User manual DAELIM BESDI 125 - SERVICE MANUAL

HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the SC125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 3). Sections 1 through 3 provide information on overall vehicle; section 4, assembly and disassembly procedures for external components, and section 5 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 20: Troubleshooting. CONTENTS SERVICE INFORMATION GENERAL ENGINE FRAME ELECTRICAL SYSTEM LUBRICATION INSPECTIONS / ADJUSTMENTS EXTERNAL PARTS FUEL SYSTEM Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co., Ltd., ENGINE REMOVAL LH.CRANK CASE COVER / KICK STARTER / CONTINUOUSLY VARIABLE TRANSMISSION A.C.GENERATOR / STARTER CLUTCH CYLINDER HEAD / VALVE CYLINDER / PISTON TRANSMISSION/CRANK SHAFT/CRANK CASE FRONT WHEEL / FRONT FORK / STEERING REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM BRAKE SYSTEM CHARGING SYSTEM / BATTERY IGNITION SYSTEM STARTER SYSTEM LIGHTS/METER/SWITCHES TROUBLESHOOTING WIRING DIAGRAM 1. SERVICE INFORMATION GENERAL SAFETY SERVICE RULES CAUTION WHEN WIRING SERIAL NUMBER LOCATION 1-1 1-1 1-5 1-9 SPECIFICATIONS TORQUE VALUES SYMBOLS / ABBREVIATIONS WIRING DIAGRAM 1-10 1-12 1-14 1-15 GENERAL SAFETY WARNING 1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children) 3. Pay attention not to be burned and always 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 electric spark. 5. When more than two person are working, always pay attention to other worker's action and alway have safety in mind. 6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash carefully with soap and water after handling. 7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc. 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 recommended parts. 2. Before maintenance, remove deposit or dust from the chasis. 1-1 SERVICE INFORMATION 3. Store the parts of each system discriminatively to install each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation. 5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation. 6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing. 7. Align the bolts to uniform the tightening points before tightening them when you don't know the bolt length. 8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque. 9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils. 10. Recommended grease must be applied to or filled in the specified place. 1-2 SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually. Replace the ball bearing having excessive axial/ longitudinal hanging. Wipe the ball bearing likely to have hanging with cleaning oil.(except double-sided sealed type ball bearing) Replace the ball bearing of which press-fitted part is slacked at the case or shaft. 14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle. ' 15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing. 16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring. 17. Check each part for proper tightening and operation after installation. 18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact. 1-3 SERVICE INFORMATION 19. Install 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 until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end. ' 21. Keep the pneumatic system interior or the engine interior from the infiltration of dust. 22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally. 23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage. 24. Install the boots with the installing groove by inserting the boots into the groove. 1-4 SERVICE INFORMATION CAUTION WHEN WIRING Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. Identify the two-colored cord by main color first and then spriped color . When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler 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 connecting the terminal, apply the grease to the terminal. When disconnecting the battery, the minus terminal must be disconnected first. Make sure that the tool such as spanner do not contact with the frame. Connect covers to the terminal after maintenance. If the fuse is short-circuited, find out the cause and repair. Replace with the fuse having the specified capacity. If there is rust in the terminal, remove the rust with sand paper prior to connecting. VALIDATION OF CAPACITY! REMOVE THE RUST! 1-5 SERVICE INFORMATION Turn off the main switch before connecting/disconnecting. Release the lock to disconnect the lock of the coupler. 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. - Typical releasing method of the coupler is illustrated in the 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. Insert the lock of the coupler until the lock is fully secured. Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler. Pay attention not to damage the vinyl cover of the coupler. Check to see if there is bended terminal and secure it to avoid disconnecting. If the wire harness coating is damaged, repair by winding vinyl tape or replace it. Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened. 1-6 SERVICE INFORMATION Insert the connector until the vinyl cover is fully inserted into the terminal. The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction. When removing 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 from the frame, replace it with the new one. Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part. Secure the wire harness firmly using the clamp. In case of the weld clamp, do not clamp in the welded part. When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part. When clamping the wire, pay attention not to contact with hot part. The wire harness must be routed without contacting with the end of the lamp or any sharp edge. The wire harness must be routed without contacting with the end of the bolt or the piece. 1-7 SERVICE INFORMATION In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. The wire must not hang down or be pulled excessively. 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. Do not twist the wire harness. Wire the wire harness not to be pulled or expanded 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 the manual carefully and understand the contents. When testing the resistance of the tester, the zero adjustment must be performed before testing. Is this measurement range or configuration in accord with the manual? Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop. 1-8 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION 1-9 SERVICE INFORMATION SPECIFICATIONS ITEM OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE / TYPE REAR TIRE SIZE / TYPE TIRE PRESSURE 1 PERSON 2 PERSON FRONT / REAR BRAKE PARKING BRAKE FUEL TANK CAPACITY CASTER ANGLE TYPE CYLINDERS / ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY TRENSMISSION OIL CAPACITY LUBRICATION SYSTEM AIR CLEANER TYPE CYLINDER COMPRESSION PRESSURE INTAKE VALVE 1,820 mm 685 mm 1,060 mm 1,300 mm 755 mm 110 mm 105 kg 235 kg Underbone Bottom link Swing arm / 66mm 3.50 - 10 51J 3.50 - 10 51J 1.75 Kgf / 2.00 Kgf / 2.00 Kgf / 2.25 Kgf / Hydraulic disk Drum brake 8.0 1.0 26 Air cooled / 4stroke 1(Single cylinder), front angle 15 52.4 57.8 mm 124.6 9.2 : 1 SOHC 2valve 0.9 After disassembly 0.75 After Oil change 0.11 After disassembly 0.09 After Oil change Forced pressure splash type Dry process 13.0 kgf / (570 rpm) 0 BTDC 25 ABDC 33 BBDC 0 BTDC 0.05 mm 0.05 mm SPECIFICATIONS DIMENSIONS FRAME FRONT REAR FRONT REAR FULL CAPACITY RESERVE CAPACITY ENGINE OPEN CLOSED EXHAUST VALVE CLOSED OPEN VALVE CLEARANCE (COOLING-OFF PERIOD) INTAKE EXHAUST 1-10 SERVICE INFORMATION ITEM TYPE / VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING BATTERY TYPE / CAPACITY SPARK PLUG SPARK PLUG GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT ( HIGH / LOW ) WINKER LIGHTS ( FR / RR ) TAIL / STOP LIGHT HIGH-BEAM PILOT WINKER PILOT LAMP SPEEDOMETER LAMP LICENSE LAMP SPECIFICATIONS CV type ( vacuum ) 23 mm PD24J Auto-bystarter # 110 2 and trust out 11 mm 1.600 100 ( rpm ) Automatic Transmission(V-belt) 2.800 3.077 AC-C.D.I Ignition 13 12V 8AH P-Z9HC(CHAMPION) 0.6 - 0.7 mm 15A Kick / starter motor 12V 35 / 35W 12V 10W 4 12V LED 12V1.7W 1 12V1.7W 2 12V 3.4W 2 12V 5W CARBURETOR DRIVE TRAIN F MARK ELECTRICAL SYSTEM 1-11 SERVICE INFORMATION TORQUE VALUES ENGINE ITEM OIL FILTER CAP OIL DRAIN PLUG BOLT VALVE ADJUST SCREW LOCK NUT CYLINDER HEAD BOLT FLYWHEEL BOLT DRIVE FACE NUT CLUTCH OUTER BOLT CAM CHAIN TENSIONER PIVOT BOLT SPARK PLUG DRIVE PLATE CAM SHAFT HOLDER NUT CAM CHAIN TENSIONER FLANGE BOLT CAM CHAIN TENSIONER PAN SCREW CYLINDER HEAD COVER BOLT MISSION COVER BOLT MISSION COVER DRAIN BOLT MISSION COVER CHECK BOLT COOLING FAN BOLT STARTING CLUTCH NUT STARTER MOTOR FLANGE BOLT Q'TY 1 1 4 2 1 1 1 1 1 1 4 2 1 4 8 1 1 3 1 2 THREAD DIA (mm) 30 12 5 6 12 12 12 8 12 30 8 6 6 6 6 8 8 6 22 6 TORQUE VALUE 1.5 kgf 2.5 kgf 1.1 kgf 1.1 kgf 5.5 kgf 7.5 kgf 5.5 kgf 1.0 kgf 1.2 kgf 5.5 kgf 2.9 kgf 1.0 kgf 0.4 kgf 0.9 kgf 1.2 kgf 1.0 kgf 0.9 kgf 1.0 kgf 5.5 kgf 0.9 kgf m m m m m m m m m m m m m m m m m m m m REFERENCE APPLY ENGINE OIL APPLY ENGINE OIL FRAME ITEM STEERING STEM NUT STEERING TOP THREAD NUT HANDLE POST FRONT AXLE NUT FRONT CALIPER BRACKET BOLT FRONT MASTER CYLINDER HOLD BOLT FRONT DISK PLATE BOLT REAR AXLE NUT SPEEDOMETER GEAR BOX SCREW FRONT FORK BOLT REAR CUSHION UPPER BOLT REAR CUSHION UNDER BOLT REAR CUSHION ROD LOCK NUT ENGINE HANGER UPPER BOLT ENGINE HANGER LAWER BOLT MAIN STAND BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT Q'TY 1 1 2 1 1 2 3 1 1 2 2 2 2 2 1 2 1 1 THREAD DIA (mm) 26 26 10 12 8 6 8 16 5 22 10 10 10 12 10 10 10 10 TORQUE VALUE 7.0 kgf 0.25 kgf 6.0 kgf 6.0 kgf 3.1 kgf 1.2kgf 4.25 kgf 12.5 kgf 0.4 3kgf 2.25kgf 4.0 kgf 4.0 kgf 3.5kgf 5.25 kgf 4.5 kgf 4.0 kgf 1.5 kgf 4.5 kgf m m m m m m m m m m m m m m m m m m REFERENCE Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table. 1-12 SERVICE INFORMATION SH (Small Head) : Indicates 6mm bolt of 8mm flange head. ITEM 5mm BOLT, NUT 6mm BOLT, NUT 8mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT TORQUE VALUE 0.5 kgf 1.0 kgf 2.2 kgf 3.5 kgf 5.5 kgf m m m m m ITEM 5mm SCREW 6mm SCREW 6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT TORQUE VALUE 0.4 kgf 0.9 kgf 1.2 kgf 2.7 kgf 4.0 kgf m m m m m 1-13 SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious WARNING accident may result if instructions are not followed. NOTE CAUTION vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures. The following symbols indicate oil adding, oil change, or parts. SYMBOL MEANING OIL GREASE ( 3-1) Add oil. If there is no specific oil indicated, use the designated or recommended engine oil. Apply grease Indicates reference page. (example : Refer to page 3-1) The following abbreviations are used in this manual. ASS'Y ASSEMBLY LH. RH. Left Right 1-14 SERVICE INFORMATION WIRING DIAGRAM FR.WINKER FUEL PUMP FUEL STRAINER COMP. FUEL TANK AIR CLEANER KICK ENGINE IGNITION COIL COMP. KEY SET MUFFLER SAI PIPE C.D.I UNIT FUEL TANK 1-15 SERVICE INFORMATION SPEEDOMETER CABLE KEY SET WINKER RELAY HEADLIGHT CONTROLLER REG. RECTIFIER FR. BRAKE HOSE CARBURETOR INSULATOR GAS RATIO CONTROLLER SAI PIPE COMP. IGNITION COIL COMP. C.D.I UNIT COMP. START MAGNETIC SWITCH 1-16 2. LUBRICATION SERVICE INFORMATION TROUBLE SHOOTING ENGINE OIL LEVEL INSPECTION ENGINE OIL CHANGE 2-1 2-2 2-3 2-3 OIL FILTER ELEMENT CHANGE OIL PUMP TRANSMISSION OIL INSPECTION LUBRICATION POINTS 2-3 2-4 2-7 2-8 SERVICE INFORMATION GENERAL SAFETY WARNING The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. Used engine oil may cause skin cancer if repeatedly left in contact 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. The oil pump can be serviced without removing the engine from the frame. ENGINE OIL 0.9 (After disassembly) 0.75 (After Oil change) OIL CAPACITY API service classification : SL grade Viscosity : SAE10W-40 RECOMMENDED (Use appropriate type of oil with viscosity satisfying OIL the atmospheric temperature In your riding area based on the table shown on the right side.) -10 0 10 20 30 40 TRANSMISSION OIL OIL CAPACITY RECOMMENDED OIL 0.11 0.09 (Full capacity) (After oil change) DMC Genuine mission oil or SAE 80W/90 TORQUE VALUES OIL FILTER SCREEN CAP OIL PUMP BOLT OIL DRAIN PLUG BOLT 1.5 f m 1.1 f m 2.5 f m 2-1 LUBRICATION TROUBLE SHOOTING Oil level low Oil consumption naturally. External oil leaks. Worn piston ring or incorrect piston ring installation. Worn valve guide or seal. Oil contamination Oil or filter not changed often enough. Faulty head gasket. Worn piston rings. Low or no oil pressure Clogged oil orifice. Incorrect oil being used. 2-2 LUBRICATION ENGINE OIL LEVEL INSPECTION Erect the motorcycle on the main stand. Warm up the engine to heat the engine oil to an appropriate level. Stop the engine, and loosen the oil level gauge and check the oil level line. ENGINE OIL CHANGE NOTE To completely and rapidly drain engine oil, warm up engine and erect the motorcycle on side stand. Loosen the oil drain bolt and drain engine oil. Operate the kick starter arm for several times to remove the remaining oil from the engine. Tighten the oil drain bolt. TORQUE VALUE : 2.5 kgf m CAUTION It is extremely important to replace oil filter or clean the oil filter screen at the first maintenance interval (after 1,000Km). Clean the oil filter screen every 4,000Km. Clean the filter screen with fresh cleaning oil. Check the hole cap O-ring for satisfactory condition if necessary replace it with new one. Tighten the hole cap with specified torque. TORQUE VALUE : 1.5 kgf m Fill the recommended engine oil to oil inlet. OIL CAPACITY : 0.9 (After disassembly) 0.75 (After Oil change) Tighten the oil level gauge. API service classification : SL grade. Start the engine and keep it idle for a few minutes. Stop the engine and check the oil level. If the oil level is low, add the recommended engine oil. Check on oil leaks. 2-3 LUBRICATION OIL PUMP REMOVAL Drain the engine oil. Remove the following parts : -Muffler ( 4-3) -Cooling fan cover -Cooling fan ( 8-2) -A.C. generator ( 8-4) -RH. crankcase cover ( 8-4) -Starter driven gear ( 8-6) -Reduction gear ( 8-5) -Starting clutch assembly ( 8-6) Remove the oil separator. Remove the oil pump drive gear nut. Remove the oil pump drive gear chain. Loosen the 2 flange bolts securing the oil pump. Remove the oil pump. 2-4 LUBRICATION DISASSEMBLY Loosen the screw securing the oil pump plate. Remove the oil pump body and the oil pump plate. Clean the oil pump body, inner and outer rotors with fresh cleaning oil. INSPECTION Assemble the inner and outer rotors to the oil pump body correctly. Measure the clearance between the pump body and outer roter. SERVICE LIMIT : 0.23mm TOOL : FEELER GAUGE Measure the clearance between lnner and outer rotor. SERVICE LIMIT : 0.18mm Measure the clearance between many faces of rotor and the pump body SERVICE LIMIT : 0.12mm 2-5 LUBRICATION ASSEMBLY Clean all parts with fresh cleaning oil. Install the inner and outer rotors to the pump body. Install the oil pump plate to the pump body. Tighten the pan screw. NOTE After installing, check the oil pump to operate smoothly. INSTALLATION Install the oil pump to the RH. crankcase. Install the following parts. -Oil pump drive gear and chain -Starting clutch assembly -Starter driven gear and reduction gear -RH. crank case cover -A.C. generator -Cooling fan and cooling fan cover -Muffler 2-6 LUBRICATION TRANSMISSION OIL INSPECTION Check the body and the connection of each engine component for any leak. Remove the oil check bolt and check to see if the oil overflows from the oil check hole. If only the small amount of oil overflows. fill the recommended transmission oil through the oil filler hole gradually. OIL CAPACITY : 0.11 0.09 (FULL) (CHANGE) NOTE Oil level inspection must be performed in the flat ground with the vehicle being straight by raising the main stand. RECOMMENDED OIL : SAE 80W/90 Tighten the oil check bolt. TORQUE VALUE : 0.9 kgf m Start the engine and check for leak. 2-7 LUBRICATION LUBRICATION POINTS Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it. 2-8 3. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE (FUEL TUBE) THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDER COMPRESSION PRESSURE CARBURETOR IDLE SPEED 3-1 3-3 3-4 3-4 3-4 3-5 3-5 3-6 3-6 BRAKE FLUID BRAKE PAD/SHOE SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING BATTERY 3-6 3-7 3-7 3-8 3-8 3-8 3-9 3-9 SERVICE INFORMATION WARNING The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. NOTE For information on engine oil and oil filter, refer to section 4. Stand the main stand prior to beginning work. SPECIFICATIONS THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE IN EX 2- 6mm P-Z9HC 0.6-0.7mm 0.05mm 0.05mm 1,600 100rpm 13kgf/ ( 570rpm ) CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE TIRES COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 1.75kgf/ 2.00kgf/ 2.00kgf/ 2.25kgf/ 3.50 - 10 51J 3.50 - 10 51J 3-1 TIRE SIZE INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG CYLINDER HEAD COVER BOLTS VALVE ADJUSTING NUTS 1.2kgf m 0.9kgf m 1.1kgf m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE 3-2 INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner's manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart. FREQUENCY ITEM ODOMETER READING(NOTE 1) x 1000Km 1 4 6 8 12 12 18 REMARK MONTH I C I I R R I I I I FUEL LINE(FUEL TUBE) THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG VALVE CLEARANCE TRANSMISSION OIL ENGINE OIL ENGINE OIL FILTER SCREEN CARBURETOR IDLE SPEED BRAKE FLUID BRAKE SHOE/PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING DRIVE BELT WEIGHT ROLLER SLIDE PIECE MOVABLE DRIVE FACE INNER PART I I C I I R R I I I I I I I I I I R I I R R I I I I I I I I I I I I I I L I I C I I R R R I I I I I I I I I I I I I L NOTE 3 NOTE 3 NOTE 2 I I I I I I I L If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections. To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops, dealers or other designated repair shops. NOTE 1. After the odometer reading exceeds 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 years. Proper technology is required for this job. 3-3 INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) Remove the luggage box.( 4-4) Check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. THROTTLE GRIP OPERATION Check if the throttle grip operates smoothly in any steering position. If the throttle grip does not operate properly, check the throttle cable for aging, damage or bending. Check the throttle grip free play. FREE PLAY : 2~6mm For adjustment, loosen the lock nut and turn adjuster. After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play. AIR CLEANER Remove the luggage box. Loosen the 5 screws securing the air cleaner case cover, remove the air cleaner case cover. Loosen the 3 screws securing the air cleaner element holder. Remove the air cleaner element. Check the element for dirty or damage, if necessary replace it with new one. CAUTION Do not clean by compressed air blowing. 3-4 INSPECTIONS / ADJUSTMENTS SPARK PLUG Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits. If the spark plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug. Always use a feeler gauge to check the gap. GENUINE PLUG : P-Z9HC SPARK PLUG GAP : 0.6~0.7mm TORQUE VALUE : 1.2 kgf m CAUTION Make sure there is no dirt or debris on the seat of the spark plug hole before inserting the spark plug. To prevent damage to the cylinder head, hand-tighten the spark plug before using a wrench to tighten to the specified torque. Do not overtighten the spark plug. VALVE CLEARANCE Remove the following parts. -Seat lock -Luggage box. -body cover -Center cover. Loosen the 4 cylinder head cover bolts. NOTE Inspect and adjust the valve clearance when the engine is cool. (under 35 C / 95 F) Remove the cooling fan cover. Turn the flywheel counterclockwise, and align the T mark on the flywheel with the index mark on the RH. crank case cover. The piston at this time must be at the top dead center of the compression stroke. Measure valve clearance with a feeler gauge. VALVE CLEARANCE : Intake : 0.05 0.02mm Exhaust : 0.05 0.02mm Loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut. TORQUE VALUES : 1.1kgf m TOOLS : WRENCH 8X9mm ADJUSTING WRENCH FEELER GAUGE Measure the valve clearance again. Install the cylinder head cover and tighten the bolts. TORQUE VALUES : 0.9 kgf m 3-5 INSPECTIONS / ADJUSTMENTS CYLINDER COMPRESSION PRESSURE Start and warm up the engine. 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 : COMPRESSION GAUGE NOTE The maximum reading is usually reached within 4~7 seconds. COMPRESSION PRESSURE : 13 kg/cm2 (570RPM) If the pressure is low, check the following: -Inadequate valve clearance adjustment -Valve gas leakage -Leakage the gasket from the cylinder head -Piston/cylinder worn If pressure is high, check the following: -Carbon deposits on the piston head, and cylinder head. CARBURETOR IDLE SPEED Turn the main key left, release the seat lock. Remove the luggage box. Adjust the throttle stop screw with (+) screw driver. NOTE Erect the motorcycle on the main stand Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. Heat the engine to make accurate idling inspection and adjustment. Stand the vehicle on the main stand. Turn the throttle stop screw and make adjustments to prescribed idling speed. -Idle spped 1600 100rpm Do not over adjustment the pilot screw, it could be effect to starting (refer to page5-9) BRAKE FLUID Check the oil level inside the front reservoirs, if the oil level is near the lower limit line, remove the reservoir diaphragms and fill DOT 3 and DOT 4 brake fluid to the top limit line. If the brake fluid reaches the lower limit line, check the entire brake system for leaks. 3-6 INSPECTIONS / ADJUSTMENTS CAUTION Brake fluid will damage painted, plastic or rubber parts. Mixing incompatible fluids can impair braking efficiency. Foreign materials can clog the system, causing a reduction or complete loss of braking ability. A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability. BRAKE PAD/SHOE BRAKE PAD REPLACEMENT Check the brake pads for wear. If the red mark on the pad reaches the brake disk, replace the pads. NOTE Replace the brake pads as a sets. BRAKE SHOE REPLACEMENT If the arrow mark of the wear limit aligns with the ` ' mark when the parking brake lever is tightly depressed, it indicates the brake lining has reached the service limit. Replace the brake shoes. Check the front brake hose for cracks or damage. If any leaks are found, replace immediately. Check the brake rod for looseness or damage, and replace it if necessary. BRAKE LEVER FREE PLAY Check the free play after pulling the lever. FRONT : 10~20mm REAR : 10~20mm SIDE STAND Erect the main stand. Pull the lower end of the side stand, and see if it moves freely. If the side stand does not move smoothly, apply grease to the pivot area. If the side stand moves too freely, check the side stand spring. Check the axial movement of the side stand. 3-7 INSPECTIONS / ADJUSTMENTS SUSPENSION NOTE Do not ride motorcycle 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. Check the front fork for oil leakage, parts damage or looseness. REAR WHEEL Compress the near cushion up and down for several times to check the operating conditions. Check the rear fork for oil leakage, parts damage or looseness. BOLTS, NUTS TIGHTENER Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value. Check all pins, clips, hose clamps and cable stays. WHEELS/TIRES NOTE Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE f/ ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 1.75(25psi) 2.00(28psi) DRIVER AND A PASSENGER 2.00(28psi) 2.25(32psi) 3-8 INSPECTIONS / ADJUSTMENTS STEERING HEAD BEARING NOTE Check the cable if it interferes with the handle operation. Lift the front wheel and check if the handle moves right and left smoothly. If the handles move heavily, check if the cable or electric cord interferes with the handle. If the handle moves satisfactorily, adjust the steering head bearing. BATTERY Remove the battery cover. Check to see if the terminal has loosed. If the terminal is loose, check the contact, clean then tighten. If the terminal is corroded, remove the battery, pouring the hot water, clean with wire brush. -When fully charged : 13.0~13.2v -Insufficientry chargen : 12.3v 3-9 MEMO 3-10 4. EXTERNAL PARTS SERVICE INFORMATION MAINTENANCE PRECEDURE FRONT FENDER REAR WHEEL MUD GUARD MUFFLER INNER COVER METER COVER HANDLE COVER FRONT COVER 4-1 4-2 4-3 4-3 4-3 FLOOR SIDE COVER FLOOR PANDER UNDER COVER BODY COVER CENTER COVER REAR FENDER SEAT LUGGAGE BOX REAR CARRIER 4-4 4-4 4-5 4-5 4-6 4-6 4-6 4-7 4-7 4-7 4-8 4-8 4-8 SERVICE INFORMATION NOTE This section describes external parts removal/installation. Do not apply unreasonable force when disassembling covers, to prevent possible damage. A muffler is hot. Do not service it immediately after the engine is stopped. 4-1 EXTERNAL PARTS MAINTENANCE PROCEDURE NAME OF COVERS This chart shows arrows connected in the order of disassembling covers. LUGGAGE BOX FRONT COVER UNDER HANDLE COVER FRONT FENDER REAR CARRIER UPPER/UNDER INNER COVER HEAD LIGHT BODY COVER CENTER COVER UPPER HANDLE COVER FLOOR SIDE COVER FLOOR PANEL CAUTION Be careful not to overturn the vehicle when removing wheels. 4-2 EXTERNAL PARTS FRONT FENDER Remove. -The 3 special screw -The flange bolt of front fender B -Front fender B -Front fender A Install in the reverse order of removal. REAR WHEEL MUD GUARD Remove the 2 air cleaner washer bolts. Remove the mud guard securing the muffler . Remove the rear wheel mud guard. Install in the reverse order of removal. MUFFLER Loosen the 2 cap nuts securing the cylinder head. Loosen the muffler flange bolt securing muffler stay. Pull the Ex.pipe downward to remove the muffler comp. Install in the reverse order of removal. NOTE Never performing the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot.. 4-3 EXTERNAL PARTS INNER COVER Remove. -The 8 screws of inner cover -Floor side cover screw -Back holder -Front cover -Floor side cover -Floor panel -Inner cover Install in the reverse order of removal. METER COVER Remove. -Head light -Upper handle cover -Speedometer cable -Coupler and wire -Screw securing meter cover Install in the reverse order of removal. 4-4 EXTERNAL PARTS HANDLE COVER Remove. -Head light lim -Head light -The 4 tapping screws securing the under handle cover -Upper handle cover Install in the reverse order of removal. FRONT COVER Loosen the 1 special screw of front cover. Loosen the 8 tapping screws securing the inner cover. Loosen the 4 tapply screw securing the under cover. Remove the front cover. Install in the reverse order of removal. 4-5 EXTERNAL PARTS FLOOR SIDE COVER Loosen the floor panel fixing bolt. Loosen the 2 screws and pull the floor side cover back ward to remove it. Install in the reverse order of removal. EX. MUFFLER FLANGE BOLT FLANGE BOLT CAP NUT FLOOR PANEL Remove. -Floor side cover -4 washer bolts -Pull the floor panel backward to remove it Install in the reverse order of removal. UNDER COVER Remove the floor side cover. Loosen the 4 bolts and remove the under cover. Install in the reverse order of removal. 4-6 EXTERNAL PARTS BODY COVER Remove. -Luggage box -Rear carrier -The 4 washer screw -Body cover Install in the reverse order of removal. CENTER COVER Remove the body cover. Loosen the floor planel fixing bolt. Loosen the washer screw. Open the fuel lid with the key, and remove the center cover. Install in the reverse order of removal. REAR FENDER Remove. -Luggage box -Rear carrier -Body cover -Loosen the 3 washer bolts -Rear fender Install in the reverse order of removal. 4-7 EXTERNAL PARTS SEAT Release the seat lock by turning the main switch key to open the seat. Loosen the flange nuts and remove the seat. Install in the reverse order of removal. LUGGAGE BOX Release the seat. Loosen the 3 flange bolts and the 2 cap nuts. EX. PIPE FLANGE NUT Remove the luggage box. Install in the reverse order of removal. REAR CARRIER Loosen the 4 flange bolts. Remove the rear carrier. Install in the reverse order of removal. 4-8 MEMO