Page 3: Table Of Contents
Contents How to use this manual Service Information This manual explains how to maintain procedure for the SN125 manufactured by DAELIM MOTOR CO., LTD. Inspections / Adjustments To ensure safety and optimal operating conditions of the External Parts vehicle, carry out regular inspections according to the maintenance schedule(Section 2).
Page 5: Service Information
SERVICE INFORMATION 1. SERVICE INFORMATION · · · · · · 1-1 WIRING DIAGRAM· · · · · · · · · · · · · · · · · · 1-6 SERIAL NUMBER LOCATION SPECIFICATIONS· · · · · · · · · · · · · · · · · · 1-2 GENERAL SAFETY·...
Page 6 SERVICE INFORMATION 1,910mm 750mm 1,090mm 1,360mm 755mm 126mm 130kg 277kg 2.00 2.25 (6.8 ) 90mm 90/70 stroke SOHC 1.05 13.8 ATDC ※ "( )" MARKED CONTENTS APPLY TO EURO 2 ONLY...
Page 7: Specifications
SERVICE INFORMATION ITEM SPECIFICATIONS TYPE / VENTURI BORE CV type ( vacuum ) / '“ 24.2 mm MODEL MARK CHOKE TYPE Auto-bystarter MAIN JET # 95 (CARBURETOR) PILOT SCREW INITIAL SETTING FLOAT LEVEL 17 mm IDLE SPEED 1.700±100 rpm CLUTCH TYPE Automatic Transmission PRIMARY REDUCTION 3.000...
Page 8 SERVICE INFORMATION...
Page 9 SERVICE INFORMATION...
Page 10 SERVICE INFORMATION...
Page 11 SERVICE INFORMATION...
Page 12 SERVICE INFORMATION...
Page 13 SERVICE INFORMATION...
Page 14: General Safety
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.
Page 15 SERVICE INFORMATION 5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data remove the cleaning oil with compressed air. Apply oil during installation. When installing, return to the state to seal face during installation. before removing.
Page 16 SERVICE INFORMATION 13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open- •Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way longitudinal hanging.
Page 17 SERVICE INFORMATION 21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of interior from the infiltration of dust. each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally.
Page 18: Caution When Wiring
SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.
Page 19 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 20 SERVICE INFORMATION •Insert the connector until the vinyl cover is fully inserted •When removing T-start, broaden the groove of T-start 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 21 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 22 MEMO...
Page 23: Inspections/Adjustments
INSPECTIONS/ADJUSTMENTS 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION··· ENGINE OIL········ MAINTENANCE SCHEDULE · · · DRIVE BELT·········· FUEL LINE········· BRAKE FLUID········· THROTTLE GRIP OPERATION · · BRAKE PAD·········· BRAKE SYSTEM· · · · · · · · AIR CLEANER······· SPARK PLUG········ SIDE STAND········· VALVE CLEARANCE·····...
Page 24 INSPECTIONS/ADJUSTMENTS...
Page 25 INSPECTIONS/ADJUSTMENTS...
Page 26 INSPECTIONS/ADJUSTMENTS 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 FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL TUBE FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP...
Page 27 INSPECTIONS/ADJUSTMENTS AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLENER AIR CLEANER ELEMENT...
Page 28 INSPECTIONS/ADJUSTMENTS COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN...
Page 29: Transmission Oil
INSPECTIONS/ADJUSTMENTS 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 PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW PILOT SCREW CARBURATOR IDLE SPEED...
Page 30: Brake Fluid
INSPECTIONS/ADJUSTMENTS BRAKE FLUID MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
Page 31: Side Stand
INSPECTIONS/ADJUSTMENTS GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE GREASE SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND SIDE STAND...
Page 32: Steering Stem
INSPECTIONS/ADJUSTMENTS STANDARD PRESSURE ㎏/㎠ ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 2.00(29 psi) 2.00(29 psi) 1.78 TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE DRIVER AND A PASSENGER 2.25(32 psi) 2.25(32 psi) TIRE PRESSURE GANGE...
Page 33: Lubrication Points
INSPECTIONS/ADJUSTMENTS LUBRICATION POINTS Use general grease unless specified here. Apply oil or grease to the other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning. Change it when the cable lengthened.
Page 34 MEMO...
Page 35: External Parts
EXTERNAL PARTS ···3-1 ·····3-6 SERVICE INFORMATION SEAT SUPPORT PIPE ··3-2 ·······3-6 MAINTENANCE PROCEDURE CENTER COVER ·········3-3 ········3-7 INNER BOX TRUSS PIPE ········3-3 ·····3-7 FRONT COVER FLOOR SIDE COVER ········3-4 ·······3-7 FRONT FENDER FLOOR PANEL ······· 3-8 ····3-4 UNDER COVER FRONT UNDER COVER ··3-8 ············3-5 REAR WHEEL MUDGUARD...
Page 36: Maintenance Procedure
EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF FRAME COVERS ●This chart shows arrows connected in the order of disassembling covers. SEAT INNER BOX CENTER COVER UNDER COVER RR. FENDER RR. WHEEL MUDGUARD TRUSS PIPE FR. COVER FR. FENDER RR. UPPER COVER FLOOR SIDE COVER BATTERY COVER FR.
Page 37: Front Cover
EXTERNAL PARTS INNER BOX FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER...
Page 38: Front Fender
EXTERNAL PARTS ●Remove the speedometer cable and speedometer. SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER SPEEDOMETER ●Loosen the 6 tapping screw securing the front side cover. SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE...
Page 39: Seat
EXTERNAL PARTS ●Remove the front under cover. ●Install in the reverse order of removal. SEAT REMOVAL/ASSEMBLY ●Release the seat lock at the back of seat. ●Loosen the 2 flange nuts and remove the seat. ●Install in the reverse order of removal. SEAT SEAT SEAT...
Page 40: Rear Under Cover
EXTERNAL PARTS REAR UNDER COVER SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW...
Page 41: Truss Pipe
EXTERNAL PARTS TRUSS PIPE REMOVAL/ASSEMBLY ●Remove the bar end cap B. ●Loosen the flange bolt. ●Loosen the 4 cap bolts. ●Remove the truss pipe. ●Install in the reverse order of removal. FLOOR SIDE COVER REMOVAL/ASSEMBLY ●Loosen the 6 special screws LH., RH. in floor side cover and loosen the 4 tapping screws RH., LH.
Page 42: Under Cover
EXTERNAL PARTS ●Remove the inner box. ●Remove the floor side cover. ●Loosen the tapping screw securing the floor panel and remove the floor panel. ●Install in the reverse order of removal. UNDER COVER UNDER COVER UNDER COVER UNDER COVER UNDER COVER UNDER COVER UNDER COVER UNDER COVER...
Page 43: Muffler
EXTERNAL PARTS ●Remove the inner box. ●Loosen the 2 flange bolts securing the pilot box. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
Page 44 MEMO...
Page 45: Lubrication System
LUBRICATION SYSTEM...
Page 46 LUBRICATION SYSTEM Inclusion of water. Low or no oil pressure Close oil valve relief. Clogged oil strainer. Worn and faulty oil pump. Internal oil leaks. Inadequate oil viscosity. Shout of oil quantity. Oil pump drivegear or sprocket it is not right.
Page 47 LUBRICATION SYSTEM OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS...
Page 48 LUBRICATION SYSTEM FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS...
Page 49 LUBRICATION SYSTEM OIL PUMP DISASSEMBLY PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR PLATE PLATE PLATE DRIVEN GEAR DRIVEN GEAR...
Page 50 LUBRICATION SYSTEM OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR OUTER ROTOR...
Page 51 LUBRICATION SYSTEM OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT...
Page 52 LUBRICATION SYSTEM RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR RADIATOR OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT...
Page 53: Ems(Engine Management System)
EMS(Engine Management System) 5. EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS 2. THE COMPONENT PARTS OF THE EMS 3.TERMINAL ARRANGEMENT OF THE ECU 4. WIRING DIAGRAM OF THE ECU 5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - Self diagnostic function - Fail safe function - How to check the fault code - How to show the fault code...
Page 54: Caution When Repairing The Ems Parts
EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS. ●If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity. ●Do not use the electlic wires or others instead of the fuse. ●Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop.
Page 55: The Component Parts Of The Ems
EMS(Engine Management System) 2. THE COMPONENT PARTS OF THE EMS EMS CONSISTS OF INTAKE AND FULE, IGNITION AND CONTROL SYSTEM. 1) INTAKE SYSTEM As a system which controls and measures air to be necessary for combustion in engine, the intake system is composed of pressure sensor of intake parts, intake on sensor, throttle position sensor, throttle body, air cleaner and ISA(Idle Speed Actuator), etc.
Page 56: Terminal Arrangement Of The Ecu
EMS(Engine Management System) 3. TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected. 4. WIRING DIAGRAM OF THE ECU...
Page 57 EMS(Engine Management System) 5. SELF-DIAGNOSTIC FUNCTION BY MIL (Malfunction Indicator Lamp) SELF-DIAGNOSTIC FUNCTION The EMS is equipped with self-diagnostic function in order to ensure that the engine control system is operation normally. If this function detects a malfunction in the system, it immediately operates and illuminates the MIL (malfunction indicator lamp).
Page 58 EMS(Engine Management System) FAIL-SAFE FUNCTION If the ECU checks something wrong , the vehicle can be driven by its fail safe function. However, if there are something wrong in fuel pump, injector, crank position sensor, the engine operation can be impossible. INTAKE : MIL on/off INTAKE...
Page 59: How To Check The Fault Code
EMS(Engine Management System) HOW TO CHECK THE FAULT CODE There are two methods of checking the fault codes. 1) Use the MIL in the speedometer. 2) The diagnostic tool. First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic methods for each part) Second) The diagnostic tool (refer to scan user’s manual.) ●...
Page 60: How To Show The Fault Code
EMS(Engine Management System) HOW TO SHOW THE FAULT CODE There are two methods to show the Fault codes. First, the methods to show in engine operation In engine operation, when there is something wrong in each part of EMS, the MIL keeps light on without the light on/off function of MIL in order for driver to acknowledge defect.
Page 61 EMS(Engine Management System) FAULT CODES TABLE Fault MIL INDICATION Priority Description code no. (The number of blinks) order No failure Injection valve failure(IV) Idle speed actuator failure (ISA) Electrical fuel pump failure (EFP) Intake Manifold absolute pressure signal failure (IMP) Throttle position signal failure (TPS) O2 sensor heater output failure (LSH) Lambda signal failure (VLS)
Page 62: Ems Trouble Shooting
EMS(Engine Management System) HOW TO REMOVE THE FAULT CODE Remove the fault codes in two ways; First) Full warm up 1. Starting the engine. - The MIL blinks continuously because the ECU memorized the fault code yet. 2. Full warm up the engine (keep idling five minutes) 3.
Page 63 EMS(Engine Management System) 6. ECU SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE SEAT SUPPORT PIPE...
Page 64: Throttle Body
EMS(Engine Management System) 7. THROTTLE BODY CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER...
Page 65 EMS(Engine Management System) DISCONNECT THE THROTTLE BODY ● Disconnect fuel tank and air cleaner. ● Remove the gasoline in fuel tube. ● Disconnect fuel tube securing injector cap. ● Disconnect TPS, ISA, MAPAT, injector coupler. ● Disconnect throttle cable. △ CAUTION ●Do not disconnect both the throttle adjust screw and adjust nut.
Page 66 EMS(Engine Management System) DISASSEMBLE THE INSULATOR ● Disconnect injector cap bolt. ● Disconnect injector and injector cap at the same time from the insulator. ● Disconnect injector and injector cap. CHECKING THE INSULATOR ● Check the O-ring. INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP...
Page 67 EMS(Engine Management System) ADJUSTMENT OF THROTTLE CABLE ● Assemble the throttle cable. ● Adjust the free play of throttle grip. INSPECTION OF SENSOR AND ACTUATOR ● Connect each sensor and the actuator coupler. ● Check the ISA. ● Check the TPS. ●...
Page 68 EMS(Engine Management System) 8. INJECTOR REMOVE INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR ● Turn off the ignition key. INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP INJECTOR CAP...
Page 69 EMS(Engine Management System) CHECKING METHODS BY FAULT CODES Checking of the Injector circuit The fault code is displayed by MIL Checking Circuit 40 : INJECTOR control 39 : FUEL PUMP control INJECTOR FUEL PUMP RELAY Coupler terminal is based on wire harness. Checking Procedure 1) Turn off the ignition key.
Page 70 EMS(Engine Management System) 9. MAPAT (Mainfold Air pressure sensor MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR Temperature sensor) MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR...
Page 71 EMS(Engine Management System) Check the MAPAT Circuit(Intake Pressure Sensor (IMP)+Intake Temperature Sensor(TBA))’s circuit Fault code number is displayed by MIL The Fault code of intake pressure sensor The Fault code of intake temperature sensor Checking circuit MAPAT 3 : Intake pressure sensor ground 3 : Inhalation pressure 26 : 5V voltage sensor GROUND...
Page 72 EMS(Engine Management System) Checking of the intake pressure sensor 1) If voltage value is normal, turn off the ignition key. Connect the MAPAT(intake pressure sensor + intake temperature sensor) coupler 2) The wire-harness to check the ECU is connected with the ECU with a wire-harness coupler. Refer to how to assemble or disassemble the ECU ( 5-11 ) 3) Turn on the ignition key.
Page 73 EMS(Engine Management System) Checking of the intake temperature sensor 1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[Ω], 25±1 Measuring terminal : ECU No.
Page 74 EMS(Engine Management System) 10. TPS(Throttle position Sensor) ● Located on the left side of throttle body. △ CAUTION ● Before disassembly, the key is off. REMOVE ● Disconnect the TPS coupler. ● Loosen 2 TPS screws. MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR MAPAT SENSOR...
Page 75 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number is displayed by MIL Checking circuit 4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key .
Page 76 EMS(Engine Management System) Checking Procedure 6) Check continuty between the Sensor Ground Terminal of TPS and Earth. The continuty TPS : 0[ ],20±1 Measuring Terminal : ECU No. 4 (W/R : WHITE/RED) ~ EARTH Remarks : Measuring unit for resistance : Resistance ‘ R ‘ [ 7) If not problem, measure the resistance of TPS.
Page 77 EMS(Engine Management System) 11. ETS(Engine Temperature Sensor) RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH.
Page 78 EMS(Engine Management System) 1)CHECKING THE CIRCUIT DIAGRAM OF ETS(Engine Temperature Sensor) ●Fault code number is displayed by MIL CHECKING CIRCUIT 4 : SENSOR GROUND 5V SUPPLY VOLTAGE 20 : ETS Coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off the ignition key .
Page 79 EMS(Engine Management System) 6-1) If the measured value is not normal, Replace the ETS with the new one, recheck. If the measured value is normal, Check the G/L electric wire, W/R electric wire to see if they have been broken or have short-circuited or if the ECU coupler is a bad contact ( No.4, No.
Page 80 EMS(Engine Management System) 12. ISA(Idle Speed Actuator) INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR ● Located on the throttle body. ● Remove the center cover. △...
Page 81 EMS(Engine Management System) 1)CHECK THE ISA(IDEL SPEED ACTUATOR) CIRCUIT. ●Showing of defects codes by MIL CHECKING CIRCUIT FUEL PUMP RELAY Coupler terminal is based on the side of the wire-harness CHECK PROCEDURE 1) Turn off ignition key . 2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of ISA, measure the resistance between ISA terminals.
Page 82 EMS(Engine Management System) CHECK PROCEDURE 5) If the measured resistance and continuty is abnormal. Replace ISA with the new one, and recheck. 6) If resistance and continuty is normal, connect the coupler of ISA. 7) Turn on ignition key 8) Measure ISA voltage of wire-harness to check ECU. Measuring terminal : B/R electric wire ~ EARTH Output voltage of ISA : Battery Voltage [V]...
Page 83 EMS(Engine Management System) 13. O2(Oxygen) SENSOR REMOVE ● Located on the exhaust pipe. O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER O2 SENSOR COUPLER...
Page 84 EMS(Engine Management System) 1) CHECKING OF OXYGEN(O ) SENSOR CIRCUIT ●Fault code number is displayed by MIL ●Fault code number is displayed by MIL of the oxygen(O )sensor lambda signal. CHECKING CIRCUIT Lamda OXYGEN SENSOR 2 : LAMBDA SENSOR GROUND 12 : OXYGEN SENSOR SIGNAL 34 : OXYGEN SENSOR HEATER 34 : OXYGEN SENSOR GROUND...
Page 85 EMS(Engine Management System) CHECKING FOR A FAULT CODE BY OXYGEN(O )SENSOR HEATER If the voltage value is abnormal, Check to see if the ECU coupler is loose or if there is bad contact. Check the ‘B/B’’ electric wire, ‘G/W’ electric wire to see if they have been broken or have short- circuited.
Page 86 EMS(Engine Management System) 14.CHECKING OF MIL ●Fault code number is displayed by MIL CHECKING CIRCUIT 24 : MALFUNCTION INDICATOR LAMP OUTPUT MALFUNCTION INDICATOR LAMP(MIL) CHECK PROCEDURE 1) Turn off ignition key. 2) Check the ESS coupler is loose, or bad. If there is no problem.
Page 87 EMS(Engine Management System) 15. CKP(Crank Position Sensor) REMOVE ● Remove the center cover. ● Remove the ACG coupler. ● Remove the CKP coupler. ● CKP is located inside the RH. crank case cover. △ CAUTION ● Before disassembly, the key is off. ●...
Page 88 EMS(Engine Management System) ● Check the fly wheel. ● Fly wheel for the EMS system have 10 spots on the fly wheel protrusion. It is different with carburetor type. ● Check the mark or contamination on the protrusion. △ CAUTION ●...
Page 89 EMS(Engine Management System) CHECK THE CIRCUIT OF CKP ●Fault code number is displayed by MIL CHECKING CIRCUIT GREEN BLUE BLUE ECU PIN NUMBER 30 : CRANK SIGNAL-A 22 : CRANK SIGNAL-B CHECK PROCEDURE 1) Turn ON ignition key. 2) Check to see if the ENGINE SINK ON is ON or OFF with diagnosis tool. When start up the ENGINE SINK ON change “OFF’...
Page 90 EMS(Engine Management System) 4) Check if crank signal A,B wires is breaks or not. Remove the ECU, connect wire harness for inspection to wire harness of vehicle. Check the wiring of crank signal A - Measure terminal : No. 30 pin of wire harness for inspection - Red wire of coupler of CKP. - Measuring resistance : 0 ~ 1[ ] CKP_B CKP_A...
Page 91: Fuel Pump
EMS(Engine Management System) 16. FUEL PUMP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP FUEL FILLER CAP...
Page 92 EMS(Engine Management System) FUEL PUMP ● The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump) CONNECTOR WIRING LOCATION COLOR FUNCTION YELLOW FUEL UNIT FUEL UNIT2 GREEN PUMP (+) GROUND BLACK 5-40...
Page 93 EMS(Engine Management System) ●Check the fuel pump. ●Remove the fuel pump. ●Measure the resistance between terminals. The FLOAT position Terminals resistance [Ω] F : 140.5[mm] 40 ± 5[Ω] 1/2 : 83.5[mm] 220 ± 5[Ω] E : 28.5[mm] 400± 3[Ω] ●The float position is based on tank bottom plate. ●Measure the resistance between Y/W (YELLOW/WHITE) wire and G(GROUND) wire of fuel unit terminal ※Remark : measuring unit of resistance : resistance[Ω]...
Page 94 EMS(Engine Management System) 17.HOW TO USE THE SCAN WHEN ECU IS INITIALIZED ●The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. ●Turn the lgnition key on. ●Press the power button of the diagnostic tool. ●Press the enter button in the initial screen.
Page 95 EMS(Engine Management System) ●Press the enter button when it is ready ●When the ECU was initialized. turn off the lgnition key and then turn on the ignition key. 5-43...
Page 96 EMS(Engine Management System) 18.HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING ●The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. ●Turn the lgnition key on. ●Press the power button of the diagnosis tool. ●Press the enter button on the initial screen.
Page 97 EMS(Engine Management System) 19.HOW TO USE THE SCAN WHEN THE IGNITION TIMING IS CHECKING ●The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. ●Turn the lgnition key. ●Start the engine. ●Press the power button of the diagnosis tool. ●Press the enter button on the initial screen.
Page 98 EMS(Engine Management System) 20.HOW TO USE THE SCAN WHEN ENGINE REVOLUTION IS CHECKING ●The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. ●Turn the lgnition key. ●Start the engine. ●Press the power button of the diagnosis tool. ●Press the enter button on the initial screen.
Page 99 MEMO...
Page 100 MEMO...
Page 101: Fuel System
FUEL SYSTEM 6. FUEL SYSTEM FLOAT CHAMBER/FLOAT/JET ·6-5 ·· 6-1 SERVICE INFORMATION TROUBLESHOOTING ···· 6-2 CARBURETOR INSULATOR· 6-8 PILOT SCREW ADJUSTMENT 6-9 FUEL TANK········ 6-3 FUEL PUMP········6-11 CARBURETOR······· 6-3 SERVICE INFORMATION GENERAL SAFETY WARNING ● Gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive.
Page 102 FUEL SYSTEM TROUBLESHOOTING Air/Fuel mixture is extremely rich. The vehicle does not start. ● Float valve is damaged. ● No gasoline in fuel tank. ● Oil level is too high. ● Fuel is not coming out of carburetor. ● Air jet is blocked. ●...
Page 103: Fuel Tank
FUEL SYSTEM FUEL TANK CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CRADLE PIPE CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER CENTER COVER...
Page 104 FUEL SYSTEM ● Loosen the throttle cable lock nut and remove the THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT THROTTLE CABLE LOCK NUT...
Page 105 FUEL SYSTEM INSPECTION VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON...
Page 106 FUEL SYSTEM ● Remove the main jet, needle jet holder, needle jet, slow jet, screw set, diaphragm comp, compression spring. NOTE CARBURETOR BODY Turn in the pilot jet and record the number of turns it takes before it seats lightly. Do not force the pilot screw against its seat;...
Page 107 FUEL SYSTEM ASSEMBLY SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET SCREW SET...
Page 108 FUEL SYSTEM NOTE Be careful not to pinch the diaphragm, and to COMPRESS keep the spring straight. STRAIGHT ● Install the drain tube and air-hose. CABURETOR INSTALLATION THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE...
Page 109 FUEL SYSTEM INSPECTION O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING ● Check the carburetor insulator O-ring for wear or damage. ● Install in the reverse order of removal. PILOT SCREW ADJUSTMENT THROTTLE STOP SCREW THROTTLE STOP SCREW...
Page 110 FUEL SYSTEM When idling, check to see if the rotation is smoothly and to return is nomal. ● Install the center cover. CAUTION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION...
Page 111 FUEL SYSTEM CAUTION If the engine cannot be adjusted by turning the pilot screw within a turn, check for other engine problems. ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION ACCELERATION...
Page 112 FUEL SYSTEM ● Check the gaskets. ● Check the suction valve, outlet valve and relief valve for damage and crack. ● Install in the reverse order of removal. FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP...
Page 113: Engine Removal/Installation
ENGINE REMOVAL/INSTALLATION 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION····· 7-1 ENGINE REMOVAL/INSTALLATION·7-2 SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation.
Page 114: Engine Removal
ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ● Drain the engine oil. ● Release the seat lock by turning the main switch key to open the seat. ● Remove the following parts. - Rear under cover. - Air cleaner (2-5) - Carburetor (6-3) ●...
Page 115: Engine Installation
ENGINE REMOVAL/INSTALLATION ● Loosen the rear cushion under bolt. REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION...
Page 116 LH. CRANKCASE COVER/CONTINUOUSL Y V ARIABLETRANSMISSION LH. CRANK CASE COVER...
Page 117 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8. LH. CRANKCASE /CONTINUOUSLY VARIABLE TRANSMISSION SERVICE INFORMATION···8-1 MOVABLE DRIVE FACE····8-5 TROUBLESHOOTING· · · · 8-1 CLUTCH/DRIVEN PULLEY ASSEMBLY· · 8-8 LH. CRANK CASE COVER· · 8-2 DRIVEN FACE INSPECTION· 8-10 DRIVE BELT· · · · · · · DRIVE PULLEY INSTALLATION·...
Page 118: Lh. Crankcase Cover
LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANKCASE COVER B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY B-STAY DISASSEMBLY AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER AIR CLEANER...
Page 119 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE BELT DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER DRIVE FACE HOLDER...
Page 120 ● Measure the width of the drive belt as shown. WIDTH SERVICE LIMIT : 20.5mm NOTE Use only a genuine DAELIM replacement drive belt. Do not get oil or grease on the drive belt or pulley faces. Clean off any grease or oil before reinstalling. DRIVE BELT INSTALLATION ●...
Page 121: Movable Drive Face
LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Install the drive face to the LH. crank shaft. FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT FLANGE NUT...
Page 122 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION MOVABLE DRIVE FACE INSPECTION WEIGHT ROLLER ● Check the rollers for wear or damage. ● Measure the O.D. of each roller. SERVICE LIMIT : 19.5mm ● Measure the abnormal wear. SERVICE LIMIT : LESS THAN 2.0mm ●...
Page 123 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Install the drive belt into the movable drive face. MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE...
Page 124: Driven Pulley
LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY REMOVAL ● Remove the LH. crankcase cover. ● Remove the drive face. ● Hold the clutch outer using the universal holder and remove the 12mm flange nut, then remove the driven pulley. TOOL : DRIVE FACE HOLDER UNIVERSAL HOLDER ●...
Page 125 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Remove the seal collar from the driven pulley. SEAL COLLAR ● Remove the guide pins and guide pin rollers and the GUIDE ROLLER PIN MOVABLE DRIVEN FACE movable driven face. GUIDE PIN ● Remove the O-ring from movable driven face. GUIDE ROLLER GUIDE PIN DRIVEN FACE...
Page 126 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY INSPECTION DRIVEN FACE BEARING INSPECTION ● Check the each parts. ● Check the driven face needle bearing(inner) for damage or excessive play and replace as necessary. ● Turn the inner race of the ball bearing with your finger. Check that the bearing turns smoothly and quietly, and that the bearing outer race fits securely.
Page 127 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION ● Check the following; - Movable driven face for damage or excessive wear. - Guide pin groove for damage or deformation. ● Replace damaged or worn parts as necessary. ● Measure the I.D. of the movable driven face; replace if the service limit is exceeded.
Page 128 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN FACE / MOVABLE DRIVEN FACE OIL SEAL ● Install new oil seal and O-ring on the movable driven pulley face. O-RING ● Install the movable face on the driven pulley face. GUIDE ROLLER PIN MOVABLE DRIVEN FACE ●...
Page 129 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY INSTALLATION ● Turning the driven pulley ass’y rightside, extend the belt assemble groove maximum. ● Install the drive belt into driven pulley sub ass’y, install the drive shaft. ● Install the drive belt into movable drive face.. DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY...
Page 130: Generator / Starter Clutch
A.C GENERATOR / STARTER CLUTCH STARTER COMP FLY WHEEL COOLING FAN SAI LID VALVE...
Page 131 A.C GENERATOR / STARTER CLUTCH...
Page 132 A.C GENERATOR / STARTER CLUTCH SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH. SHROUD RH.
Page 133 A.C GENERATOR / STARTER CLUTCH ● Install the universal holder on the flywheel. ● If the universal holder connot be used, remove the LH. FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL FLYWHEEL...
Page 134 A.C GENERATOR / STARTER CLUTCH A.C GENERATOR INSTALLTION ● Install the stator to the RH. Crankcase cover. STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP STARTER COMP...
Page 135 A.C GENERATOR / STARTER CLUTCH ● Remove the RH. Crankcase cover gasket and dowelpin. REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR...
Page 136: Starter Clutch
A.C GENERATOR / STARTER CLUTCH STARTER REDUCTION GEAR INSTALLATION REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR REDUCTION GEAR...
Page 137 A.C GENERATOR / STARTER CLUTCH ● Remove the thrust washer. ● Remove the starter driven gear and starter clutch. THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER...
Page 138 A.C GENERATOR / STARTER CLUTCH STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET STARTER ONEWAY CLUTCH SET...
Page 139 MEMO...
Page 140 CYLINDER HEAD / VALVES FLANGE NUT IN VALVE ROCKER ARM CAM SHAFT HORDER EX. VALVE ROCKER ARM CAM SHAFT COMP EX. VALVE INLET VALVE CARBURETOR INSULATOR CYLINDER HEAD COMP SAI PIPE CYLINDER HEAD GASKET 10-0...
Page 141: Cylinder Head / Valves
CYLINDER HEAD / VALVES 10. CYLINDER HEAD / VALVES VALVES ········· 10-6 SERVICE INFORMATION·· 10-1 TROUBLESHOOTING···· 10-2 VALVE GUIDES······ 10-7 VALVE SEATS ······ 10-8 CAMSHAFT········ 10-3 CYLINDER HEAD ····· 10-5 CYLINDER HEAD ASSEMBLY·10-12 VALVE SPRINGS ······ 10-6 CAMSHAFT ASSEMBLY···10-13 SERVICE INFORMATION GENERAL SAFETY ●...
Page 142 CYLINDER HEAD / VALVES TOOLS VALVE GUIDE REAMER VALVE GUIDE DRIVER VALVE SPRING COMPRESSOR VALVE SEAT CUTTER SEAT CUTTER IN 37° (21.5mm) EX 37° (18.5mm) IN 45° (22.0mm) EX 45° (22.0mm) IN 55° (20.0mm) EX 55° (20.0mm) TROUBLESHOOTING Enging top-end problems useally affect engine performance. These can be diagnosed by a compression or leak down test, or by tracing noises to the top-end with a sounding rod or stethoscope.
Page 143 CYLINDER HEAD / VALVES CAMSHAFT REMOVAL ● Remove the following parts. - Rear fender - Seat support pipe - Center cover SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS...
Page 144 CYLINDER HEAD / VALVES ● Remove the cam chain from the camshaft. △ NOTE ● Take precautions not to allow the cam chain to drop into the crankcase. ● Remove the camshaft. CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT...
Page 145: Cylinder Head / Piston
CYLINDER HEAD / VALVES ● Manually turn the camshaft bearing outer race, and check if it turns smoothly. ● Check the bearing for wear or damage. △ CAUTION ● Be sure to check the valve clearance. CAMSHAFT BEARING CAMSHAFT BEARING CAMSHAFT BEARING CAMSHAFT BEARING CAMSHAFT BEARING...
Page 146: Cylinder Head Inspection
CYLINDER HEAD / VALVES ● Remove the valve spring, valve cotter, retainer, spring and valve. Using the valve spring compressor. TOOL : VALVE SPRING COMPRESSOR △ NOTE ● To prevent the loss of tension, do not compress the valve spring more than necessary. ●...
Page 147 CYLINDER HEAD / VALVES VALVE GUIDES VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER VALVE GUIDE REAMER...
Page 148 CYLINDER HEAD / VALVES ● Apply oil to a new O-ring and install it onto a new VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE VALVE GUIDE...
Page 149 CYLINDER HEAD / VALVES ● Remove the valve and inspect the valve seat face. VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT...
Page 150 CYLINDER HEAD / VALVES ● Using a 55 degree cutter, remove the bottom ¼ of the old seat. ● Using a 45 degree cutter, cut the seat to the proper width. SEAT WIDTH ● If the contact area is too high on the valve, the seat must be lowered using a 37 degree flat cutter.
Page 151 CYLINDER HEAD / VALVES ● After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. △ NOTE ● Do not excessively press and turn the valve to set it as it may cause damage.
Page 152 CYLINDER HEAD / VALVES ● Tap the valve stems gently with a soft hammer to firmly seat the cotters. △ CAUTION ● Take necessary precautions not to damage the valve. VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING VALVE SPRING...
Page 153 CYLINDER HEAD / VALVES CAMSHAFT ASSEMBLY EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX. VALVE ROCKER ARM EX.
Page 154 CYLINDER HEAD / VALVES ● Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. CAM SHAFT CAM SHAFT CAM SHAFT ● Assemble the cam chain and cam sprocket after CAM SHAFT CAM SHAFT CAM SHAFT CAM SHAFT...
Page 155 CYLINDER HEAD / VALVES ● Fix the tensioner shaft with a hard clip. HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP HARDCLIP TENSIONER LIFTER TENSIONER LIFTER TENSIONER LIFTER TENSIONER LIFTER TENSIONER LIFTER TENSIONER LIFTER TENSIONER LIFTER...
Page 156 CYLINDER / PISTON CYLINDER TOP RING SECOND RING OIL RING CYLINDER GASKET PISTON 11-0...
Page 157 CYLINDER / PISTON 11. CYLINDER / PISTON SERVICE INFORMATION ··· 11-1 PISTON / PISTON RING ··11-3 CYLINDER INSTALLATION · 11-6 TROUBLESHOOTING···· 11-1 CYLINDER········· 11-2 SERVICE INFORMATION GENERAL SAFETY ● Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins.
Page 158 CYLINDER / PISTON CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER REMOVAL ● Remove EX. pipe. ● Remove the cylinder head cover. ● Remove the cam shaft. ●...
Page 159 CYLINDER / PISTON WARPAGE INSPECTION ● Check the cylinder for warpage by placing a straight edge and feeler gauge across the stud holes. Replace the cylinder if the service limit is exceeded. SERVICE LIMIT : 0.02 mm △ NOTE ● Any clearance between the cylinder and head due to damage or warpage will result in compression leaks and reduced performance.
Page 160 CYLINDER / PISTON 11-4...
Page 161 CYLINDER / PISTON MARK TOP RING SECOND RING SIDE RAIL SPACER RING SIDE RAIL 20mm PISTON TOP RING SECOND RING CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD...
Page 162 CYLINDER / PISTON CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET...
Page 163 MEMO...
Page 164: Transmission/Crankshaft/Crank Case
TRANSMISSION/CRANKSHAFT/CRANK CASE 12-0...
Page 165 TRANSMISSION/CRANKSHAFT/CRANKCASE 12-1 12-7 12-2 12-8 12-3 12-9 12-6 12-10 ( SECTION 4-4) ( SECTION 7) ( SECTION 10 AND 11) ( SECTION 9) ( SECTION 8) ( SECTION 8) ( SECTION 12) 12-1...
Page 166 TRANSMISSION/CRANKSHAFT/CRANK CASE TORQUE VALUE CRANK CASE BOLT 1.0kg-m TOOLS -UNIVERSAL BEARING PULLER -BEARING REMOVER SET -REMOVER ASSEMBLY -REMOVER SHAFT -REMOVER HEAD -SLIDING WEIGHT -ASSEMBLY SHAFT TROUBLESHOOTING Engine Noise ● Connecting rod big and small ends loose. ● Crank pin bearing loose. Engine started but unable to move out ●...
Page 167 TRANSMISSION/CRANKSHAFT/CRANK CASE 14-6 15-8 14-3 TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER TRANSMISSION COVER...
Page 168 TRANSMISSION/CRANKSHAFT/CRANK CASE FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT...
Page 169 TRANSMISSION/CRANKSHAFT/CRANK CASE NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING NEEDLE BEARING...
Page 170 TRANSMISSION/CRANKSHAFT/CRANK CASE Replace the new oil seal on the transmission cover. Insrall the transmission cover. MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER MISSION COVER...
Page 171 TRANSMISSION/CRANKSHAFT/CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH. CRANK CASE RH.
Page 172 TRANSMISSION/CRANKSHAFT/CRANK CASE DIAL GAUGE MEASURING POINT FILLER GAUGE DIAL GAUGE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH. CRANK CASE LH.
Page 173 TRANSMISSION/CRANKSHAFT/CRANK CASE BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET BEARING REMOVER SET...
Page 174 TRANSMISSION/CRANKSHAFT/CRANK CASE DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN...
Page 175 MEMO...
Page 176 FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE STEERING STEM FRONT FORK FRONT DISK FRONT WHEEL FRONT TIRE 13-0...
Page 177: Front Wheel/Front Fork/Steering
FRONT WHEEL/FRONT FORK/STEERING 13. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION····13-1 SPEEDOMETER GEAR····13-6 TROUBLESHOOTING····· 13-2 FRONT WHEEL INSTALLATION·13-7 STEERING HANDLE ····· 13-3 FRONT FORK ········13-7 FRONT WHEEL ······· 13-4 STEERING STEM ······13-12 FRONT WHEEL BEARING··· 13-5 SERVICE INFORMATION GENERAL SAFETY CAUTION ● Use special tire levers and rim protectors to remove or assemble tires to protect the rim from being damaged. ●...
Page 178: Troubleshooting
FRONT WHEEL/FRONT FORK/STEERING TROUBLESHOOTING Hard steering ● Steering top cornice too tight. ● Damaged steering stem steel ball. ● Faulty steering ball race, cone race. ● Insufficient tire pressure. ● Tire is worn. Steers to one side or does not track straight ●...
Page 179: Steering Handle
FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
Page 180: Front Wheel
FRONT WHEEL/FRONT FORK/STEERING INSTALLATION STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE STEERING HANDLE...
Page 181 FRONT WHEEL/FRONT FORK/STEERING ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION ROTATION BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD BEARING REMOVER HEAD...
Page 182: Speedometer Gear
FRONT WHEEL/FRONT FORK/STEERING SPEEDOMETER GEAR GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER GEAR WASHER...
Page 183: Front Wheel Installation
FRONT WHEEL/FRONT FORK/STEERING ● Apply grease to the dust seal rim. GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER GEAR BOX RETAINER...
Page 184 FRONT WHEEL/FRONT FORK/STEERING ● When removing the front fork, loosen the flange bolt lightly. STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP...
Page 185 FRONT WHEEL/FRONT FORK/STEERING ● Remove the dust seal. DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL DUST SEAL...
Page 186: Front Fork Inspection
FRONT WHEEL/FRONT FORK/STEERING FRONT FORK INSPECTION ● Place the fork spring on a level place, and measure the free length. ● If the free length deviates from the service limit, replace the springs with new ones. ● Check components for damage or abnormal wear. Replace defective parts with new ones.
Page 187 FRONT WHEEL/FRONT FORK/STEERING ● Apply ATF to a new oil seal. FORK SEAL DRIVER ● Assemble the oil seal to the bottom case. ● Insert the oil seal with special tools until the attachment groove of the bottom case set ring is exposed. TOOLS : FORK SEAL DRIVER FORK SEAL DRIVER BODY ●...
Page 188: Steering Stem
FRONT WHEEL/FRONT FORK/STEERING ● Assemble the fork bolt to the fork pipe. FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT FORK PIPE BOLT...
Page 189 FRONT WHEEL/FRONT FORK/STEERING ● Remove the front fork. ● Check the steel ball, cone race and ball race for damage STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP...
Page 190 REAR WHEEL/SUSPENSION/REAR SWING ARM 14-0...
Page 191: Rear Wheel / Suspension
REAR WHEEL/SUSPENSION/REAR SWING ARM 14. REAR WHEEL / SUSPENSION / REAR SWING ARM ··· 14-1 REAR CUSHION ······ · 14-5 SERVICE INFORMATION REAR SWING ARM······ · 14-6 TROUBLESHOOTING···· 14-2 REAR WHEEL · · ········14-3 SERVICE INFORMATION CAUTION ● Use the specified tire lever and rim protector to remove or assemble tires to protect the rim from being damage. SPECIFICATIONS ITEM STANDARD VALUE...
Page 192 REAR WHEEL/SUSPENSION/REAR SWING ARM TROUBLESHOOTING Wobble or vibration in motorcycle ● Bent wheel tire ● Faulty tire ● Axle not tightened properly ● Insufficient air in tire ● Wheel out of balance Soft suspension ● Weak springs ● Rear damper improperly adjusted, oil leakage Hard suspension ●...
Page 193 REAR WHEEL/SUSPENSION/REAR SWING ARM REAR WHEEL REMOVAL ● Support the motorcycle on the main stand. ● Remove the muffler. MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER MUFFLER ●...
Page 194 REAR WHEEL/SUSPENSION/REAR SWING ARM DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE DIAL GAUGE...
Page 195: Rear Cushion
REAR WHEEL/SUSPENSION/REAR SWING ARM REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION...
Page 196: Rear Swing Arm
REAR WHEEL/SUSPENSION/REAR SWING ARM INSTALLATION ● Install the spring, stopper rubber to the damper comp. ● Apply thread locking agent to the hex nut, and install the rear cushion compressor attachment on the damper rod. ● Fix the upper metal, and tighten the hex nut. TORQUE VALVE : 3.0~4.5kgf m TOOLS : REAR CHUSION COMPRESSOR ATTACHMENT REAR CHUSION COMPRESSOR...
Page 197 REAR WHEEL/SUSPENSION/REAR SWING ARM DISASSEMBLY ● Disassemble the rear wheel outside collar from the rear swing arm. 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 198 MEMO...
Page 199 MEMO...
Page 200 BRAKE SYSTEM 15-0...
Page 201: Brake System
BRAKE SYSTEM 15. BRAKE SYSTEM SERVICE INFORMATION····15-1 FRONT BRAKE CALIPER·· 15-6 TROUBLESHOOTING·····15-2 REAR BRAKE CALIPER··· 15-8 BRAKE FLUID········ 15-3 MASTER CYLINDER·····15-11 ··15-5 BRAKE DISK········ 15-13 FRONT BRAKE P AD REPLACEMENT REAR BRAKE PAD······ 15-6 SERVICE INFORMATION GENERAL SAFETY ● Do not allow foreign material to enter the system when replenishing brake fluid. ●...
Page 202 BRAKE SYSTEM TROUBLESHOOTING Brake lever / pedal soft or spongy Brake lever / pedal hard ● Air bubbles in the hydraulic system. ● Clogged / restricted brake system. ● Leaking hydraulic system. ● Sticking / worn caliper piston. ● Contaminated brake pad / disk . ●...
Page 203 BRAKE SYSTEM BRAKE FLUID MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
Page 204 BRAKE SYSTEM < > When the brake bleeder is not available BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE BREEDER HOSE...
Page 205 BRAKE SYSTEM ③ If no air leaks out of the breeder hose after operate the brake lever, stop pumping it. RR. BRAKE LEVER RR. BRAKE LEVER RR. BRAKE LEVER RR. BRAKE LEVER RR. BRAKE LEVER RR. BRAKE LEVER RR. BRAKE LEVER RR.
Page 206 BRAKE SYSTEM REAR BRAKE PAD RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR. CALIPER RR.
Page 207 BRAKE SYSTEM DISASSEMBLY AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN...
Page 208: Rear Brake Caliper
BRAKE SYSTEM HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN ASSEMBLY HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN HANGER PIN...
Page 209 BRAKE SYSTEM DISASSEMBLY AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN AIR GUN...
Page 210 BRAKE SYSTEM ASSEMBLY CALIPER CALIPER CALIPER LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE CALIPER CALIPER CALIPER CALIPER CALIPER CALIPER LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE LOCK PLATE CALIPER CALIPER CALIPER CALIPER CALIPER...
Page 211 BRAKE SYSTEM MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER...
Page 212 BRAKE SYSTEM INSPECTION PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON ● Check the piston periphery for scores, scratches or nicks replace if necessary. ● Check the primary and secondary cups for wear. PRIMARY CUP PRIMARY CUP PRIMARY CUP...
Page 213: Brake Disk
BRAKE SYSTEM INSTALLATION ● Install the front rear master cylinder to the handle. △ NOTE ●Install the holder with its “UP” mark facing upwards, and align the holder joint with the punch mark on the handle bar. BRAKE HOSE OIL BOLT BRAKE HOSE OIL BOLT BRAKE HOSE OIL BOLT BRAKE HOSE OIL BOLT...
Page 214 CHARGING SYSTEM 16-0...
Page 215: Charging System
CHARGING SYSTEM 16. CHARGING SYSTEM CHARGING SYSTEM INSPECTION · 16-4 SERVICE INFORMATION·····16-1 A.C. GENERATOR INSPECTION · · ·16-5 TROUBLESHOOTING······ 16-2 BATTERY ···········16-3 REGULATOR RECTIFIER INSPECTION · 16-5 SERVICE INFORMATION △ WARNING ·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.
Page 216 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 217 CHARGING SYSTEM BATTERY BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER...
Page 218: Charging System Inspection
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 allow to exceed 0.5A TOOL : DIGITAL TESTER △...
Page 219 CHARGING SYSTEM A.C GENERATOR INSPECTION AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER AC GENERATOR COUPLER...
Page 220 IGNITION SYSTEM IGNITION SYSYTEM SIDE STAND SWITCH IGNITION COIL SPARK PLUG MAIN FUSE (15A) GENERATOR BATTERY PULSE UNIT (12V 10AH) GENERATOR 17-0...
Page 221: Ignition System
IGNITION SYSTEM 17. IGNITION SYSTEM SERVICE INFORMATION···· 17-1 IGNITION COIL INSPECTION·· 17-4 TROUBLESHOOTING····· 17-2 IGNITION TIMING INSPECTION· 17-5 CDI UNIT·········· 17-3 SIDE STAND IGNITION CUT-OFF PULSE GENERATOR INSPECTION· 17-3 SWITCH·········· 17-5 SERVICE INFORMATION GENERAL SAFETY ● Follow the steps described in the troubleshooting flow chart when servicing the ignition system. ●...
Page 222 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 223 IGNITION SYSTEM CDI UNIT INSPECTION (EURO2) CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT CDI UNIT...
Page 224 IGNITION SYSTEM IGNITION COIL INSPECTION ● Remove the rear under cover. ● Remove the primary wire. △ NOTE ● Since the resistance value of the primary coil is inherently very small, it is difficult to distinguish it from a shorted wire. IGNITION COIL IGNITION COIL IGNITION COIL...
Page 225 IGNITION SYSTEM IGNITION TIMING INSPECTION RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD RH SHROUD...
Page 226 STARTER SYSTEM STARTER SYSTEM STARTER RELAY CABLE CABLE STOP LAMP STARTER MOTOR REAR FRONT STARTER STOP STOP SWITCH SWITCH SWITCH MAIN SWITCH FUSE BATTERY (12V 10AH 18-0...
Page 227: Starter System
STARTER SYSTEM 18. STARTER SYSTEM STARTER MOTOR ······ 18-3 SERVICE INFORMATION···· 18-1 TROUBLESHOOTING ····· 18-2 STARTER MAGNETIC SWITCH · 18-6 SERVICE INFORMATION GENERAL SAFETY △ WARNING ·Always turn the ignition switch OFF before servicing the starter motor. The moter could suddenly start, causing serious injury.
Page 228 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 “ON”and squeeze With the ignition switch...
Page 229: Starter Motor
STARTER SYSTEM 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 STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR...
Page 230 STARTER SYSTEM ● Remove the brush spring, and then remove the brush. ● Measure the brush length. Replace the brush if it is BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH BRUSH...
Page 231 STARTER SYSTEM STARTER MOTOR ASSEMBLY BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET BRUSH HOLDER SET...
Page 232 STARTER SYSTEM STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH STARTER MAGNETIC SWITCH...
Page 233 STARTER SYSTEM OPERATION CHECK ● Disconnect the magnetic switch wire connector. ● Apply battery voltage between terminals, when the yellow / red wire is connected to the positive (+) battery terminal and the green / yellow wire to the negative (-) battery terminal. ●...
Page 234 MEMO...
Page 235: Lights/Switches/Horn
LIGHTS/SWITCHES/HORN 19. LIGHTS/SWITCHES/HORN SERVICE INFORMATION ···· 19-1 SPEEDOMETER······· 19-3 MAIN SWITCH ········ 19-4 TROUBLESHOOTING·····19-1 HEADLIGHT ·········19-2 HANDLE BAR SWITCH ···· 19-4 FRONT WINKER ·······19-2 HORN SWITCH ········19-5 REAR TAIL LIGHT······ 19-3 FRONT/REAR STOP SWITCH·· 19-5 REAR WINKER······· 19-3 FUEL GAUGE········19-6 SERVICE INFORMATION GENERAL SAFETY ●...
Page 236: Headlight
LIGHTS/SWITCHES/HORN HEADLIGHT BULB REMOVAL ● Loosen the washer screw securing the headlight. ● Disconnect the headlight wiring. HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT HEAD LIGHT...
Page 237: Rear Tail Light
LIGHTS/SWITCHES/HORN REAR TAIL LIGHT REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER...
Page 238: Main Switch
LIGHTS/SWITCHES/HORN MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH MAIN SWITCH...
Page 239: Headlight Switch
LIGHTS/SWITCHES/HORN HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH HEADLIGHT SWITCH...
Page 240: Fuel Gauge
LIGHTS/SWITCHES/HORN FUEL GAUGE FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK FUEL TANK...
Page 241 MEMO...
Page 242 MEMO...
Page 243: Wiring Diagram(Euro2,Euro3)
WIRING DIAGRAM 20-1. WIRING DIAGRAM (EURO-2)
Page 244 WIRING DIAGRAM 20-2. WIRING DIAGRAM (EURO-3)
Page 245 SERVICE MANUAL 2009. 02 PRINTED 2009. 02 PUBLICATION...
Page 246 SM57-0902-01E...

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B-bone sn125

DAELIM B-Bone Service Manual

Table of Contents

2. Inspections/Adjustments

External Parts

Front Wheel/Front Fork/Steering 13. Front Wheel/Front Fork/Steering

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Chapters

Troubleshooting

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