SERVICE MANUAL Engine How to use this manual This manual describes effective maintenance procedure for the NS125DLX 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 Lubrication Inspections/Adjustments External Parts Fuel System Engine Removal/Installation L. Crank Case Cover / Kick Starter / Continuously Variable Transmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Generator/Starter Clutch Cylinder Head/Valve Cylinder/Piston Frame Electrical 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.. Transmission/Crankshaft/Crank Case Front Wheel/Front Fork/Steering Rear Wheel/Brake/Suspension Brake System Charging System/Battery Ignition System Starter System Light/Switch/Horn Wiring Diagram Troubleshooting Service Information 1. Service Information General Safety Removal/Installation Safety Identification Numbers Specifications 1-1 1-1 1-2 1-3 Torque Values Symbols/Abbreviations Cable & Harness Routing 1-5 1-7 1-8 1 General Safety WARNING 1. The Exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. 2. The battery acid (sulfuric acid) is poisonous, and contact with skin or eyes may cause severe burns or loss of sight. If the acid gets on your skin, flush with large amount of water, and consult a physician. If your clothing makes contact with the acid, wash in water and avoid your skin from making direct contact with the battery acid. Store battery and the battery acid in a safe place. Keep out of reach of children. 3. The dust accumulated in the brake drum contains carcinogenic substance. If you clean the brake drum with an air hose, dust may be blown and dispersed into air, and inhaled. Use brake cleaner or other appropriate method to minimize hazard caused by airborne dust. 4. Gasoline is extremely flammable. Never allow fire in the working area. Take particular precautions not only for general flames but also electric sparks. Furthermore, evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated area. 5. 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. Removal/Installation Safety 1. Use only the genuine Daelim or Daelim-recommended parts and lubricants. 2. Use the special tools designed for this product. 3. Install new gaskets, O-rings, piston pins, clips, cotter pins (split pins), etc. when reassembling them. 4. When tightening bolts, nuts or screws, temporarily tighten them first, and tighten diagonally to the specified torque, starting with those having larger diameter to those with smaller diameter, from inner side towards outer side. 5. Use only metric bolts, nuts, and screws. Do not use inch screws. 6. Clean parts prior to inspection after disassembly, and remove cleaning oil with compressed air lubricate sliding parts prior to reassembly. 7. Use recommended grease on designated lubricating points. 8. Upon completion of assembly, check all parts for appropriate tightness and operation. 1-1 Service Information Identification Numbers Frame serial number Engine serial number 1-2 Service Information Specifications Item Overall length Overall width Overall height Dimensions Wheel base Seat height Ground clearance Dry weight Curb weight Type Front suspension/stroke Rear suspension/stroke Front tire size/type Rear tire size/type Tire Pressure 1 person Front Rear Frame 2 person Front Rear Front brake Rear brake Fuel tank capacity Full capacity Reserve capacity Caster angle Trail Front fork oil capacity Type Cylinders/Arrangement Bore and stroke Displacement Compression ratio Valve train Oil capacity Engine Lubrication system Air cleaner type Cylinder compression Intake valve: Exhaust valve: Valve clearance(cooling-off period) intake Exhaust 0.12 ± 0.02 0.12 ± 0.02 Specifications 1,970mm 700mm 1,110mm 1,350mm 765mm 130mm 110kg 240kg Underbone Telescopic/97mm Swing arm/74mm 120/70-13/Tubeless 130/60-13/Tubeless 1.75kg/(175kPa) 2.00kg/(200kPa) 2.25kg/ (225kPa) 2.25kg/ (225kPa) Hydraulic disk Drum brake 7.5 1.2 25 84.7 80 Oil cooled/air cooled 4 cycle SOHC engine 1(Single cylinder), front angle 80 56 ×50.7 mm 124.9 10.8 : 1 SOHC chain drive 1.1 After disassembly 0.75 After Oil change 0.8 After Oil filter change 0.9 After Oil change with Oil in the Oil hose removed Forced pressure splash type Wet sump 13.8kg/ 5 BTDC 14 ABDC 18 BBDC 1 ATDC Open Closed Closed Closed 1-3 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 F mark Full advance AC generator capacity Battery type/capacity Spark plug Spark plug gap Fuse capacity starting system Headlight(high/low) Position light Turn signal light(Fr/Rr) Tail/stop light High-beam indicator Turn signal indicator Speedometer lamp Trunk lamp Specifications CV type(vacuum)24.2mm BDS 26 92 H1 Autoby-starter 92.5 3 and 1/4 trust out 17.5 1,600±100(rpm) Automatic Transmission 3.231(42/14) 2.786(39/14) C.D.I. lgnition 8 BTDC/1,600(rpm) 19 125W/5,000(rpm) Closed type (MF)12V 6AH CR8EH-9 0.8-0.9mm(0.031-0.035in) 15A Kick/starter motor 12V 35/35W 12V 3.4W 12V 10W×4 12V 21 / 5W 12V 3.4W 12V 3.4W×2 1.7W×2 1.4W×1 Carburetor Drive Train Electrical Systems 1-4 Service Information Torque Values Engine Item Oil filter cap Valve adjust screw lock nut Kick starter pedal bolt Flywheel bolt Drive face bolt Clutch outer bolt Cam chain tensioner pivot bolt Spark plug Cam sprocket bolt Camshaft holder nut Cam chain tensioner mounting bolt Cam chain tensioner sealing screw Cylinder head cover bolt Transmission cover bolt Transmission cover drain bolt Transmission cover check bolt Cooling fan bolt Starting clutch nut Starter motor terminal nut Radiator hose eye joint bolt Radiator hose nut Q'ty 1 4 1 1 1 1 1 1 2 4 2 1 4 8 1 1 3 1 2 4 2 Thread dia(mm) 20 5 6 12 12 12 8 12 6 8 6 6 6 6 8 8 6 22 6 12 14 Torque value kg.m(N.m,ft-lb) 1.5(15, 11) 1.1(11, 8) 1.2(12, 8) 5.5(55, 40) 5.5(55, 40) 5.5(55, 40) 1.0(10, 7) 1.2(12, 9) 1.2(12, 9) 2.0(20, 14) 1.2(12, 9) 0.4(4, 2.9) 1.0(10, 7) 1.2(12, 8) 1.0(10, 7) 0.9(9, 6) 1.0(10, 7) 9.5(95, 67) 0.9(9, 6) 3.2(32, 23) 3.2(32, 23) Remarks Apply engine oil Apply engine oil Apply engine oil Frame Item Steering stem lock nut Steering top thread nut Handle post nut Front fork bottom bridge bolt Front fork socket bolt Front axle nut Front brake disk bolt Ignition coil bolt Rear axle nut Engine hanger nut Engine hanger plate bolt Q'ty Thread dia(mm) 1 1 1 4 2 1 3 1 1 2 6 26 26 10 10 8 12 8 5 14 10 10 Torque value kg.m(N.m,ft-lb) 7.5(75, 55) 0.3(3, 2) 6.0(60, 44) 7.5(75, 55) 2.0(20, 14) 5.5~6.5(55~65, 40~47) 3.9(39, 28) 0.5(5, 4) 6.0-8.0(60-80, 43-58) 7.3(73, 53) 2.7(27, 20) Remarks Initial torque Apply locking agent Apply locking agent 1-5 Service Information Item Brake caliper bracket bolt Brake caliper bleeder valve Brake caliper slide pin (socket bolt) Brake caliper pin bolt Brake pad pin bolt Master cylinder reservoir cap Brake hose bolt Brake lever pivot bolt Brake lever pivot lock nut Rear shock-absorber upper bolt Rear shock-absorber lower bolt Rear shock-absorber damper rod lock nut Q'ty Thread dia(mm) 2 1 1 1 2 4 2 1 1 1 1 2 8 8 8 8 8 4 10 6 6 10 10 10 Torque value kg.m(N.m,ft-lb) 2.7(27, 20) 0.6(6, 4.3) 2.3(23, 17) 1.8(18, 13) 1.8(18, 13) 0.13(1.3, 0.94) 3.5(35, 25) 1.0(10, 7) 1.0(10, 7) 2.7(27, 20) 4.0(40, 29) 3.8(38, 27) Remarks Apply locking agent Apply locking agent Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table. 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 N.m Kg-m ft-lb 5 10 22 35 55 0.5 1.0 2.2 3.5 5.5 4 7 16 25 40 Item 5mm screw 6mm screw 6mm flange bolt, nut 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut Torque Value N-.m Kg-m ft-lb 4 9 9 12 27 40 0.4 0.9 0.9 1.2 2.7 4.0 3 7 7 9 20 29 1-6 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 vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures. WARNING CAUTION Indicates dangerous area. Serious accident may result if instructions are not followed. NOTE The following symbols indicate oil adding, oil change, or parts. Symbol OIL GREASE ( 3-1) Meaning 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 L. R. Assembly Left Right 1-7 Service Information Cable & Harness Routing Note the following when routing cables and wire harnesses: A loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. Do not squeeze wires against the weld or its clamp. Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire or wire harnesses. Route harnesses so they are neither pulled tight nor have excessive slack. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. Do not use a wire or harness with a broken insulator. Repair by wrapping them with protective tape or replace them. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. Keep wire harnesses away from the exhaust pipes and other hot parts. Be sure grommets are seated in their grooves properly. After clamping, check each harness to be certain that it is not interferring with any moving or sliding parts. After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched by or interfere with adjacent or surrounding parts in all steering positions. Do not twist or band the cable excessively. Distorted or damaged cables may lead to mechanical malfunctions or other damages. : Correct ×: Incorrect 1-8 Service Information Front brake master cylinder Winker relay Rear brake cable Speedometer Cable Front winker connector Main switch Stop switch connector Front winker connector Charge socket connector Front brake hose Side stand switch connector Packing lever Chage socket Horn Radiator Front brake hose Throttle cable Radiator hose Rear brake cable Side stand switch Speedometer cable 1-9 Service Information CDI unit Ignition coil Radiator hose CDI unit Ignition coil Throttle cable Fuel filter Fuel pump Side stand switch Rear brake cable 1-10 Lubrication 2. Lubrication Service information Troubleshooting Engine Oil Level Check Engine Oil Change 2-1 2-2 2-3 2-3 Oil Filter Element Change Oil Pump Radiator Lubrication Points 2-4 2-4 2-7 2-9 2 Service Information General Safety WARNING 1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. 2. 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. 3. The oil pump can be serviced without removing the engine from the frame. Engine Oil Oil capacity 1.1 (After disassembly) 0.75 (After Oil change) 0.8 (After Oil filter change) 0.9 (After Oil change with Oil in the Oil hose removed) API service classification: SE, SF, SH grade Viscosity: SAE10W-30 (Use appropriate type of oil with viscosity satisfying the atmospheric temperature In your rid ...