DAELIM S2-250, Service Manual

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Page 2: ...f you cannot find the cause of trouble refer to Section 18 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No p...

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Page 4: ...ays put on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must performed in the place free of the open fire or ele...

Page 5: ...e bigger diameter to the smaller one from inside to outside and diagonally with the specified torque 5 Clean the parts after the overhaul and before the test and remove the cleaning oil with compresse...

Page 6: ...rection in case of the single sided sealed ball bearing Install the open direction or double sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer...

Page 7: ...ll the oil seal so that the manufacturer marked surface directs outer surface direction not covered with oil Pay attention not to bend or damage the lip Apply the grease to the lip 20 Connect the tube...

Page 8: ...er in case of water proof coupler Recheck the condition of contact securing and continuity of each part after maintenance When connecting the battery the plus terminal must be connected first After co...

Page 9: ...following When disconnecting the coupler disconnect it while holding the coupler body Pull while holding the wire harness cord and do not remove the coupler connection Release the lock by inserting t...

Page 10: ...ng T start broaden the groove of T start using the wiring driver and release the torque Connect the harness and the hose to T start and then insert until the groove is locked When removing T start fro...

Page 11: ...ess not to be pulled or expended when the handle is turned to the right or the left completely Avoid excessive bending or chewing and interference with the engine Prior to using the tester please read...

Page 12: ...1 9 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

Page 13: ...rpm 8 BTDC 42 ABDC 33 BBDC 1 ATDC 0 1 mm 0 1 mm OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION STROKE REAR SUSPENSIO...

Page 14: ...ET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING F MARK BATTERY TYPE CAPACITY SPARK PLUG SPARK PLUG GAP STARTING...

Page 15: ...gf m 0 25 kgf m 7 5 kgf m 6 0 kgf m 6 0 kgf m 3 1 kgf m 1 2 kgf m 4 25 kgf m 12 5 kgf m 3 1 kgf m 1 2 kgf m 4 25 kgf m 0 43 kgf m 2 25 kgf m 4 0 kgf m 4 0 kgf m 3 5 kgf m 5 25 kgf m 4 5 kgf m 4 0 kgf...

Page 16: ...rnings or cautions MEANING Indicates dangerous area Serious accident may result if instructions are not followed The following symbols indicate oil adding oil change or parts MEANING Add oil If there...

Page 17: ...ROOVE PISTON PIN AROUND CONNECTING ROD PISTON PIN HOLE CONNECTING ROD BIG END CRANK SHAFT CRANK SHAFT ONE WAY CLUTCH OPERATING PARTS OIL PUMP DRIVE CHAIN STARTER REDUCTION GEAR PARTS COUNTER SHAFT GEA...

Page 18: ...HOSE CLIP WATER PASS TUBE C E M I UNIT COMP E M I CORD WIRE E M I CORD FAN MOTOR RADIATOR HOSE A HORN LICENSE LAMP WIRE REGULATOR RECTIFIER HEADLIGHT CONTROL UNIT STARTER MAGNETIC SWITCH FUEL TUBE CAR...

Page 19: ...PIPE WATER PASS TUBE B E M I UNIT COMP WATER PASS TUBE B THROTTLE CABLE RADIATOR CAP HOSE RADIATOR HOSE A RADIATOR HOSE A RADIATOR HOSE B THERMO SWITCH WIRE THERMO SWITCH WIRE SEAT LOCK CABLE WATER P...

Page 20: ...LATOR RECTIFIER START MAGNETIC SWITCH BATTERY EARTH CABLE HEADLIGHT CONTROLLER CODE REGULATOR COUPLER 2EA HEAD LIGHT RELAY THERMO SWITCH RELAY WINKER RELAY EARTH CABLE BATTERY BOX COUPLER NOTE WHITE C...

Page 21: ...1 18 SERVICE INFORMATION HEADLIGHT RELAY BATTERY EARTH CABLE RESERVE FUSE BATTERY BOX FUSE BOX WINKER RELAY THERMO SWITCH RELAY HEADLIGHT RELAY FUSE BOX ASS Y BATTERY BOX...

Page 22: ...L TANK FUEL TUBE CARBURETOR TRUNK LAMP WIRE THERMO SENSOR WIRE NOISE SUPPRESSOR CAP AUTO CHOCK CORD I G COIL SIDE STAND SWITCH COUPLER THROTTLE POSITION COUPLER RR BRAKE HOSE WATER HOSE B WATER HOSE A...

Page 23: ...MEMO...

Page 24: ...RCOMPRESSIONPRESSURE 2 6 CARBURETOR IDLING 2 6 FINAL REDUCTION GEAR OIL 2 6 GEAR OIL REPLACEMENT 2 7 DRIVE BELT 2 7 COOLING LEVEL INSPECTION 2 8 COOLANT REPLACEMENT 2 8 BRAKE FLUID 2 9 BRAKE PAD 2 9 B...

Page 25: ...ADJUSTMENTS TIRES COLD TIRE PRESSURE TIRE SIZE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 2 00kgf 2 00kgf 2 00kgf 2 25kgf 120 70 12 Tubeless 140...

Page 26: ...ceeds 12 000km repeat maintenance service at intervals indicated in the table 2 After riding in areas with high humidity or pollution carry out maintenance service more frequently 3 Replace every 2 ye...

Page 27: ...djustment loosen the lock nut and turn adjuster After adjusting tighten lock nut After adjustment is completed recheck the throttle grip free play For simple adjustment use the adjuster under the thro...

Page 28: ...aner and wire brush to clean the plug Always use a feeler gauge to check the gap GENUINE PLUG DPR7EA9 SPARK PLUG 0 9 1 0mm TORQUE VALUE 1 47 1 96kgf m Remove the air cleaner element Wash away any accu...

Page 29: ...er Stop engine and remove the spark plug cap and spark plug Install a compression gauge Open the throttle completely and crank the engine with the starter motor until the gauge reading rising TOOL COM...

Page 30: ...rpm Verify all engine adjustments satisfy specifications Make adjustments if necessary Heat the engine to make accurate idling inspection and adjustment Stand the vehicle on the main stand Turn the th...

Page 31: ...ature too high or low Fill to the F UPPER LEVEL line Start the engine Bleed air from the coolant and check the level of coolant Install the radiator cap Fill the coolant with the reserve tank up to th...

Page 32: ...e pads for wear If the red mark on the pad reaches the brake disc replace the pads Replace the brake pads in sets Brake fluid will damage painted plastic or rubber parts Mixing incompatible fluids can...

Page 33: ...nsion parts will lead to deterioration in the vehicle s safety and operation efficiency 2 10 SIDE STAND Erect the main stand Pull the lower end of the side stand and see if it moves freely If the side...

Page 34: ...Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value Check all pins clips hose clamps and cable stays FRONT WHEEL 2 00 200 2 00 200 R...

Page 35: ...MEMO...

Page 36: ...EXTERNAL PARTS 3 SERVICE INFORMATION 3 1 SEAT 3 2 PILLION SEAT 3 2 LUGGAGE BOX TOP COVER 3 2 REAR GRIP 3 2 LUGGAGE BOX 3 3 CENTER COVER 3 3 BODY SIDE COVER 3 3 BODY COVER 3 4 REAR FENDER 3 4 FLOOR SI...

Page 37: ...R GRIP Remove the rear grip cap R L Loosen the 4 special bolts Install in the reverse order of removal LUGGAGE BOX TOP COVER Loosen the 5 Tapping screws and remove the top cover Install in the reverse...

Page 38: ...amp Install in the reverse order of removal CENTER COVER Remove the floor mat Loosen the 2 washer screws and 1 special screw Install in the reverse order of removal BODY SIDE COVER Remove the center c...

Page 39: ...er of removal REAR FENDER Remove the body cover Loosen the 4 washer bolts and remove the Rr fender Install in the reverse order of removal FLOOR SIDE COVER Remove the center cover Loosen the 3 body co...

Page 40: ...the 4 special screws R L 2Ea for each to remove the under cover Install in the reverse order of removal HANDLE COVER Loosen the washer screw and tapping screw securing the under handle cover Loosen t...

Page 41: ...al FRONT UNDER COVER A Remove the front cover and windscreen Loosen the 7 tapping screws securing the inner cover Install in the reverse order of removal FRONT UNDER COVER B Loosen the 2 flange bolts...

Page 42: ...be clip Remove the breather tube Loosen the 3 screws securing the inner cover Remove the bag holder Loosen the 2 tapping screws securing the speedometer cover Install in the reverse order of removal S...

Page 43: ...curing Ex pipe comp Loosen the 3 bolts securing the Rr Fork Remove the Ex muffler comp REAL WHEEL MUDGUARD Loosen the 2 flange bolts of RH Loosen the flange bolt securing the air cleaner and mudguard...

Page 44: ...MEMO...

Page 45: ...4 0 LUBRICATION SYSTEM ROCKER ARM SHAFT CRANK SHAFT OIL FILTER SCREEN OIL PUMP...

Page 46: ...contect with the skin for prolonged periods It is desirable not to handle used oil frequently however wash your hands thoroughly with soap and water immediately after handling the used oil 3 The oil...

Page 47: ...ption External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed often enough Faulty head gasket Worn piston rings L...

Page 48: ...filter screen every 4 000Km Clean the filter screen with fresh cleaning oil Check the hole cap O ring for satisfactory condition Tighten the hole cap with specified tightening torque TORQUE VALUE 1 5...

Page 49: ...PERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE...

Page 50: ...ump body clearance SERVICE LIMIT 0 25mm TOOL FEELER GAUGE Measure the rotor tip clearance SERVICE LIMIT 0 20mm Measure the pump side clearance SERVICE LIMIT 0 12mm OIL PUMP ASSEMBLY Clean all parts wi...

Page 51: ...R OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL PUMP DRIVE SPR...

Page 52: ...MEMO...

Page 53: ...5 0 FUEL SYSTEM...

Page 54: ...e for a period longer than 3 weeks drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits and idlin...

Page 55: ...perly Air screw is adjusted improperly Compression pressure is low Air Fuel mixture is either too lean or rich Carburetor is blocked Mis firing occurs when driving at high speeds Ignition system is da...

Page 56: ...ring coupler of the auto bystarter After removing the fuel tank be sure to close the fuel tank cap Gasoline is extremely flammable Avoid fire during work and pay particular attention to electric spark...

Page 57: ...r cleaner connecting tube band and the carburetor intake manifold band Remove the carburetor Remove the two vacuum chamber cover screws and the cover Remove the compression spring and vacuum piston VA...

Page 58: ...VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOA...

Page 59: ...PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S SLOW JET...

Page 60: ...TARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTE...

Page 61: ...VALVE COVER AIR CUT OFF VALVE COVER AIR CUT OFF VALVE COVER AIR CUT OFF VALVE COVER DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPH...

Page 62: ...S SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS O RING O RING O...

Page 63: ...VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NE...

Page 64: ...CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE INTAKE MANIFOLD BAND INTAKE...

Page 65: ...or foreign matters Install in the reverse order of removal OUTPUT 40CC 1 700rpm 10 seconds Measure the fuel pump output Start the engine and disconnect the fuel outlet fube and place a clean containe...

Page 66: ...MEMO...

Page 67: ...6 0 COOLING SYSTEM...

Page 68: ...the radiator cap if the coolant temperature is over 100 C Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding When the temperature is below carefully...

Page 69: ...d in radiator hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck Thermostat stuck...

Page 70: ...of coolant is 2000cc RADIATOR COOLANT MIXTURE CHART ANTICORROSIVE AND ANTIFREEZE COOLANT GRAVITY CHART Minimum temperature 9 C 16 C 25 C 37 C 44 5 C Mixture 20 30 40 50 60 Ratio 400 600 800 1 000 1 10...

Page 71: ...ube from the radiator filler Remove the overflow tube clamp and disconnect the overflow tube Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compress...

Page 72: ...R HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS NUT NUT...

Page 73: ...he radiator on the radiator bracket with the 2 bolts and 1 nut Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire and fan motor wire couplers Instal...

Page 74: ...owed out from the air vent tube 3 Put the air vent tube on TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE T...

Page 75: ...crankcase cover BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOL...

Page 76: ...assembly from the inside Drive in a new mechanical seal using a mechanical seal driver WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP...

Page 77: ...R BEARING INNER BEARING INNER BEARING INNER BEARING INNER BEARING WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAF...

Page 78: ...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 BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOL...

Page 79: ...t and the thermostat housing from the cylinder head Remove the 2 bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Be sure to bleed air from the coolin...

Page 80: ...er and gradually raise the water temperature to check its operation Technical Data Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays ope...

Page 81: ...MEMO...

Page 82: ...n the coolant before removing the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks T...

Page 83: ...d connectors Disconnect the engine fuel tube Drain the coolant Disconnect the water hose Disconnect the starter motor wire from the starter relay Disconnect the fuel tube and vacuum tube Disconnect th...

Page 84: ...REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOC...

Page 85: ...t bolts TORQUE VALUE 3 92kgf m After installation inspect and adjust the following Throttle grip free play Fill the rear brake reservoir with brake fluid and bleed air from the rear brake Fill the coo...

Page 86: ...MEMO...

Page 87: ...8 0 LH CRANKCASECOVER CONTINUOUSLYVARIABLE TRANSMISSION...

Page 88: ...40 000 40 025mm 40 06mm DRIVE FACE COLLAR OUTER DIAMETER 39 965 39 955mm 39 85mm DRIVE BELT WIDTH 23 6 24 4mm 22 0mm CLUTCH LINING WICTH 3 963 4 037mm 2 0mm CLUTCH OUTER AND INNER DIAMETER 153 0 153 2...

Page 89: ...R TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER...

Page 90: ...from the movable drive face Remove the movable drive face assembly Remove the drive pulley collar INSPECTION Check the drive bolt for cracks sepuration or abnormal or excessive wear Inspect the drive...

Page 91: ...heck the pump shaft to rotate smoothly RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PL...

Page 92: ...SEMBLY RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP P...

Page 93: ...ey collar Install the washer and drive nut into the drive pulley face temperarilly DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLL...

Page 94: ...Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch outer INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D SERVICE LIMI...

Page 95: ...clutch spring compressor and disassemlble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face...

Page 96: ...D SERVICE LIMIT 40 06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Remove the inner needle bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of th...

Page 97: ...the retainer plate and secure with the circlips Keep grease off the clutch linings BALL BEARING OUTER CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS...

Page 98: ...er pins and then install them into the holes of the driven face Install new seal collar Remove any excessive grease Tighten the drive flate nut temperily Set teh tool invise and righten the drive plat...

Page 99: ...ch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the clutch outer nut TORQUE VALUE 4 9 5 88kgf m Install the drive bel...

Page 100: ...MEMO...

Page 101: ...9 0 A C GENERATOR STARTER CLUTCH...

Page 102: ...ase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket SPECIFICATIONS 9 SERVICE INFORMATION 9 1 R CRANKCASE COVER R...

Page 103: ...PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL A C GENERATOR STATOR A C GENERATOR STATOR A C GENERATOR STATOR A C...

Page 104: ...START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEA...

Page 105: ...CTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR...

Page 106: ...PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT ALIGNING...

Page 107: ...10 0 CYLINDER HEAD VALVE...

Page 108: ...ARPAGE CAMSHAFT CAM HEIGHT VALVE ROCKER ARM I D VALVE ROCKER ARM SHAFT O D VALVE SEAT WIDTH VALVE STEM O D VALVE GUIDE I D VALVE STEM TO GUIED CLEARANCE IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX...

Page 109: ...TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT H...

Page 110: ...FT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT...

Page 111: ...HAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER A...

Page 112: ...NG COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPR...

Page 113: ...HAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE VALVE SPRING COMPRESSOR VALVE SPRING COMPRESS...

Page 114: ...M CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS D...

Page 115: ...e O ring into the groove properly WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS BOLTS BOLTS BOLTS BOLT...

Page 116: ...MEMO...

Page 117: ...11 0 CYLINDER PISTON...

Page 118: ...ICITY TRUE ROUNDNESS RING TO GROOVE TOP CLEARANCE SECOND TOP RINGENDGAP SECOND OIL RING PISTON O D PISTON TO CYLINDERCLEARANCE PISTON PIN HOLE I D 72 705 72 715 0 01 0 01 0 01 0 2 0 015 0 050 0 1 0 25...

Page 119: ...CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DO...

Page 120: ...emove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap SERVICE LIMITS 0 5mm replace if over Measure the piston pin hole I D SERVICE LIMITS 17 04mm...

Page 121: ...ar or damage SERVICE LIMITS 72 80mm replace or replace if over Measure the cylinder to piston clearance SERVICE LIMITS 0 1mm replace or replace if over The true roundness is the difference between the...

Page 122: ...thlout sticking stagger the ring end gaps as the figure shown Inspect the top of the cylinder for warpage SERVICE LIMITS 0 05mm replace or replace if over Measure the connecting rod small end I D SERV...

Page 123: ...TON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN...

Page 124: ...to the cylinder Install the cylinder head Tighten the cylinder base bolt 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 P...

Page 125: ...12 0 CRANKSHAFT CRANKCASE...

Page 126: ...be removed before separating the crakcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pum...

Page 127: ...l bearing puller Bearing remover set Remover ass y Remover shaft Remover head Slieding weight Assembly shaft TROUBLESHOOTING Excessive engine noise Excessive bearing play Excessive crankpin bearing pl...

Page 128: ...CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRAN...

Page 129: ...place if over Measure the crankshaft runout SERVICE LIMITS 0 10mm replace if over LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE L...

Page 130: ...et material from the crankcase mating surfaces Place the LH crankcase down and install the crankshaft into the LH crankcase Avoid damaging the oil seal Apply grease to the lip of the oil seal PLAY AXI...

Page 131: ...ioner slipper Install the tighten the cam chain tensioner slipper bolt TORQUE VALUE 0 78 1 18kgf m Install the two dowel pins and a new gasket Install the RH crankcase squarely and do not tap it with...

Page 132: ...MEMO...

Page 133: ...13 0 FINAL REDUCTION...

Page 134: ...CIAL TOOLS Bearing remover 12mm Bearing remover 15mm Pilot 12mm Pilot 15mm TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn...

Page 135: ...GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR COUNTER...

Page 136: ...FINAL SHAFT BEARING FINAL SHAFT BEARING FINAL SHAFT BEARING FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SH...

Page 137: ...l shaft into the left crankcase FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive new bearings into the left crankcase Install a new drive shaft oil seal DRIVE SHAFT DRIVE...

Page 138: ...removal Install the transmission case cover Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT...

Page 139: ...14 0 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 140: ...BER BOLT 1 98 2 45 f m FRONT AXLE NUT 4 41 4 9 f m BRAKE CALIPER BOLT 2 45 3 43 f m 14 SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT WHEEL BEARING 14 5 SPEE...

Page 141: ...uide bushings Insufficient fluid in forks Loose front fork fasteners Lack of grease in speedometer gear box Brake lever soft or spongy Air in hydraulic system Mixed brake fluid and wet Contaminated br...

Page 142: ...e the throttle grip from the handlebar Remove the handlebar lock nut and take out the bolt Remove the handlebar INSTALLATION Install the handlebar onto the steering stem and install the handlebar coll...

Page 143: ...e actual runout is 1 2 of the total indicator reading SERVICE LIMIT 0 2mm replace if over Adjust the throttle grip free play to the specified range of 2 6mm Install the brake master cylinders by align...

Page 144: ...y sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left...

Page 145: ...GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER G...

Page 146: ...rst drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove the two bolts securing the brake master cylinder Remov...

Page 147: ...INDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTE...

Page 148: ...SPRING Replace the piston spring cups and snap ring as a set Be sure that each part is free from dust or dirt before reassembly When cleaning with the brake fluid use the specified brake fluid Instal...

Page 149: ...lable Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this...

Page 150: ...evel is near the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Tighten the bleeder valve TORQUE VALUE 0 4 0 7 kgf m Be sure that the brake fl...

Page 151: ...caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the brake hose 14 12 FRONT WHEEL FRONT FOR...

Page 152: ...N PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON...

Page 153: ...ghten the oil bolt to the specified torque TORQUE VALUE 3 4kgf m Fill the brake fluid to the upper limit line and bleed air FRONT FORK REMOVAL Remove the following parts Front under cover Front brake...

Page 154: ...lt 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 SPRING VISE...

Page 155: ...if the deflection is greater than 0 2mm 14 16 FRONT WHEEL FRONT FORK STEERING BRAKE Take precautions not to damage the interior and exterior rim of the bottom case OIL SEAL STOPPER RING OIL SEAL STOPP...

Page 156: ...ew locking agent to the socket bolt thread and assemble the socket bolt to the fork piston TORQUE VALUE 2 0kgf m Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil sea...

Page 157: ...L STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL...

Page 158: ...ball assembly top cone race and ball race for damage or abnormal and replace as necessary Check the bottom cone race for wear and damage STEERING STEM REMOVAL Remove the following parts Handle cover...

Page 159: ...ring top thread onto the steering head Tighten the top thread to specified torque then loosen the top thread 1 8 turn TORQUE VALUE 0 15 0 25kgf m Recheck that the steering stem moves smoothly without...

Page 160: ...MEMO...

Page 161: ...15 0 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 162: ...LOCK BOLT 2 94 3 92 f m REAR AXLE NUT 7 84 9 8 f m REAR SHOCK ABSORBER LOWER MOUNT BOLT 1 96 2 94 f m REAR SHOCK ABSORBER UPPER MOUNT BOLT 3 92 f m REAR BRAKE CALIPER BOLT 1 96 2 94 f m 15 SERVICE INF...

Page 163: ...re 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 Rear...

Page 164: ...in caliper bracket and boot from the caliper body Check the boot for wearand damage and replace if necessany INSPECTION Inspect break pad and disk Measure the break disk thickness SERVICE LIMIT 3mm 15...

Page 165: ...PER PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PIST...

Page 166: ...exhaust muffler Remove the rear brake caliper Remove the rear fork Remove the rear axle collar Remove the rear wheel Rotate the inner bearing with finger and check it for smooth operation Check the ma...

Page 167: ...shion lower bolt 1 96 2 94kgf m Rear axle nut 7 84 9 8kgf m REAR CUSHION ADJUST Adjust the cushion spring according to the load condition The rear cushion can be adjusted as below 1 2 3 4 5 soft mediu...

Page 168: ...INSTALLATION Install in the reverse order of removal TORQUE VALUE 3 92kgf m 15 7 REAR WHEEL BRAKE SUSPENSION SWING ARM...

Page 169: ...16 0 CHARGING SYSTEM REGULATOR RECTIFIER MAIN SWITCH A C GENERATOR...

Page 170: ...tedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to n...

Page 171: ...oose broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Battery...

Page 172: ...the charger negative cable to the battery negative terminal When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the...

Page 173: ...erminal and ground cable With the ignition switch off measure the leakage current LEAK CURRENT Not to exceed 0 5A max TOOL DIGITAL TESTER A C GENERATOR INSPECTION AMPERE METER EARTH CABLE BATTERY TERM...

Page 174: ...move the regulator rectifier coupler Measure each terminal Replace the regulator rectifier unit if the resistance value between the terminals is abnormal RESISTANCE VALUE Tester Tester Unit 20 R B Y Y...

Page 175: ...17 0 IGNITION SYSTEM BATTERY REGULATOR RECTIFIER IGNITION UNIT A C GENERATOR MAIN SWITCH IGNITION UNIT...

Page 176: ...to removing wiring Connect the same color couplers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on...

Page 177: ...cted ignition unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty peak voltage adaptor 6 Faulty ignition unit in case when above No 1 5 are normal 1 Faulty spark p...

Page 178: ...If the resistance is open wire disconnect the spark plug cap and measure the secondary coil resistance STANDARD VALUE 17 21 Measure resistance between the primary coil terminal and high tension cord...

Page 179: ...esistance between the blue white and green white wire terminals Black white Ground 23 35 L Y B Y G GR G W B W G B V R V B V G G 11 22M 67 125K 11 22M 36 67K 110 200K 36 67K 36 67K 0 5 2K 67 125K 11 22...

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Page 181: ...18 0 STARTER SYSTEM BATTERY MAIN SWITCH STARTER MOTOR STOP SWITCH CABLE STARTER MOTOR STOP LAMP BATTERY CABLE...

Page 182: ...engine cannot turn over The engine may not be turned over if the stop switch is faulty SPECIFICATION 18 SERVICE INFORMATION 18 1 TROUBLESHOOTING 18 2 STARTER MOTOR 18 3 STARTER MAGNETIC SWITCH 18 5 I...

Page 183: ...at starter magnetic switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 7 Connect the starter magnetic s...

Page 184: ...al powder between the seaments Check for continuity between pairs of the commutator segments and there should be continuity STARTER MOTOR Release the seat lock with the main key Remove the luggage box...

Page 185: ...low Check the continuity between brush and cord terminal Normal if there is continuity Check the continuity between cord terminal and case Normal if there is no continuity Make a continuity check betw...

Page 186: ...se with the groove on the front cover Tighten the starter motor case screws STARTER MAGNETIC SWITCH INSPECTION Check if the starter magnetic switch clicks when it is turned ON Clicks Poorly connected...

Page 187: ...ery 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 If there is continuity between battery a...

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Page 190: ...these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity test on normal parts can be carried out without removing...

Page 191: ...ove the headlight Disconnect the connector of handle switch Check for continuity between teminals Remove the Fr cover Remove the coupler wire Test each teminal of handle switch HEADLIGHT SWITCH RED WH...

Page 192: ...s FUEL UNIT Remove the foor panel Be cover full not to be damaged for the wire Check the base packing for damage Measure the resistance between the fuel unit upper and lower BAT3 HI BLACK BLUE HI COLO...

Page 193: ...voltage Start engine and if the temperature of heater controller unit is under 0 C Check if the white yellow wire of heater controller unit has output voltage If it has not any voltage it is damaged...

Page 194: ...meter illumination taillight position light and license light turns on COOLANT TEMPERATURE GAUGE If the gauge needle indicates the red zone when idling or running turn the main switch OFF Wait until t...

Page 195: ...e taillight bulb and winker bulb When replacing the bulb be sure not to put finger and contaminated gloves prints on the headlight bulb as they may create hot spots on the bulb and cause is to fail No...

Page 196: ...dlight switch in mounted wiht the vehicle connect the white colored coupler only If hazard switch is mounted with the vehicle connect the black colored coupler only FUSE CAPACITY Fuse A 30A Charging c...

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Page 198: ...g 9P MINI O Gr B G Y G Y B BAT TRUNK LAMP FREE IGN BAT 2 2 OFF UNIT THERMO G L G Lg O Gr Br L G Y THERMO SW RELAY B G L B Lg R Sb G Y Br L Br Br L Y R P G Y MINI 6P Y R G Y R Br P Br L Br P Br L G G B...

Page 199: ...MEMO...

Page 200: ...SERVICEMANUAL 2004 9 PRINTED 2004 9 PUBLICATION NO COPY...

Page 201: ...01E 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...