DAELIM a.four Service Manual
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DAELIM a.four Service Manual

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  • Page 2: Table Of Contents

    HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for the A-Four 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 3: Service Information

    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 4 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 5 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball 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 6 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 7 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 8 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 9 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 10 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 11: Serial Number Location

    SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

  • Page 12: Maintenance Specifications

    SERVICE INFORMATION MAINTENANCE INFORMATION SPECIFICATIONS TYPE OF VEHICLE a-Four FRAME TYPE UNDER BONE 1,798mm 8.0m(30km/h VELOCITY) OVERALL LENGTH BRAKING DISTANCE OVERALL WIDTH 683mm MIN. REVOLUTION RADIUS 1,800mm 1,107mm AIR-COOLED OVERALL HEIGHT COOLING TYPE WHEEL BASE 1,260mm STARTING STARTER MOTOR, KICK SJ50R 2-CYCLE MOTOR TYPE...
  • Page 13 SERVICE INFORMATION ITEM STANDARD USE LIMITS FUEL SYSTEM FUEL TANK CAPACITY FULL CAPACITY 6ℓ AIR CLEANER TYPE Urethane Foam CARBURETOR SETTING MARK P B1 1P VENTURI DIAMETER 16mm AIR SCREW OPENING 1 1/4 Rotation FLOAT LEVEL 8.0mm IDLING RPMS 1,800±100rpm NO.
  • Page 14 SERVICE INFORMATION ITEM STANDARD USE LIMITS CLUTCH Automatic Centrifugal CLUTCH AUTOMATIC TYPE Continuously Variable Transmission CLUTCH OUTER DIAMETER 107.0-107.2mm 107.5mm 3.0mm 2.0mm CLUTCH LINING THICKNESS 17.5mm 16.5mm DRIVE BELT WIDTH MOVABLE DRIVE FACE BUSH INSIDE DIAMETER 20.035-20.085mm 20.60mm BOSS OUTSIDE DIAMETER 20.011-20.025mm 19.97mm 15.920-16.080mm...
  • Page 15 SERVICE INFORMATION ITEM STANDARD USE LIMITS IGNITION SYSTEM BR8HSA SPARK PLUG STANDARD 0.6~0.7mm PLUG GAP BTDC 17。 ±2。 /1,800rpm IGNITION TIMING F MARK over 120V PEAK VOLTAGE IGNITION COIL(PRIMARY VOLTAGE) over 120V EXCITE COIL PULSE GENERATOR over 1.5V IGNITION COIL RESISTANCE VALUES(20℃) PRIMARY COIL 0.1-0.5Ω...
  • Page 16 SERVICE INFORMATION TWIST TORQUE STANDARD TWIST TORQUE TYPE TWIST TORQUE TYPE TWIST TORQUE 0.4㎏f · m 5mm BOLT, NUT 0.5㎏f·m 5mm SCREW 0.9㎏f · m 6mm BOLT, NUT 1.0㎏f·m 6mm SCREW 1.2㎏f · m 8mm BOLT, NUT 2.2㎏f·m 6mm SCREW FLANGE BOLT, NUT 2.7㎏f ·...
  • Page 17 SERVICE INFORMATION FRAME PARTS REFERENCE NUMBER SCREW DIAMETER TWIST TORQUE TWIST PART STEERING STEM LOCK NUT 7.0㎏f·m HANDLE POST TWIST NUT 5.0㎏f·m 1.0㎏f·m FRONT BRAKE LEVER PIVOT BOLT 1.0㎏f·m FRONT BRAKE LEVER PIVOT NUT 0.3㎏f·m REAR BRAKE LEVER PIVOT SCREW 0.4㎏f·m REAR BRAKE LEVER PIVOT NUT 1.2㎏f·m...
  • Page 18 SERVICE INFORMATION SPECIALIZED TOOLS CHAPTER TOOL NAME TOOL NO. USAGE FLOAT LEVEL GAUGE 07401-001000 Carburetor Oil Level Measurement BEARING DIRVER 07945-GC80000 Change of Driven Face Outer Bearing 07936-3710300 Disassembly of Driven Face Needle Bearing BEARING REMOVER 07936-3710100 REMOVER HANDLE REMOVER WEIGHT 07741-0010201 DRIVER HANDLE A 07749-0010000...
  • Page 19 SERVICE INFORMATION LUBRICATION OIL ENGINE PARTS APPLICATION AREAS OIL TYPE CAUTIONARY SUGGESTIONS CRANK CASE JOINING FACE Gasket Fluid(TB 1215) CRANK CASE REVOLUTION PART Ultra-2 Super, 2-Cycle Oil CYLINDER BIG REVOLUTION PART, FRICTION PART (Separation Lubrication Use) TRANSMISSION(FINAL REDUCTION) SAE 80W/90 Capacity : 0.09ℓ...
  • Page 20 SERVICE INFORMATION SYMBOLS The following symbols appear in this manual and offer cautionary suggestions which need to be heeded when performing maintenance work on the vehicle. SYMBOL CAUTION SYMBOL CAUTION Indicates an important step or operation. Indicates special caution needed. CAUTION Possibility of resulting in minor WARNING...
  • Page 21 SERVICE INFORMATION WIRING DIAGRAM LIGHTING SW. CORD LIGHTING, START SW. CORD RR. STOP SW. CORD FR. BRAKE HOSE FR. BRAKE HOSE FR. WINKER LIGHT CORD THROTTLE CABLE RR. BRAKE CABLE SPEEDOMETER CABLE SPEEDO METER CORD FR. WINKER LIGHT CORD WINKER SW. CORD PILOT BOX CORD VIEW X SPEEDOMETER CABLE...
  • Page 22 SERVICE INFORMATION WINKER REALY, ASS’Y WIRE HARNESS COUPLER HEAD LIGHT ASS’Y HEAD LIGHT REAR WIRING DETAIL FUEL UNIT SEAT LOCK CABLE FUEL AUTO COCK ASS’Y FUEL VENT TUBE AUTO BY STARTER CORD THERMOSTAT SW. CORD SPEEDOMETER ASS’Y FUEL TUBE OIL TUBE OIL PASS TUBE THROTTLE CABLE OIL PUMP CABLE...
  • Page 23 SERVICE INFORMATION COMB. & LOCK SW. HORN COMP. WINKER REALY, ASS’Y WIRE HARNESS CLIP SEAT LOCK CABLE HEAD LIGHT ASS’Y FR. BRAKE HOSE FR. WINKER CORD RR. BRAKE CABLE SPEEDO METER CORD RR. STOP SW. CORD THROTTLE CABLE LIGHTING SW. CORD PILOT BOX CORD COUPLER WIRE FRONT WIRING DETAIL STARTER REALY, ASS’Y...
  • Page 24 SERVICE INFORMATION REGULATE RECTIFIER RESISTOR AUTO BY STARTER 5W 6.7 HEAD LIGHT COUPLER HORN COMP. SPEEDOMETER CABLE FR. BRAKE HOSE RR. BRAKE CABLE SEAT LOCK CABLE BATTERY THROTTLE CABLE FUSE CASE RR. BRAKE CABLE WIRE HARNESS SPARK PLUG CAP SIDE STAND SW. COUPLER SIDE STAND SW.

  • Page 25: Service Information

    2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION BRAKE FLUID REGULAR INSPECTION SCHEDULE BRAKE PAD/SHOE FUEL LINE (FUEL TUBE) BRAKE SYSTEM FUEL LINE FOR CLOGGING HEADLIGHT ADJUSTMENT THROTTLE GRIP OPERATION SIDE STAND AIR CLEANER SUSPENSION SPARK PLUG BOLTS, NUTS, FASTENERS CYLINDER COMPRESSION PRESSURE WHEELS/TIRES CARBURETOR IDLING STEERING HEAD BEARING 2-10...

  • Page 26: Regular Inspection Schedule

    INSPECTIONS/ADJUSTMENTS REGULAR INSPECTION 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(Fuel Tube)

    INSPECTIONS/ADJUSTMENTS FUEL LINE(FUEL TUBE) LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX ●...

  • Page 28: Air Cleaner

    INSPECTIONS/ADJUSTMENTS ● For adjustment, loosen the lock nut and turn adjuster. ● After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play. LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT LOCK NUT...

  • Page 29: Spark Plug

    INSPECTIONS/ADJUSTMENTS SPARK PLUG ● Remove the plug maintenance cover. ● Remove the spark plug cap and disassemble the plug. PLUG MAINTENANCE COVER SPARK PLUG CAP ● Check the plug for damage, contamination or deposits. ● If the spark plugs are severely contaminated or damaged, raplace with new ones.

  • Page 30: Carburetor Idling

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

  • Page 31: Brake Pad/Shoe

    INSPECTIONS/ADJUSTMENTS BRAKE PAD/SHOE BRAKE PAD REPLACEMENT ● Check the brake pads for wear. ● If the red mark on the pad reaches the brake disc, replace the pads. RED MARK •Replace the brake pads in sets. BRAKE SHOE REPLACEMENT ● If the arrow mark of the wear limit aligns with the ‘△’ mark when the rear brake lever is fully pressed, it indicates the brake lining has reached the service limit.

  • Page 32: Headlight Adjustment

    INSPECTIONS/ADJUSTMENTS REAR BRAKE FREE PLAY ADJUSTMENT ● Turn the adjuster nut to adjust the free play. ● After initial adjustment, check the operation of the rear brake light switch. Make additional adjustments, if necessary. ADJUSTER NUT HEADLIGHT ADJUSTMENT ● Adjust the headlight beam level by operating the adjusting screw located on the upper side of the front fender.

  • Page 33: Suspension

    INSPECTIONS/ADJUSTMENTS SUSPENSION •Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle’s safety and operation efficiency. FRONT WHEEL ● Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.

  • Page 34: Steering Head Bearing

    INSPECTIONS/ADJUSTMENTS ● Check the tread depth at the tire center. ● If the tread depth has reached the service limit, replace the tire. SERVICE LIMIT : 4.0mm 7.5mm STEERING HEAD BEARING •Check the cable if it interferes with the handle operation.

  • Page 35: External Parts

    3. EXTERNAL PARTS ENGINE HANGER SIDE COVER SERVICE INFORMATION FRONT COVER MAINTENANCE PRECEDURE FRONT FENDER LUGGAGE BOX INNER COVER PLUG MAINTENANCE COVER/CENTER COVER FRONT UNDER COVER REAR CARRIER MUFFLER BODY COVER REAR FENDER TAILLIGHT BASE REAR WHEEL MUD GUARD FLOOR SIDE COVER UNDER COVER FLOOR PANEL SERVICE INFORMATION...

  • Page 36: Maintenance Precedure

    EXTERNAL PARTS MAINTENANCE PROCEDURE NAMES OF FRAME COVERS ● This chart shows arrows connected in the order of disassembling covers. ① LUGGAGE BOX ⑦ FLOOR SIDE COVER ⑩ FRONT COVER ② PLUG MAINTENANCE ⑧ FLOOR PANEL ⑪ FRONT FENDER COVER ⑨...

  • Page 37: Luggage Box

    EXTERNAL PARTS LUGGAGE BOX ● Release the seat lock using the main key to open the seat. ● Loosen 4 washer bolts and 2 flange bolts. ● Remove the oil tank cap and the fuel tank cap. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...

  • Page 38: Taillight Base

    EXTERNAL PARTS TAILLIGHT BASE WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT ●...

  • Page 39: Front Cover

    EXTERNAL PARTS FRONT COVER SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT SPECIAL BOLT ●...

  • Page 40: Front Under Cover

    EXTERNAL PARTS FRONT UNDER COVER ● Remove the front cover. ( 3-5) ● Remove the inner box. ( 3-5) ● Remove the front fender. ( 3-5) ● Remove the front wheel. ( 10-5 ) CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP CLIP...

  • Page 41: Engine Hanger Side Cover

    EXTERNAL PARTS REAR FENDER WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT WASHER BOLT ●...
  • Page 42 LUBRICATION SYSTEM LUBRICATION POINTS THROTTLE SPEEDOMETER GREASE BRAKE HOSE THROTTLE GRIP GREASE STEERING BEARING WHEEL BEARING WHEEL BEARING GREASE SIDE STAND PIVOT SPEEDOMETER GEAR BOX GREASE GREASE GREASE...

  • Page 43: Lubrication System

    4. LUBRICATION SYSTEM SERVICE INFORMATION OIL PUMP BLEEDING TROUBLESHOOTING ENGINE OIL LEVEL INSPECTION OIL SYSTEM DRAWING TRANSMISSION OIL INSPECTION OIL PUMP DISASSEMBLY/ OIL TANK DISASSEMBLY ASSEMBLY LUBRICATION POINTS OIL PUMP INSPECTION/ ADJUSTMENT SERVICE INFORMATION ·Remove air from oil tube and oil pump if the oil tube is taken off or if air enters the oil tube. ●...
  • Page 44 LUBRICATION SYSTEM OIL SYSTEM DRAWING...

  • Page 45: Oil Pump Disassembly

    LUBRICATION SYSTEM OIL PUMP DISASSEMBLY/ASSEMBLY OIL PUMP CONTROL CABLE ● Remove - Luggage box. ( 3-3) - Rear wheel mud guard. ( 3-8 ) INLET PIPE - Air cleaner. ( 5-4 ) - Carburetor. ( 5-4 ) FLANGE BOLT ● Loosen the oil pump cable stay bolt to remove the oil pump anchor plate.

  • Page 46: Oil Pump Bleeding

    LUBRICATION SYSTEM ADJUSTMENT CONTROL •Perform after inspection and adjustment of throttle LEVER cable. ● Check to see if the matching mark of the oil pump body and control lever are aligned in a state where the throttle grip is completely rotated. ●...
  • Page 47 LUBRICATION SYSTEM OIL PUMP/OIL TUBE INSPECTION ● Fill the oil tank with engine oil. ● Cap around the oil pump and the carburetor with dry cloth. ● Locate the end of the oil tube in the level lower than the oil tank and drain the oil to bleed the air.

  • Page 48: Engine Oil Level Inspection

    LUBRICATION SYSTEM ● Connect the oil pump and then the carburetor quickly with the both ends of the tube pressed to avoid the air from entering. •Make sure that the tubes are arranged correctly. ● Start the engine. •Do not start the engine in the poorly-ventilated area. ●...

  • Page 49: Transmission Oil Inspection

    LUBRICATION SYSTEM ● Remove the oil tank cap and fill the oil tank with oil to the level of the projected portion RECOMMENDED OIL : ULTRA 2 SUPER OIL ● Reinstall the oil tank cap and check to see if the pilot lamp turns off when the main swich is turned on.

  • Page 50: Oil Tank Disassembly

    LUBRICATION SYSTEM OIL TANK DISASSEMBLY ● Remove the luggage box. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT ● Remove the oil level switch connector. FLANGE BOLT FLANGE BOLT FLANGE BOLT FLANGE BOLT...
  • Page 51 MEMO...
  • Page 52 FUEL SYSTEM FUEL GAUGE FUEL TANK FUEL AUTO COCK STRAINER CARBURETOR...

  • Page 53: Fuel System

    5. FUEL SYSTEM SERVICE INFORMATION CARBURETOR REMOVAL/ INSTALLATION TROUBLESHOOTING CARBURETOR INSPECTION FUEL TANK THROTTLE VALVE AIR CLEANER REMOVAL FUEL AUTO COCK AIR CLEANER ELEMENT DISASSEMBLY INLET PIPE REED VALVE SERVICE INFORMATION GENERAL SAFETY •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 54: 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 55: Fuel Tank

    FUEL SYSTEM FUEL TANK 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 FLANGE BOLT FLANGE BOLT REMOVAL •Gasoline is extremely flammable.

  • Page 56: Air Cleaner Removal

    FUEL SYSTEM AIR CLEANER REMOVAL FLANGE BOLT WASHER ● Loosen the air cleaner connecting bend screw pin. SCREW ● Loosen the 2 bottom air cleaner washer bolts. ● Loosen the top rear fender flange bolt. ● Remove the air cleaner from the carburetor. ●...
  • Page 57 FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY ● Remove the auto by starter cover. ● Loosen the 2 washer screws ● Remove the auto by starter set plate. WASHER SCREW ● Remove the auto by starter. AUTO BY ● Remove the auto by starter O-ring. STARTER COVER AUTO BY STARTER ●...

  • Page 58: Carburetor Inspection

    FUEL SYSTEM CARBURETOR PASSAGES CLEANING ● Disassemble all component parts of carburetor and then clean the air and fuel passages of carburetor body with compressed air. •Do not use it wire, otherwise the carburetor body and fuel pump get damaged. ●...

  • Page 59: Throttle Valve

    FUEL SYSTEM ● Connect the battery to the auto bystarter terminals and wait for 5 minutes. ● Insert a vinyl tube into the fuel increasing circuit and blow into the tube. ● Air should not flow into the circuit. If air flows into the circuit, replace the auto bystarter.

  • Page 60: Fuel Auto Cock

    FUEL SYSTEM FUEL AUTO COCK REMOVAL/INSTALLATION ● Remove - Luggage box. (⇨3-3) - Plug maintenance cover. (⇨3-3) - Center cover. (⇨3-3) - Rear carrier. (⇨3-3) - Body cover. (⇨3-3) - Fuel tube A, B connected to the carburetor. - Inlet pipe negative pressure tube. - Fuel tube A, B connected to the fuel tank.

  • Page 61: Inlet Pipe Reed Valve

    FUEL SYSTEM INLET PIPE•REED VALVE REMOVAL/INSTALLATION ● Remove - Luggage box. (⇨3-3) FLANGE FLANGE - Air cleaner. (⇨5-4) BOLT BOLT - Carburetor. (⇨5-4) - Negative pressure tube connected to the inlet pipe. - Oil pump cable. (⇨4-3) - Rear wheel mud guard. (⇨3-8) - Inlet pipe securing 4 flange bolts connected to the L crank case.
  • Page 62 ENGINE REMOVAL/INSTALLATION...

  • Page 63: Engine Removal/Installation

    6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL/INSTALLATION ENGINE HANGER LINK REMOVAL SERVICE INFORMATION GENERAL SAFETY •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 64 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION OIL TUBE CAP TOP ● Remove - Luggage box. (⇨3-3 ) - Plug maintenance cover. (⇨3-3 ) - Center cover. (⇨3-3 ) ● Disconnect - AC generater coupler. (⇨13-7 ) - Carburetor auto bystarter coupler. ● Remove - Spark plug cap.
  • Page 65 ENGINE REMOVAL/INSTALLATION ● Check the following after the engine is assembled. -Electric systems. -Adjust of the rear brake free play. -Inspection of the throttle cable operation. -Inspection of the oil pump cable operation.
  • Page 66 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION SHOE SPRING GUIDE PIN CLUTCH SHOE CLUTCH OUTER MOVABLE DRIVEN MOVABLE DRIVEN FACE DRIVE PLATE FACE SPRING DRIVEN FACE DRIVE BELT DRIVE FACE KICK DRIVEN GEAR DRIVE FACE BOSS RAMP PLATE WEIGHT ROLLER MOVABLE DRIVE FACE KICK STARTER SPINDLE KICK STARTER RETURN SPRING KICK SPINDLE BUSH...

  • Page 67: Kick Starter/Continuously Variable Transmission

    7. KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION SERVICE INFORMATION DRIVE BELT TROUBLESHOOTING DRIVE PULLEY L. SIDE COVER REMOVAL CLUTCH/DRIVEN PULLEY KICK STARTER SERVICE INFORMATION GENERAL SAFETY ● Do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil contact.
  • Page 68 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION L. SIDE COVER REMOVAL ● Remove - 13 flange bolts securing L. side cover. - Rear brake cable clamp. - L. side cover gasket. - Dowel pin. ● Install in the reverse order of removal. L. SIDE COVER FLANGE BOLT ·Install the new gasket and dowel pin after removing the gasket of the crankcase surface.
  • Page 69 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION KICK STARTER INSTALLATION INSTALL ● Kick spindle bush, spring in the L. side cover. ● Kick starter spindle in the L. side cover. ● Kick starter spindle washer. ● 14mm external circlip in the L. side cover. ●...

  • Page 70: Drive Belt

    KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE BELT REMOVAL ● Remove the L. side cover. ( 7-2 ) ● Hold the clutch outer using the universal holder and remove the nut. ● Remove the clutch outer. TOOL: UNIVERSAL HOLDER ·Use the special tool when loosening the lock nut. L.
  • Page 71 ● Replace the belt if the service limit is exceeded. SERVICE LIMIT : 16.5mm ·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.
  • Page 72 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE PULLEY REMOVAL ● Remove the L. side cover. ( 7-2 ) ) X h @ ) X ? g @ V / X g @ ? V / X ? f @ @ @ @ @ @ @ @ @ @ @ ? ? V / X f @ ? h f V / X ? e @ ? h f ? V / X e N 1 e...
  • Page 73 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION MOVABLE DRIVE FACE INSPECTION ● The weight rollers push on the movable drive pulley face (by centrifugal force); worn or damaged weight rollers will interfere with this force. ● Check the rollers for wear or damage and replace as necessary.
  • Page 74 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE FACE INSTALLATION ● Squeeze the drive belt into the pulley groove and pull the drive belt over the drive face shaft. ● Hold the drive pulley face using the clutch center holder and tighten the nut to the specified torque. TORQUE VALUE : 5.5kgf·m TOOL : CLUTCH CENTER HOLDER ●...
  • Page 75 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION 28mm SPECIAL NUT DISASSEMBLY ● The clutch/driven face are assembled toward the clutch spring compressor. ·Make sure that the boss portions of the clutch/driven face are matched with the clutch spring compressor hole. TOOL : CLUTCH SPRING COMPRESSOR ●...
  • Page 76 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Clutch Shoe Inspection ● Measure the thickness of each shoe ; replace if the service limit is exceeded. SERVICE LIMIT : 2.0mm Movable Driven Face Spring Inspection ● Measure the free length of the driven pulley spring and replace if the service limit is exceeded.
  • Page 77 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH SHOE REPLACEMENT ● Remove the E-clip and washers, then remove the clutch shoes and shoe springs from the drive plate. ·Some models use one retainer plate instead of three washers. ● Check the shoe springs for damage or loss of tension. ●...
  • Page 78 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION ● Install the E-clip and washers or retainer plate into the pivot pins. ·Apply only to the belt type gearless transmission. ·Wipe the grease came out from the pivot pin thoroughly. DRIVEN FACE BEARING REPLACEMENT ● Remove the inner bearing ·If the driven face has an oil seal at inner bearing side, remove the oil seal first.
  • Page 79 KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION CLUTCH/DRIVEN PULLEY ASSEMBLY ● Install new oil seals and O-rings on the movable driven pulley face. ●Lubricate the inside of the movable face with the specified amount of grease. GREASE APPLICATION : 5.0~5.5g ● Install the movable face on the driven pulley face. ●...
  • Page 80 CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD BOLT CYLINDER HEAD CYLINDER HEAD GASKET CYLINDER TOP RING SECOND RING EXPANDER CYLINDER GASKET STOPPER PIN PISTON CLIP PISTON PIN NEEDLE BEARING...

  • Page 81: Cylinder Head/Cylinder/Piston

    8. CYLINDER HEAD/CYLINDER/PISTON SERVICES INFORMATION TROUBLESHOOTING FAN COVER, SHROUD REMOVAL CYLINDER HEAD/ CYLINDER/ PISTON SERVICE INFORMATION GENERAL SAFETY ● Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling pin by striking the cylinder too hard.
  • Page 82 CYLINDER HEAD/CYLINDER/PISTON FAN COVER, SHROUD REMOVAL REMOVE ● Luggage box. ( 3-3 ) ● Plug maintenance cover. ( 3-3 ) ● Center cover. ( 3-3 ) ● Floor side cover. ( 3-4 ) ● Floor panel. ( 3-4 ) ● Plug cap. BOLT BOLT BOLT...
  • Page 83 CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD/ CYLINDER/ PISTON REMOVAL ● Luggage box. ( 3-3 ) ● Plug maintenance cover. ( 3-3 ) ● Center cover. ( 3-3 ) ● Floor side cover. ( 3-4 ) ● Floor panel. ( 3-4 ) ● Exhaust muffler assembly. ( 3-7 ) ●...
  • Page 84 CYLINDER HEAD/CYLINDER/PISTON REMOVE ● Piston. ● Piston ring. ● Expander. ● Needle bearing from the small end of the connecting rod. BEARING ·Do not damage or scratch the piston. ·Do not apply side force to the connecting rod. ·Do not let the clip fall into the crankcase. ·Mark and store the pistons and piston pins so that they can be reinstalled in their original positions.
  • Page 85 CYLINDER HEAD/CYLINDER/PISTON Cylinder Wear Inspection ● Inspect the cylinder wall for scratches and wear. ·Inspect the area near T.D.C (Top Dend Center) carefully. This area is especially subject to wear due to the possibility of borderline lubrication fro heat and top ring compression. ●...
  • Page 86 CYLINDER HEAD/CYLINDER/PISTON Piston Pin Inspection ● Measure the piston pin O.D. at three points. ● Replace the piston pin if the service limit is exceeded. SERVICE LIMIT : 11.98mm Piston Pin Bore Inspection ● Measure the piston pin bore I.D. in an X and Y axis. Take the maximum reading to determine the I.D.
  • Page 87 CYLINDER HEAD/CYLINDER/PISTON ● Coat the needle bearing (2-stroke engine only) and piston pin with the recommended oil. Lubricate the piston pin 2-Stroke engine : Recommended engine oil. ·Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase. ●...
  • Page 88 TRANSMISSION/CRANKSHAFT/CRANKCASE R.CRANK CASE CRANKSHAFT L.CRANK CASE COUNTER GEAR FINAL GEAR COUNTER SHAFT MISSION COVER DRIVE SHAFT...

  • Page 89: Transmission/Crankshaft/Crankcase

    9. TRANSMISSION/CRANKSHAFT/CRANKCASE SERVICE INFORMATION CRANKSHAFT REMOVAL TROUBLESHOOTING CRANKCASE BEARING REMOVAL 9-6 TRANSMISSION CRANKSHAFT INSTALLATION SERVICE INFORMATION GENERAL SAFETY ● This section describes how to remove the crank case and to maintain the transmission and the crankshaft. ● Always use special tools to change the drive shaft. Fix the bearing inner race, andn install the shaft. ●...
  • Page 90 TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION DISASSEMBLY ● Remove - L. side cover. ( 7-2 ) - Continuously variable transmission. ( SECTION 7 ) - Exhaust muffler. ( 3-7 ) - Rear wheel. ( 11-3) ● Install the oil sump under the cover of transmission. ●...
  • Page 91 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Inspect the final shaft for wear or damage. FINAL GEAR ● Inspect the countershaft for wear or damage. COUNTER SHAFT COUNTER GEAR Bearing Inspection ● Manually turn the bearing inner race installed inside 6203 the transmission cover, and check if the race is turning BEARING smoothly.
  • Page 92 TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION ASSEMBLY ● Install the drive shaft on the transmission cover. ● Install a new drive shaft oil seal. TOOL : CRANK ASSEMBLY ● Install the thrust washer, final gear and counter gear, FINAL GEAR side washer on the L. crankcase. COUNTER GEAR ●...
  • Page 93 TRANSMISSION/CRANKSHAFT/CRANKCASE CRANKSHAFT REMOVAL ● Loosen the 6 R. crankcase flange bolts. ● Secure a crankcase puller on the R. crankcase and remove the R. crankcase from the L. crankcase. TOOL : CRANKCASE PULLER(0751-00003) ● Secure a crankcase puller on the L. crankcase and remove the crankshaft from the L.
  • Page 94 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Measure the side gap between the connecting rod big end and the crank weight. SERVICE LIMIT : 0.6mm ● Check the vertical shaft play of the connecting rod big end from the X and Y direction. SERVICE LIMIT : 0.05mm CRANKCASE BEARING REMOVAL ●...
  • Page 95 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Apply clean engine oil to a new bearing, and assemble it to the crank case. ● Install a new final gear oil seal. CRANKSHAFT INSTALLATION DRIVER ● Apply clean engine oil to the new R. crankshaft HANDLE A bearing, and press in the bearing into the R.
  • Page 96 TRANSMISSION/CRANKSHAFT/CRANKCASE ● Apply a liquid gasket to the L. crankcase joining face, install the dowel pins. ● Install the R. crankcase. CRANKSHAFT ● Install the 6 flange bolts. ASSEMBLER ·Make sure that there is no adhesion of gasoline to the R., L.
  • Page 97 MEMO...
  • Page 98 FRONT WHEEL/FRONT FORK/STEERING STEERING HANDLE STEERING STEM FRONT FORK FRONT BRAKE DISK FRONT TIRE FRONT CASTING WHEEL 10-0...

  • Page 99: Front Wheel/Front Fork/Steering

    10. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION 10-1 TUBELESS TIRE 10-9 TROUBLESHOOTING 10-2 FRONT FORK 10-14 STEERING HANDLE 10-3 STEERING STEM 10-20 FRONT WHEEL 10-5 SERVICE INFORMATION GENERAL SAFETY ● Keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance.

  • Page 100: Troubleshooting

    FRONT WHEEL/FRONT FORK/STEERING TROUBLESHOOTING Hard steering ● Steering bearing adjustment nut too tight. ● Faulty steering stem bearings. ● Damaged steering stem bearings. ● Insufficient tire pressure. Steers to one side or does not track straight ● Unevenly adjusted right and left shock absorbers. ●...

  • Page 101: Steering Handle

    FRONT WHEEL/FRONT FORK/STEERING 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 102 STEERING HANDLE STEERING HANDLE STEERING HANDLE ● Apply DAELIM Bond A to the inside surface of the grip and to the clean surface of the left handle bar. Wait 3~6 minutes and install the grip. (Bond A :ROYAL BOND 1300) ·Clean the bonding surface to avoid oil, grease or...

  • Page 103: Front Wheel

    FRONT WHEEL/FRONT FORK/STEERING FRONT WHEEL SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE SPEEDOMETTER CABLE REMOVAL ●...
  • Page 104 FRONT WHEEL/FRONT FORK/STEERING Bearing Inspection ● Manually turn the bearing inner race, and replace if it makes noise or is worn. Check if the bearing outer race is accurately fitted into the wheel hub, and replace worn ones. ·Replace bearings in pairs (left and right set). FRONT WHEEL DISASSEMBLY ●...
  • Page 105 FRONT WHEEL/FRONT FORK/STEERING WHEEL BEARING REPLACEMENT BEARING REMOVER HEAD ● Install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance collar. BEARING ·Always replace bearings in pairs, and never use old REMOVER bearings.
  • Page 106 FRONT WHEEL/FRONT FORK/STEERING TIRE DISTANCE COLLAR RADIAL BEARING SPEEDOMETER GEAR BOX R. SIDE COLLAR BRAKE DISK RADIAL BEARING OIL SEAL AXLE FRONT WHEEL ASSEMBLY ● Apply grease to the right side dust seal rim. ● Install the right side dust seal. ●...

  • Page 107: Tubeless Tire

    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 TUBELESS TIRE REMOVAL ●...
  • Page 108 FRONT WHEEL/FRONT FORK/STEERING ● Be sure that the bead is completely collapsed. ● In case of the tube type tire, insert the tire lever from the opposite side of the valve and raise the bead over the rim. ● On tubeless tires, insert the tire lever from the valve side and raise the bead over the rim.
  • Page 109 FRONT WHEEL/FRONT FORK/STEERING RIM VALVE REPLACEMENT ● Cut off the rim valve at its base. ● Apply mild detergent solution to a replacement rim valve and insert it from inside of the rim. ·Be sure to use the recommended rim valve. ·Do not damage the valve hole.
  • Page 110 FRONT WHEEL/FRONT FORK/STEERING ● If the tire has an light mark (yellow paint mark), install the tire with this mark aligned with the valve. ● If the tire has an arrow mark, install the tire with the mark pointing in the direction of rotation. ●...
  • Page 111 FRONT WHEEL/FRONT FORK/STEERING ● After 3/4 of the bead has been installed, check the bead on the opposite side. Be sure it is still in the center of the rim. ·The last portion of the bead is more difficult to install.

  • Page 112: Front Fork

    FRONT WHEEL/FRONT FORK/STEERING ·For tubeless tires, you may hear a loud sound as the bead seats onto the rim. This is normal. ·For tubeless tires, if air leaks out from between the rim and bead, let the wheel stand with the valve at the bottom and put air in while pushing down on the tire.
  • Page 113 FRONT WHEEL/FRONT FORK/STEERING ● Loosen the 2 steering stem front fork R., L. stay bolts. ● Remove the front fork. 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 114 FRONT WHEEL/FRONT FORK/STEERING ·If the socket bolt turns idle but cannot be removed, temporarily assemble the spring and the fork tube cap bolt first. ·Hold the bottom case firmly with a vise, taking precautions not to distort or damage it. ●...

  • Page 115: Front Fork Inspection

    FRONT WHEEL/FRONT FORK/STEERING ● Remove the fork tube from the bottom case. ● Remove the piston and rebound spring from the fork tube. FRONT FORK INSPECTION ● Place the fork spring on a level place, and measure the free length. ●...
  • Page 116 FRONT WHEEL/FRONT FORK/STEERING ● Wrap the bottom case with a piece of cloth, and fix it to the vise. ● Apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. TORQUE VALUE : 2.0kgf·m ·When a vise is used to hold the bottom case, do not insert the case itself but insert the bracket.
  • Page 117 FRONT WHEEL/FRONT FORK/STEERING ● Assemble the spring to the fork pipe. FREE LENGTH ·Install the spring with the smaller pitch side facing downward. FORK SPRING ● Assemble the fork bolt to the fork tube. FORK BOLT FRONT FORK INSTALLATION ● Install the front fork to the steering stem. STEERING STEM STEERING STEM STEERING STEM...

  • Page 118: Steering Stem

    FRONT WHEEL/FRONT FORK/STEERING STEERING STEM REMOVAL ● Front cover. ● Front fender. STEERING LOCK ● Front handle cover/rear handle cover. NUT SOCKET ● Steering handle. ● Front wheel. ● Front brake caliper. ● Front fork. ● Loosen the steering stem lock nut. ●...
  • Page 119 FRONT WHEEL/FRONT FORK/STEERING ● Remove the upper ball race/ steering bottom cone race. TOOL : BALL RACE DRIVER ·Check all of the races and balls for damage or abnormal wear and replace as necessary. BALL RACE ·If the vehicle has been involved in a collision, the DRIVER steering stem may be damaged.
  • Page 120 FRONT WHEEL/FRONT FORK/STEERING ● Install the top cone race and the steering head top thread nut on the steering head. ● Tighten the top thread nut completely, and loosen by 1/8 turn. STEERING LOCK TORQUE VALUE : 1.0㎏f·m NUT SOCKET ●...

  • Page 121: Rear Wheel/Brake/Suspension

    11. REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 11-1 REAR BRAKE 11-4 TROUBLESHOOTING 11-2 REAR CUSHION 11-6 REAR WHEEL 11-3 SERVICE INFORMATION GENERAL SAFETY ● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.
  • Page 122 REAR WHEEL/BRAKE/SUSPENSION 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 ● Weak springs ● Rear damper improperly adjusted, oil leakage Hard suspension ●...

  • Page 123: Rear Wheel

    REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL ● Support the motor cycle on the main stand. ● Loosen the rear brake adjuster, and remove the brake cable. ● Remove the brake arm joint B. BRAKE ARM JOINT B ADJUST NUT ● Remove U NUT - Muffler.

  • Page 124: Rear Brake

    REAR WHEEL/BRAKE/SUSPENSION ● Insert the washer, and tighten with the U nut. U NUT TORQUE VALUE : 6.0~8.0kgf·m INSTALL ● Brake arm joint B. ● Rear brake cable. ● Rear brake rod adjusting nut. ● Rear wheel mud guard. ● Muffler. ADJUST NUT REAR BRAKE ●...
  • Page 125 REAR WHEEL/BRAKE/SUSPENSION REAR BRAKE DISASSEMBLY ● Manually open the brake shoe and remove it. BRAKE SHOE ● Remove the shoe spring from the brake shoe. SHOE SPRING SHOE SPRING BRAKE CAM BRAKE SHOE ● Loosen the rear brake arm fixing bolt. ●...

  • Page 126: Rear Cushion

    REAR WHEEL/BRAKE/SUSPENSION REAR CUSHION REMOVAL ● Remove the plug maintenance cover/ center cover. REAR CUSHION ( 3-3 ) SETTING ● Remove the luggage box. ( 3-3 ) BOLT ● Remove the body cover. ( 3-3 ) ● Loosen the top and bottom rear cushion setting bolts. ·Support the frame firmly prior to working.
  • Page 127 REAR WHEEL/BRAKE/SUSPENSION REAR CUSHION ASSEMBLY/INSTALLATION ● Assemble the spring, spring guide, and stopper rubber. ·Install the spring with its narrow pitch side facing upward ● Apply thread locking agent to the lock nut, and install the rear cushion compressor attachment on the damper rod.
  • Page 128 BRAKE SYSTEM 12-0...

  • Page 129: Brake System

    12. BRAKE SYSTEM SERVICE INFORMATION 12-1 BRAKE DISK INSPECTION 12-6 TROUBLESHOOTING 12-1 BRAKE CALIPER 12-7 BRAKE FLUID/BLEEDING 12-3 MASTER CYLINDER 12-9 BRAKE PAD REPLACEMENT 12-4 SERVICE INFORMATION GENERAL SAFETY ● Do not allow foreign material to enter the system when replenishing brake fluid. ●...
  • Page 130 BRAKE SYSTEM MECHANICAL DRUM BRAKE Poor brake performance ● Improperly adjusted brake ● Worn brake linings ● Worn brake drum ● Worn brake cam ● Improperly installed brake linings ● Brake cable sticking/needs lubrication ● Contaminated brake linings ● Contaminated brake drum ●...
  • Page 131 BRAKE SYSTEM BRAKE FLUID/BLEEDING 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 BRAKE FLUID CHANGE ·A contaminate disk or pad reduces braking power.
  • Page 132 BRAKE SYSTEM ● If the brake bleeder is not used, do the following, 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 133 BRAKE SYSTEM ● Loosen the 2 front brake caliper fixing bolts from the 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 FLANGE BOLT...
  • Page 134 BRAKE SYSTEM ● Install the brake caliper into the left front fork. 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 FLANGE BOLT...
  • Page 135 BRAKE SYSTEM BRAKE CALIPER REMOVAL ● Remove the brake oil bolts and the brake hose from the brake caliper. ● Remove the caliper from the L. front fork and remove the pad spring, hanger pin and brake pad. OIL BOLT OIL BOLT OIL BOLT OIL BOLT...

  • Page 136: Brake Caliper Inspection

    BRAKE SYSTEM BRAKE CALIPER INSPECTION Caliper Cylinder ● Check the caliper cylinder bore for scoring, scratches or other damage. ● Measure the caliper cylinder I.D. in X and Y axis at serveral points. ● Replace the caliper cylinder if the largest measurement is beyond the specified service limit.
  • Page 137 BRAKE SYSTEM ● Connect the brake hose to the caliper, and install 2 sealing washers and the brake hose bolt. TORQUE : 3.5kgf·m ● Install the slide pin cap. OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT OIL BOLT...

  • Page 138: Master Cylinder Inspection

    BRAKE SYSTEM ● Remove the washer, piston, spring from the master MASTER cylinder. CYLINDER SET ● Clean the master cylinder, reserve, master piston with the recommended brake fluid. MASTER CYLINDER HOLDER PISTON BOOT CIR CLIP MASTER CYLINDER INSPECTION ● Check the piston periphery for kink or scratch. ●...
  • Page 139 BRAKE SYSTEM ● Install the primary cup with its concaved side toward the inner side of the master cylinder. ● Install the snap ring. TOOL : SNAP RING PLIERS ·When installing the cups, do not allow the lips to turn inside out.
  • Page 140 MEMO...

  • Page 141: Charging System/A.c.generator

    13. CHARGING SYSTEM/A.C.GENERATOR SERVICE INFORMATION 13-1 CHARGING SYSTEM INSPECTION 13-4 CHARGING DEVICES LOCATION 13-2 HEADLIGHT VOLTAGE INSPECTION 13-6 TROUBLESHOOTING 13-3 REGULATOR/RECTIFIER INSPECTION 13-6 BATTERY REMOVAL/INSTALLATION 13-4 A.C. GENERATOR 13-7 BATTERY INSPECTION 13-4 RESISTER INSPECTION 13-9 SERVICE INFORMATION ·Do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery.

  • Page 142: Charging Devices Location

    CHARGING SYSTEM/A.C.GENERATOR CHARGING DEVICE LOCATION START SWITCH RESISTOR AUTO BY STARTER 5W 6.7 WINKER REALY, ASS’Y COMB. & LOCK SW REGULATOR RECTIFIER CDI UNIT STARTER REALY, ASS’Y WIRE HARNESS IG COIL ACG. CORD COUPLER A.C.GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS’Y BATTERY ASS’Y WHITE GREEN...

  • Page 143: Troubleshooting

    CHARGING SYSTEM/A.C.GENERATOR TROUBLESHOOTING Battery is Overcharged ● Headlight bulb is out. ● No headlignt beam wire. ● Headlight register is damaged (disconnected). ● Lighting switch is connected incorrectly. ● Regulator/rectifier is not grounded or connected incorrectly. Problems with the Charging System Measure battery voltage leakage.

  • Page 144: Battery Removal/Installation

    - FULLY CHARGED : 13.0-13.2V - INSUFFICIENTLY CHARGED : Under 12.3V ·Use a digital voltmeter when measuring charge level. : DAELIM PVA multi-tester ·Take special care not to deform the battery terminals. TOOL : DIGITAL CIRCUIT TESTER CHARGING SYSTEM INSPECTION LEAK TEST ●...

  • Page 145: Battery Charging

    CHARGING SYSTEM/A.C.GENERATOR ·Check with fully charge the battery which has the voltage between terminal of 13.0~13.2V. ·In case that the engine is started by the starter motor, measurement must be performed after accelating (charging) for 10 seconds. CHARGING CURRENT CHECK ●...

  • Page 146: Headlight Voltage Inspection

    CHARGING SYSTEM/A.C.GENERATOR HEADLIGHT VOLTAGE INSPECTION ● Remove the front cover. ( 3-5) ·Check voltage with the headlight coupler connected. ● After starting the engine, place the dimmer switch to HI and check the voltage between the blue (+) and green (-) wires of the headlight coupler. ·Measurement is performed in AC area.

  • Page 147: Generator

    CHARGING SYSTEM/A.C.GENERATOR A.C. GENERATOR REMOVE ● Luggage box. ( 3-3 ) ● Plug maintenance cover. ( 3-3 ) ● Center cover. ( 3-3 ) ● Floor side cover. ( 3-4 ) ● Floor panel. ( 3-4 ) ● Engine hanger side RH. cover. ( 3-5 ) ●...

  • Page 148: Flywheel Installation

    CHARGING SYSTEM/A.C.GENERATOR STATOR INSTALLATION ● Note the direction of stator, and install the stator on the crankcase. INSTALL ● Grommet to R. crankcase cover. ● A.C. generator wire coupler to wire harness. ● Connector to starter motor, then install the ground wire. STATOR COMP.

  • Page 149: Resister Inspection

    CHARGING SYSTEM/A.C.GENERATOR A.C. GENERATOR(CHARGING COIL) INSPECTION ·This test is done with the starter mounted to the engine. ● Remove the luggage box. ( 3-3 ) ● Disconnect the AC generator coupler. ( 3-3 ) COUPLER ● Measure the resistance of the charging coil (between the white wire and ground) and the lighting coil (between the yellow wire and ground).
  • Page 150 MEMO...

  • Page 151: Ignition System

    14. IGNITION SYSTEM SERVICE INFORMATION 14-1 EXCITE COIL INSPECTION 14-6 IGNITION DEVICES LOCATION 14-2 PULSE GENERATOR INSPECTION 14-6 TROUBLESHOOTING 14-3 IGNITION TIMING INSPECTION 14-7 IGNITION SYSTEM INSPECTION CDI UNIT 14-7 (PEAK VOLTAGE MEASUREMENT) 14-4 SIDE STAND IGNITION IGNITION COIL 14-5 CUT-OFF SWITCH 14-8 SERVICE INFORMATION...

  • Page 152: Ignition Devices Location

    IGNITION SYSTEM IGNITION DEVICES LOCATION START SWITCH RESISTOR AUTO BY STARTER 5W 6.7 WINKER REALY, ASS’Y COMB. & LOCK SW REGULATOR RECTIFIER CDI UNIT STARTER REALY, ASS’Y WIRE HARNESS IG COIL ACG. CORD COUPLER A.C.GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS’Y BATTERY ASS’Y GREEN BLUE / YELLOW...

  • Page 153: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING Spark plug does not emit sparks. ABNORMAL STATE POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER) 1. Using a tester with a low internal resistance. 2. Cranking speed is low. - Battery is low or kick power is weak. 3.

  • Page 154: Ignition System Inspection (Peak Voltage Measurement)

    ● Connect the peak voltage adaptor to the digital tester. DAELIM PVA MULTI TESTER IGNITION COIL PRIMARY VOLTAGE ·Make sure each wire is correctly connected to ensure correct measurement.

  • Page 155: Ignition Coil

    IGNITION SYSTEM PULSE GENERATOR ·Inspect with the spark plug assembled and while there is compression pressure. ● Remove the CDI unit. ( 14-7 ) ● Remove the coupler from the CDI unit and connect the peak voltage adaptor to the pulse generator wire (blue/ yellow and green) of harness coupler.

  • Page 156: Excite Coil Inspection

    IGNITION SYSTEM INSPECTION (RESISTANCE MEASUREMENT) ● Remove the luggage box. ( 3-3 ) ● Measure primary coil resistance between the green and black/yellow terminals. STANDARD VALUE : 0.1~0.5Ω(20℃) ● Measure the secondary coil resistance between the plug cap and green wire terminals. RESISTANCE VALUE (SPARK PLUG CAP CONNECTION) : 6.5~9.5 ㏀...

  • Page 157: Ignition Timing Inspection

    IGNITION SYSTEM IGNITION TIMING INSPECTION TIMING LIGHT ·As a CDI device is used in this vehicle, there is no need for adjusting ignition timing. If ignition timing problems occur, inspect the CDI unit and the AC generator and replace if any malfunctions are found in the devices.
  • Page 158 MEMO...

  • Page 159: Starting System

    15. STARTING SYSTEM SERVICE INFORMATION 15-1 STARTER MOTOR 15-4 STARTING DEVICES LOCATION 15-2 STARTER RELAY INSPECTION 15-7 TROUBLESHOOTING 15-3 STARTER PINION GEAR INSPECTION 15-7 SERVICE INFORMATION GENERAL SAFETY ·When performing maintenance on the starter motor and related parts, turn the main switch to OFF. There is the danger of the starter motor unexpectedly operating if the main switch is not turned to OFF.
  • Page 160 STARTING SYSTEM STARTING DEVICES LOCATION START SWITCH RESISTOR AUTO BY STARTER 5W 6.7 WINKER REALY, ASS’Y COMB. & LOCK SW REGULATOR RECTIFIER CDI UNIT STARTER REALY, ASS’Y WIRE HARNESS IG COIL ACG. CORD COUPLER A.C.GENERATOR HIGH TENSION CORD SPARK PLUG CAP ASS’Y BATTERY ASS’Y MAIN SWITCH RED/WHITE...
  • Page 161 STARTING SYSTEM TROUBLESHOOTING Starter motor does not rotate (No response from starter motor). ● Check to see if the fuse is burned out. With the main switch turned to ON, squeeze Remove the starter motor “⊕” wire, connect the brake lever. In this state push the starter it to the battery “⊕”...

  • Page 162: Starter Motor

    STARTING SYSTEM STARTER MOTOR REMOVAL/INSTALLATION REMOVE ● Luggage box. ( 3-3 ) STARTER MOTOR ● Center cover. ( 3-3 ) ● Floor side RH. cover. ( 3-4 ) ● Engine hanger side cover RH. ( 3-5 ) ● Disconnect the starter wire connector, remove the wire from the wire fixing clamp.
  • Page 163 STARTING SYSTEM ● Check the commutator for : -Damage or abnormal wear. → Replace with a new one. -Discoloration of the commutator bar. → Replace with a new one. -Metallic debris between commutator bars.→ Clean it off. COMMUTATOR ● Check for continuity between pairs of commutator bars.
  • Page 164 STARTING SYSTEM ● Insert the brush spring into the brush holder and install the front bracket. ·Insert the brush spring with care so that it does not lean in the holder. BRUSH HOLDER ● Apply grease to both ends of the armature shaft. GREASE ●...

  • Page 165: Starter Relay Inspection

    STARTING SYSTEM STARTER RELAY INSPECTION ● Remove the luggage box. ( 3-3 ) ● When battery voltage is applied between the starter relay green/yellow wire and yellow/red terminals, there should be continuity between the red and red/white terminals. The terminals are distinguished by the corresponding wire color of the wire harness connector.
  • Page 166 MEMO...

  • Page 167: Lights/Meter/Switches

    16. LIGHTS/METER/SWITCHES SERVICE INFORMATION 16-1 HANDLE SWITCH INSPECTION 16-4 TROUBLESHOOTING 16-1 FRONT STOP SWITCH INSPECTION 16-4 FUEL UNIT 16-2 BULBS REPLACEMENT 16-5 OIL LEVEL SWITCH 16-3 METER REPLACEMENT 16-7 MAIN SWITCH 16-3 HORN INSPECTION 16-7 SERVICE INFORMATION GENERAL SAFETY ● Refer to tester owner’s manuals when performing continuity inspections. ●...

  • Page 168: Fuel Unit

    LIGHTS/METER/SWITCHES FUEL UNIT REMOVAL ● Remove the luggage box. ( 3-3 ) ● Remove the fuel unit wire from the wire harness. ● Turn the fuel unit fixing unit set cap comp to the left, and remove it. ● Remove the fuel unit from the fuel tank. ·Be careful of prevention the fuel unit wire from damaging.

  • Page 169: Oil Level Switch

    LIGHTS/METER/SWITCHES OIL LEVEL SWITCH REMOVAL/INSTALLATION REMOVE ● Luggage box. ( 3-3 ) ● Oil level switch wire. ● Oil level switch from the oil tank. ● Install in the reverse order of remeval. OIL LEVEL ·Disassemble after adjusting the oil level. SWITCH INSPECTION ●...

  • Page 170: Handle Switch Inspection

    LIGHTS/METER/SWITCHES HANDLE SWITCH INSPECTION REMOVE ● Front handle cover. ( 3-6 ) ● Handle switch coupler, connector, inspect continuity of each terminal. ● If abnormal, inspect the switch. STARTER SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH LIGHTING SWITCH...

  • Page 171: Bulbs Replacement

    LIGHTS/METER/SWITCHES BULBS REPLACEMENT HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER HEADLIGHT RUBBER COVER...
  • Page 172 LIGHTS/METER/SWITCHES REAR WINKER BULB REPLACEMENT TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB TAILLIGHT BULB ●...

  • Page 173: Horn Inspection

    LIGHTS/METER/SWITCHES ● Roose the 3 tapping screws securing the speedometer 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 FLANGE BOLT FLANGE BOLT...
  • Page 174 MEMO...

  • Page 175: Wiring Diagram

    17. WIRING DIAGRAM 17-1...
  • Page 176 MEMO...

  • Page 177: Troubleshooting

    18. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 18-1 ENGINE OUTPUT INSUFFICIENT 18-2 POOR PERFORMANCE AT LOW SPEED AND IDLING 18-3 POOR PERFORMANCE AT HIGH SPEED 18-3 UNSATISFACTORY OPERATION 18-4 FUEL GAUGE 18-6 STARTER MOTOR 18-7 ENGINE DOES NOT START OR IS HARD TO START CAUSE OF TROUBLE 1.
  • Page 178 TROUBLESHOOTING ENGINE OUTPUT INSUFFICIENT CAUSE OF TROUBLE 1. Gently accelerate engine. Engine speed does not (1) Air cleaner clogged. increase sufficiently. (2) Insufficient fuel supply. Engine speed increases. (3) Fuel tank cap air hole clogged. (4) Muffler clogged. 2. Check ignition timing. Abnormal (1) Faulty CDI unit.
  • Page 179 TROUBLESHOOTING POOR PERFORMANCE AT LOW SPEED AND IDLING CAUSE OF TROUBLE 1. Check ignition timing. Abnormal (1) Faulty CDI unit. Normal 2. Check the carburetor air screw. Incorrect (1) Excessive fuel mixture. (Loosen screw to correct Correct adjustment level.) (2) Lean fuel mixture. (Tighten screw to correct adjustment level.) 3.
  • Page 180 TROUBLESHOOTING UNSATISFACTORY OPERATION CLUTCH DRIVE/DRIVEN PULLEY CAUSE OF TROUBLE (1) Drive belt worn or slips. 1. Engine starts but motorcycle does not move. (2) Ramp plate damaged. (3) Drive face spring damaged. (4) Clutch lining came off. (5) Driven pulley shaft spline damaged. (6) Faulty transmission.
  • Page 181 TROUBLESHOOTING Check tire pressure. POOR FRONT/REAR SUSPENSION PERFORMANCE CAUSE OF TROUBLE (1) Cushion spring weak. 1. Suspension excessively soft. (2) Overloaded. (3) Damper oil leaks. 2. Suspension excessively hard. (1) Fork pipe or cushion rod bent. (1) Sliders stuck. 3. Noise from the suspension. (2) Cushion stopper rubber damaged.

  • Page 182: Fuel Gauge

    TROUBLESHOOTING FUEL GAUGE GAUGE READING INACCURATE (IGNITION SWTICH ON) CAUSE OF TROUBLE (1) Fuse cut. 1. Operate the turn signal to check the Signal continuously battery circuit. operates dim or does not (2) Battery weak or totally discharged. (3) Faulty ignition swtich. operate at all.
  • Page 183 TROUBLESHOOTING STARTER MOTOR STARTING MOTOR WILL NOT TURN CAUSE OF TROUBLE (1) Fuse cut. 1. Apply the brake and check the brake Light not activated. stop light for operation. (2) Battery weak or totally discharged. (3) Faulty stop switch. Light is activated. (4) Faulty terminal connection.
  • Page 184 MEMO...
  • Page 185 SERVICE MANUAL 2005. 6. PRINTED NO COPY 2005. 6. PUBLICATION...
  • Page 186 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 SM52-0506-01E...

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