · · · · · · · · · · · · · · · 8-3 TROUBLESHOOTING· · · · · · · · · · 8-1 CLUTCH DRIVEN PULLY·...

  • Page 89: Lh.crank Case Cover/Transmission

    LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANKCASE COVER AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND...
  • Page 90 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE FULLEY LOCK WASHER/LOCK NUT REMOVAL ● Remove the LH. crankcase cover. ● Loosen the Drive face flange nut with the drive face holder. ● Remove the drive face. LOCK NUT WRENCH ● Remove the drive bolt from the movable drive face. INSPECTION ●...
  • Page 91 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DISASSEMBLY RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE ●...
  • Page 92 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Check the drive pully collar for damage or wear. ● Measure the O.D of the drive pully collar sliding surface. SERVICE LIMIT : 26.9mm replace if below ASSEMBLY ● Install the weight rollers into the movable face. WEIGHT ROLLERS WEIGHT ROLLERS WEIGHT ROLLERS...
  • Page 93 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Insert the drive pulley collar into the movable drive DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR...
  • Page 94 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Hold the dirve pulley with the drive face holder and tighten the drive face nut. DRIVE FACE TORQUE VALUE : 8.82~9.8kgf·m ·Do not get the grease on the drive belt or drive pulley faces. CLUTCH/DRIVEN PULLEY ●...
  • Page 95 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY LOCK NUT WRENCH DISASSEMBLY LOCK NUT ● Hold the clutch/driven pulley assembly with the clutch spring compressor. ● Set the tool in a vise and remove the clutch drive plate nut. (39mm) CLUTCH SPRING COMPRESSOR ●...
  • Page 96 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Check the driven face assembly for wear or damage. ● Measure the driven face O.D. SERVICE LIMIT : 39.85mm replace if below MOVABLE GUIDE GROOVE DRIVEN FACE ● Check the movable driven face for wear or damage. ●...
  • Page 97 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Press a new needle bearing into the driven face. NEEDLE BEARING (INNER) BALL BEARING (OUTER) CLUTCH DISASSEMBLY CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS ●...
  • Page 98 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY ASSEMBLY MOVABLE DRIVEN FACE OIL SEAL ● Clean the pulley faces and remove any grease from them. ● Apply frease to the O-ring and install them onto the moveable driven face. O-RING GUIDE PIN ●...
  • Page 99 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ●Install the clutch/driven pulley onto the drive shaft. ● Install the clutch outer. ● Hold the clutch outer with the universal holder. CLUTCH OUTER ● Install and tighten the clutch outer nut. TORQUE VALUE : 4.9~5.88kgf·m ●...
  • Page 100 MEMO...
  • Page 101 A.C GENERATOR/STARTER CLUTCH...
  • Page 102 9. A.C GENERATOR / STARTER CLUTCH INFORMATION· · · · · · · · · · 9-1 FLYWHEEL INSTALLATION· · · · · · 9-4 SERVICE R. CRANKCASE COVER REMOVAL· · 9-2 STATOR INSTALLATION· · · · · · · · · · 9-5 STARTER CLUTCH·...
  • Page 103 A.C GENERATOR/STARTER CLUTCH RIGHT CRANKCASE COVER REMOVAL BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS ● Disconnect the water hoses from the right crankcase cover. ● Remove the 9 bolts securing the right crankcase cover and the cover.
  • Page 104 A.C GENERATOR/STARTER CLUTCH STARTER CLUTCH START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR...
  • Page 105 A.C GENERATOR/STARTER CLUTCH ● Remove the starter one-way clutch rollers, plungers and springs. INSTALLATION START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR...
  • Page 106 A.C GENERATOR/STARTER CLUTCH STATOR INSTALLATION PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL ●...

  • Page 107: Cylinder Head/Valve

    CYLINDER HEAD / VALVE 10-0...
  • Page 108 10. CYLINDER HEAD/CYLINDER/PISTON SERVICES INFORMATION· · · · · · · · · · · · · · · · 10-1 CYLINDER HEAD COVER· · · · · · · · · · · · · · · · 10-1 CAM SHAFT·...
  • Page 109 CYLINDER HEAD / VALVE CYLINDER HEAD COVER REMOVAL ● Remove the center cover. ● Remove the luggage box. ● Remove the cylinder head cover 4 bolts and then remove the cylinder head cover. CAMSHAFT CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER...
  • Page 110 CYLINDER HEAD / VALVE ● Remove the camshaft gear from the cam chain to 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 CAM CHAIN CAM CHAIN CAM CHAIN...
  • Page 111 CYLINDER HEAD / VALVE CAMSHAFT HOLDER INSPECTION CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER ●...
  • Page 112 CYLINDER HEAD / VALVE DISASSEMBLY CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD ●...
  • Page 113 CYLINDER HEAD / VALVE ● Inspect each valve for bending, burning, scratches or abnormal stem wear. ● Check valve movenment in the guide. ● Measure each valve stem O.D. SERVICE LIMITS: IN : 4.925mm replace if below EX : 4.925mm replace if below ASSEMBLY ●...
  • Page 114 CYLINDER HEAD / VALVE ● Install the cylinder head and take out the 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 CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN...
  • Page 115 CYLINDER HEAD / VALVE ● Install the camshaft holder, washers and nuts on the WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS cylinder head. ● Tighten the 4 cylinder head nuts and the 2 bolts between the cylinder head and cylinder.
  • Page 116 MEMO...
  • Page 117 CYLINDER/PISTON 11-0...

  • Page 118: Cylinder/Piston

    11. CYLINDER / PISTON SERVICE INFORMATION· · · · · · 11-1 PISTON RING INSTALLATION· · 11-5 TROUBLESHOOTING · · · · · · · · · · 11-1 PISTON INSTALLATION· · · · · · · · 11-6 CYLINDER REMOVAL· · · · · · · · · · 11-2 CYLINDER INSTALLATION·...
  • Page 119 CYLINDER/PISTON CYLINDER REMOVAL CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER ● Remove the cylinder head. ● Remove the water hose from the cylinder. ● Remove the cam chain guide. CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE...
  • Page 120 CYLINDER/PISTON ● Install the piston, piston pin and piston rings. ● Remove the piston rings. ·Take care not to damage or break the piston rings during removal. ● Clean carbon deposits from the piston ring grooves. ● Install the piston rings onto the piston. ●...
  • Page 121 CYLINDER/PISTON ● Measure the piston pin O.D. SERVICE LIMITS : 16.96mm replace if below ● Measure the piston O.D. ·Take measurement at 9mm from the bottom and 90° to the piston pin hole. SERVICE LIMITS : 72.60mm replace if below ●...
  • Page 122 CYLINDER/PISTON ● Inspect the top of the cylinder for warpage. SERVICE LIMITS : 0.05mm replace or replace if over ● Measure the connecting rod small end I.D. SERVICE LIMITS : 17.06mm replace if over PISTION RING INSTALLATION ● Install the piston rings onto the piston. ●...
  • Page 123 CYLINDER/PISTON PISTION INSTALLATION ● Remove any gasket material from the crankcase surface. ·Be careful not to drop foreign matters into the crankcase. ● Install the piston, piston pin and a new piston pin clip. ·Position the piston “IN” mark on the intake valve side.
  • Page 124 CYLINDER/PISTON ● Install the cam chain guide. ·Insert the tab on the cam chain guide into the cylinder groove. ● Install the cylinder gasket and dowel pins. ● Connect the water hohse to the cylinder. ● Install the cylinder head. ●...
  • Page 125 CRANKSHAFT/CRANKCASE 12-0...

  • Page 126: Crankshaft/Crankcase

    12. CRANKSHAFT/CRANKCASE SERVICE INFORMATION· · · · · · 12-1 CRANKSHAFT INSPECTION· · 12-4 TROUBLESHOOTING · · · · · · · · · · 12-2 CRANKCASE INSTALLATION· · 12-5 CRANKCASE REMOVAL· · · · · · 12-3 SERVICE INFORMATION GENERAL SAFETY ●...
  • Page 127 CRANKSHAFT/CRANKCASE TOOL Universal bearing puller Bearing remover set Remover ass’y Remover shaft Remover head Slieding weight Assembly shaft TROUBLESHOOTING Excessive engine noise ● Excessive bearing play ● Excessive crankpin bearing play ● Worn piston pin and piston pin hole 12-2...
  • Page 128 CRANKSHAFT/CRANKCASE CRANKCASE REMOVAL CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER...
  • Page 129 CRANKSHAFT/CRANKCASE ● Remove the oil seal from the LH. crankcase. LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH. CRANKCASE LH.
  • Page 130 CRANKSHAFT/CRANKCASE ● Measure the crankshaft bearing play. SERVICE LIMITS : PLAY PLAY AXIAL : 0.20mm replace if over RADIAL : 0.05mm replace if over AXIAL RADIAL CRANKCASE INSTALLATION ● Clean off all gasket material from the crankcase mating surfaces. ·Avoid damaging the crankcase mating surfaces. ●...
  • Page 131 CRANKSHAFT/CRANKCASE ● Install the two dowel pins and a new gasket. DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS...
  • Page 132 MEMO...
  • Page 133 FINAL REDUCTION 13-0...

  • Page 134: Final Reduction

    13. FINAL REDUCTION INFORMATION· · · · · · · · 13-1 FINAL REDUCTION INSPECTION· · 13-2 SERVICE TROUBLESHOOTING· · · · · · · · · · · · 13-1 FINAL REDUCTION ASSEMBLY· · 13-4 FINAL REDUCTION DISASSEMBLY· · 13-2 SERVICE INFORMATION SPECIFICATIONS Specified Oil : SAE 90#...
  • Page 135 FINAL REDUCTION FINAL REDUCTION BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS DISASSEMBLY ● Remove the exhaust muffler. ● Remove the rear brake caliper. ● Remove the RH. rear shock absorber. ●...
  • Page 136 FINAL REDUCTION ● Check the LH. crankcase bearings for excessive play COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING COUNT SHAFT BEARING...
  • Page 137 FINAL REDUCTION BEARING REPLACEMENT (TRANSMISSION CASE COVER) ● Remove the transmission case cover bearings using the bearing remover. ● Remove the final shaft oil seal. ● Drive new bearings into the left crankcase. ● Install a new drive shaft oil seal. FINAL REDUCTION ASSEMBLY ●...
  • Page 138 FINAL REDUCTION ● Install the countershaft and gear into the left crankcase. ● Install the resin washer onto the counter-shaft. ● Install the dowel pins and a new gasket. COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT...
  • Page 139 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 14-0...

  • Page 140: Front Wheel/Front Fork/Steering/Brake

    14. FRONT WHEEL/FRONT FORK/STEERING/BRAKE SERVICE INFORMATION· · · · · · · · 14-1 FRONT WHEEL INSTALLATION· · 14-7 TROUBLESHOOTING· · · · · · · · · · 14-2 FRONT BRAKE· · · · · · · · · · · · · · · · 14-7 STEERING HANDLE ·...

  • Page 141: Troubleshooting

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE TROUBLESHOOTING Hard steering Brake lever hard ● Steering bearing adjustment nut too tight. ● Clogged brake system ● Faulty steering stem bearings. ● Sticking caliper piston ● Damaged steering stem bearings. ● Caliper not sliding properly ● Insufficient tire pressure. ●...

  • Page 142: Steering Handle

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE STEERING HANDLE REMOVAL ● Remove the upper handle cover and the under handle cover from the handle bar. ● Loosen the bolts securing the front and rear break master cylinder. ● Remove the front cover, front under cover and speedometer cover.

  • Page 143: Front Wheel

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Lubricate the throttle grip front end with grease and then install the throttle grip. ● Connect the throttle cable to the throttle grip. ● Install the right and left handlebar switches and tighten the screws. ·Adjust the throttle grip free play to the specified range of 2~6mm.

  • Page 144: Front Wheel Bearing

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE WHEEL RIM ● Check the wheel rim runout. SERVICE LIMIT : RADIAL : 2.0mm replace if over AXIAL : 2.0mm replace if over DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE...
  • Page 145 FRONT WHEEL/FRONT FORK/STEERING/BRAKE SPEEDOMETER GEAR REPLACEMENT ● Remove the speedometer gear and washer from the speedometer gear box. ● Check the gear for wear or damage. ● Install the washer. ● Apply grease to the speedometer gear prior to assembling. ●...

  • Page 146: Front Wheel Installation

    FRONT WHEEL/FRONT FORK/STEERING ● Apply grease to the dust seal rim. ● Install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box. SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX...
  • Page 147 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ·When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid. ·When removing the brake fluid tube bolt, be sure to plug the tube end to avoid brake fluid leakage. DISASSEMBLY ●...
  • Page 148 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ·If there is any leak of fluid when installing new piston, it may indicate the side wear of the cylinder by the direction of the piston contacting face. In this case, the master cylinder must be replaced also. ●...

  • Page 149: Brake Fluid

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Install the brake hose to the master cylinder with 2 new sealing washers and the hose bolt. TORQUE VALUE : 2.5~3.5 kgf·m ● Loosen the 2 flat screws, remove the oil cup cap, diaphragm plate and diaphragm. ●...
  • Page 150 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ·Check the fluid level often, and replenish fluid if the amount of fluid is reduced to the lower level. ·Read the user’s manual carefully prior to disassembling or using the brake bleeder. ·Protect the bleeder valve with tape to prevent air from entering the bleeder valve.

  • Page 151: Brake Caliper

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE BRAKE CALIPER REMOVAL ● First drain the brake fluid from the hydraulic brake system. ● Remove the brake fluid tube bolt. ● Remove the two bolts securing the brake master cylinder. ● Remove the brake caliper. ·Pay attention not to let the brake fluid adhere to the parts because it can damage the painted surface.
  • Page 152 FRONT WHEEL/FRONT FORK/STEERING/BRAKE INSPECTION ● Check the caliper cylinder bore for scoring, scratches or other damage. ● Measure the caliper I.D. SERVICE LIMIT : 25.42mm ● Check the piston for scratches or wear. ● Measure the piston O.D. with a micrometer gauge. SERVICE LIMIT : 25.27mm ●...

  • Page 153: Front Fork

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Apply the silicone grease to the boot. ● Connect the boot to the portion of the caliper. ● Install the pad spring in the caliper. ● Install the caliper pin bolt and the slide pin in the caliper.
  • Page 154 FRONT WHEEL/FRONT FORK/STEERING/BRAKE DISASSEMBLY ● Remove the fork pipe bolt. SPRING ·If the screw is completely loosened, the fork tube cap bolt may spring out by the force of the spring. Take due precautions. ·Remove the fork spring, and expand and release the fork pipe several times to drain fork oil.
  • Page 155 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Remove the oil seal stop ring. OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL...
  • Page 156 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Check the slider bush contact face. ● If the slider bush is extensively damaged, replace the bottom case. FORK TUBE FRONT FORK ASSEMBLY ● Wash parts with clean oil prior to assembling. ● Assemble the rebound spring and thd fork piston to the BOTTOM CASE fork tube.
  • Page 157 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Install the oil seal stopper ring ● Accurately assemble the oil seal stop ring to the bottom OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL...

  • Page 158: Steering Stem

    FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Install the front fork to the steering stem. ● Install the front fork setting bolts. TORQUE VALUE : 7.5 kgf·m ● Install the brake hose clip A to the RH. front fork. STEERING STEM REMOVAL ● Remove the following parts. -Handle cover -Handle bar -Front cover...
  • Page 159 FRONT WHEEL/FRONT FORK/STEERING/BRAKE ● Remove the steering top ball race from the head pipe. ● Remove the steering bottom race. ·Check all of the races and balls for damage or abnormal wear and replace as necessary. ·If the vehicle has been involved in an accident, examine the area around the steering head for crack.
  • Page 160 MEMO...

  • Page 161: Rear Wheel / Brake / Suspension / Rear Swing Arm

    REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM 15-0...
  • Page 162 15. REAR WHEEL/BRAKE/SUSPENSION/SWING ARM SERVICE INFORMATION· · · · · · 15-1 REAR WHEEL· · · · · · · · · · · · · · · · · · 15-5 TROUBLESHOOTING· · · · · · · · · · 15-2 REAR CUSHION ADJUST·...

  • Page 163: Rear Wheel/Brake/Suspension/Swing Arm

    REAR WHEEL / BRAKE / SUSPENSION / SWING ARM TROUBLESHOOTING Wobble or vibration in motorcycle ● Tire pressure incorrect ● Faulty tire ● Bent rim ● Loose wheel bearing ● Swing arm bushing worn ● Wheel out of balance Soft suspension ●...

  • Page 164: Rear Brake

    REAR WHEEL / BRAKE / SUSPENSION / SWING ARM REAR BRAKE REMOVAL ● Remove the muffler. ● Loosen the rear break tube bolt and remove the break tube. ● Loosen 2 bolts and remove rear break caliper. INSPECTION ● Inspect break pad and disk. ●...
  • Page 165 REAR WHEEL / BRAKE / SUSPENSION / SWING ARM ● Disassemble the piston seal and the dust seal. ● Clean the piston and inside of caliper with break fluid. DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL...

  • Page 166: Rear Fork

    REAR WHEEL / BRAKE / SUSPENSION / SWING ARM INSTALLATION ● Install the brack caliper to the front fork and tighten the bolt to specified torque. TORQUE VALUE : 3.0kgf·m ● Connect the brcakhose to the caliper body and tighten 2 oil bolts and washers to specified torque.

  • Page 167: Rear Cushion Adjust

    REAR WHEEL / BRAKE / SUSPENSION / SWING ARM INSPECTION ● Measure the rear wheel rim runout. SERVICE LIMIT : RADIAL : 1.0mm replace if over AXIAL : 1.0mm replace if over ASSEMBLY ● Install in the reverse order of removal. TORQUE VALUE Rear cushion lower bolt: 1.96~2.94kgf·m Rear axle nut: 7.84~9.8kgf·m...
  • Page 168 REAR WHEEL / BRAKE / SUSPENSION / SWING ARM INSTALLATION ● Install in the reverse order of removal. TORQUE VALUE : 3.92kgf·m 15-7...
  • Page 169 CHARGING SYSTEM REGULATOR RECTIFIER MAIN SWITCH A.C. GENERATOR 16-0...

  • Page 170: Charging System

    16. CHARGING SYSTEM INFORMATION· · · · · · · · · · · · 16-1 CHARGING SYSTEM INSPECTION· · 16-3 SERVICE TROUBLESHOOTING· · · · · · · · · · · · · · · · 16-2 A.C. GENERATOR INSPECTION · · · · 16-4 BATTERY ·...
  • Page 171 CHARGING SYSTEM TROUBLESHOOTING No power (Key turned on) Low power (Engine running) ● Dead battery. ● Battery undercharged. ● Battery is failing. -Low fluid level. ● Charging system failure. -Low specific gravity. -Charging system failure. ● Disconnected battery cable. Intermittent power ●...
  • Page 172 CHARGING SYSTEM BATTERY ● Remove the seat and luggage box. ● Loosen the screws secuning the battery cover and remove the battery cover. ● Remove the battery. ● First disconnect the negative “⊖” battery cable, and then disconnect the positive “⊕” cable. ·When disconnecting the battery positive ⊕...
  • Page 173 CHARGING SYSTEM CHARGING SYSTEM INSPECTION LEAK TEST ● Trun off the ignition switch, and disconnect the ground (-) cable from the battery. ● Connect an ampere meter between negative (-) terminal and ground cable. ● With the ignition switch off, measure the leakage current. LEAK CURRENT : Not to exceed 0.5A(max) TOOL : DIGITAL TESTER ·When measuring current using a tester, set it to a...
  • Page 174 CHARGING SYSTEM REGULATOR RECTIFIER INSPECTION ● Remove the luggage box. ● Remove the regulator rectifier coupler. ● Measure each terminal. RESISTANCE VALUE Unit : ㏀, (20℃) Tester ⊕ Tester ⊖ ∞ ∞ ∞ ∞ 25-40K ∞ ∞ ∞ ∞ ∞ ∞...
  • Page 175 IGNITION SYSTEM BATTERY REGULATOR RECTIFIER IGNITION UNIT MAIN SWITCH A.C. GENERATOR IGNITION UNIT 17-0...

  • Page 176: Ignition System

    17. IGNITION SYSTEM SERVICE INFORMATION· · · · · · · · · · 17-1 A.C. GENERATOR INSPECTION· · 17-4 TROUBLESHOOTING· · · · · · · · · · · · · · 17-2 IGNITION UNIT· · · · · · · · · · · · · · · · · · · · · · 17-4 IGNITION COIL INSPECTION·...
  • Page 177 IGNITION SYSTEM TROUBLESHOOTING No spark at plug. UNUSUAL CONDITION PROBABLE CAUSE (CHECK IN NUMERICAL ORDER) 1. The multitester impedance is too low. 2. Cranking speed is too slow. - Battery is undercharged (or operating force of the kick starter is weak).
  • Page 178 IGNITION SYSTEM IGNITION COIL INSPECTION ● Remove the seat lock with the main key. ● Remove the luggage box. ● Remove the center cover. ● Remove the primary wire. ·Since the resistance value of the primary coil is inherently very small, it is difficult to distinguish it from a shorted wire.
  • Page 179 IGNITION SYSTEM A.C. GENERATOR INSPECTION EXCITER/PUISE COIL INSPECTION ● Remove the luggage box. ● Disconnect the A.C. generator connector. ● Measure the exciter coil resistance between the black/white wire terminal and ground. ·Black/white~Ground 23~35 ㏀ ● Disconnect the pulser coil wire coupler. ●...
  • Page 180 MEMO...
  • Page 181 STARTER SYSTEM STOP SWITCH BATTERY MAIN SWITCH STARTER MOTOR CABLE (STARTER MOTOR) STOP LAMP BATTERY + CABLE 18-0...
  • Page 182 18. STARTER SYSTEM SERVICE INFORMATION· · · · · · · · 18-1 STARTER MOTOR · · · · · · · · · · · · 18-3 TROUBLESHOOTING · · · · · · · · · · 18-2 STARTER MAGNETIC SWITCH ·...
  • Page 183 STARTER SYSTEM TROUBLESHOOTING Starter motor will not turn. ● Check for a blown main fuse before servicing. ● Check that the stop light is correctly adjusted. ● Check that the side stand is positioned in the condition under which the engine can be started. Connect the starter motor (+) terminal to the With the ignition switch “ON”and squeeze battery positive terminal.
  • Page 184 STARTER SYSTEM STARTER MOTOR ● Release the seat lock with the main key. ● Remove the luggage box. ● Remove the core tubeband from the carbureter ● Remove the starter motor cable from the starter magnetic switch. ● Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor.
  • Page 185 STARTER SYSTEM ● Make a continuity check between individual commutator segments and the armature shaft. There should be no coninuity. ● Measure the length of the brushes. SERVICE LIMIT : 8.5m replace if below ● Check the continuity between brush ⊕and cord terminal.
  • Page 186 STARTER SYSTEM ● Check if the needle bearing in the front cover turns freely and has no excessive play. Replace if necessary. ● Check the dust seal for wear or damage. ASSEMBLY ● Apply grease to the dust seal in the front cover. ●...
  • Page 187 STARTER SYSTEM REMOVAL ● Release the seat lock with the main key. ● Remove the luggage box. ● Remove the center cover. ● Remove the battery (+) cable from the starter magnetic switch terminal. ● Remove the starter motor cable from the starter magnetic switch terminal.
  • Page 188 MEMO...
  • Page 189 MEMO...
  • Page 190 19. LIGHTS/SWITCHS/HORN SERVICE INFORMATION · · · · · · · · 19-1 HEADLIGHT CONTROLLER · · 19-4 TROUBLESHOOTING· · · · · · · · · · 19-1 COOLANT TEMPERATURE GAUGE· · 19-5 MAIN SWITCH· · · · · · · · · · · · · · 19-2 THROTTLE POSITION SENSOR·...

  • Page 191: Lights/Switchs/Horn

    LIGHTS/SWITCH/HORN MAIN SWITCH ● Remove the front covers. ● Disconnect the ignition switch wire couplers. ● Check for continuity between the wire terminals. RED/WHITE BLACK HANDLE SWITCH ● Remove the headlight. ● Disconnect the connector of handle switch. ● Check for continuity between teminals. ●...

  • Page 192: Horn

    LIGHTS/SWITCH/HORN PASSING SWITCH BAT3 COLOR BLACK BLUE WINKER SWITCH BAT3 BAT3 COLOR BROWN/WHITE BLUE WHITE BLACK HORN ● Remove the horn from the wire connector. ● Connect the horn terminal with 12V battery. ● Normal if it sounds. FUEL UNIT ●...

  • Page 193: Thermostatic Switch

    LIGHTS/SWITCH/HORN THERMOSTATIC SWITCH ● Remove the front covers. ● Start and run engine to make the water temperature reaches 85° C~90° C and check if the cooling fan motor operates. ● Lower the water temperature to 85° C and check if the fan motor stops.

  • Page 194: Headlight Controller

    LIGHTS/SWITCH/HORN HEADLIGHT CONTROLLER ● When the main switch turns ON, the headlight (low), meter illumination, taillight, position light and license light turns on during a second and turns off. ● If the engine RPM becomes over 1,100rpm, the headlight (low), the meter illumination, taillight, position light and license light turns on CORD A TERMINAL : EARTH...

  • Page 195: Headlight Bulb Replacement

    LIGHTS/SWITCH/HORN HEADLIGHT BULB REPLACEMENT ● Remove the front cover. ● Remove the headlight coupler and winker coupler. ● Remove the bulb socket of rubber boots. ● Remove the rubber boots. ● Replace the headlight bulb. •When replacing the bulb, be sure not to put finger and contaminated gloves prints on the headlight bulb, as they may create hot spots on the bulb and cause is to fail.

  • Page 196: Fuse Capacity

    LIGHTS/SWITCH/HORN FUSE CAPACITY Fuse A 30A Charging, combi S/W, trunk lamp, regulator Winker relay, meter lighting, horn, headlight (HI), front/rear stop switch, Fuse B taillight, heater control, fuel meter, water temp. meter Fuse C 10A Ignition coil, auto bi-starter Fuse D 10A Fan motor Fuse F 10A Headlight (LO) COUPLER CONNECTION...
  • Page 197 MEMO...

  • Page 198: Wiring Diagram

    20. WIRING DIAGRAM COMBINATION METER ASS'Y. 2P MINI MINI Br/L MINI Br/L Br/W Br/G Br/L Br/G Br/L Br/L Br/W Br/L Br/G Br/L Br/W Br/W Br/W Br/L Br/L B/Br Lg/R B/Br G/Gr G/Gr G/Gr Br/L BAT4 Br/L SIGNAL HEAT 6P MINI MINI 20-1...
  • Page 199 MEMO...
  • Page 200 SERVICE MANUAL 2004. 9. PRINTED NO COPY 2004. 9. PUBLICATION...
  • Page 201 HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997 SM50-0409-01E...

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Sq250S2 250

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