User manual DAELIM NS125DLX - SERVICE MANUAL

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 riding area based on the table shown on the right side.) 10W 20·20W 30 40 20W 50 20W 40 10W 40 10W - 30 ­10 0 10 20 30 40 Oil Recommendation Oil Pump Item Pump body clearance Rotor tip clearance Pump side clearance Standard value 0.08­0.17(0.003-0.007) 0.03­0.13(0.001-0.005) 0.04­0.09(0.002-0.004) Unit: mm(in) Tolerance 0.23(0.009) 0.18(0.007) 0.12(0.005) Torque Values Oil filter screen cap Oil filter cover bolt Oil pump mounting bolt 1.5kg­m, (15N.m, 11ft­Ib) 1.1kg­m, (11N.m, 8ft­Ib) 1.1kg­m, (11N.m, 8ft­Ib) 2-1 Lubrication Troubleshooting Oil level too low - high oil consumption External oil leaks Worn piston rings Worn valve guide or seal Oil contamination Oil or filter not changed often enough Head gasket faulty Worn piston rings Low oil pressure Oil level now Pressure relief valve stuck open Plugged oil pick-up screen Oil pump worn External oil leaks High oil pressure Pressure relief valve stuck closed Plugged oil filter, gallery, or metering orifice Incorrect oil being used No oil pressure Oil level low Oil Pump drive gear broken Oil pump faulty Internal oil leakage 2-2 Lubrication Engine Oil Level Check Erect the motorcycle on the main stand. Warm up the engine to heat the engine oil to an appropriate level. Stop the engine, and check the oil level line on the sight-glass installed on the L. crank case cover. If the oil level is between the lower and higher sight-glass oil level line, oil level is satisfactory. If the oil level is below or near the lower level mark, add the recommended engine oil. Sight-glass Engine Oil Change NOTE ·To completely and rapidly drain engine oil, warm up engine and erect the motorcycle on its side stand. Loosen the oil drain plug bolt and drain engine oil. Operate the kick starter arm several times to remove the remaining oil from the engine. Tighten the oil drain plug bolt. Torque value: 2.0-3.0kgf 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. · Tighten the hole cap with specified tightening torque. Torque value: 1.5kgf m Loosen the special screw, remove the plug maintenance cover. Fill the recommended oil after opening oil filter cap of cylinder head cover. 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 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. Filter screen Drain plug bolt Tappet adjusting hole cap 2-3 Lubrication Oil Filter Element Change Drain engine oil. ( 2-3) Remove the oil filter cover bolts, filter cover, filter element and spring. Oil filter cover Change the oil filter element with a new one. Check the relief valve inside the oil filter cover for satisfactory operation. Check if the oil filter seal is in good condition. Assemble the filter element spring and filter cover, and tighten bolts. Torque value: Oil filter cover 1.1kg-m(11N.m.8ft-lb) Element Oil filter seal Oil Pump Remove the following parts: - Luggage box ( 4-5) - Rear cushion bolt( 6-2) - RH. floor side cover( 4-5) - Exhaust muffler( 4-9) - Center cover ( 4-4) - Shroud ( 8-2) - Cooling fan( 8-2) - R. Crank cover ( 8-4) - A.C. generator ( 8-2) - Starter driven gear and reduction gear ( 8-5) - Starter clutch ( 8-6) Loosen the oil pump drive gear setting nuts. Drive gear Nut Setting bolts Remove the oil pump drive gear. Remove the oil pump driven gear. 2-4 Lubrication Remove the oil pump. Clean the oil pump body, inner and outer rotors with fresh cleaning oil. Pump plate Pump body Pump shaft Outer rotor Inner rotor Setting pin Inspection Assemble the inner and outer rotors to the oil pump Measure the pump body clearance. Service limit: 0.23mm (0.009in) Measure the rotor tip clearance. Service limit: 0.18mm (0.007in) Outer rotor Inner rotor Measure the pump side clearance. Service limit: 0.12mm (0.005in) 2-5 Lubrication Removal/Installation Remove the inner and outer rotors from the pump body. Clean all parts with fresh cleaning oil. Install the inner and outer rotors. Assemble the pump shaft with setting pins. Pump plate Pump body Pump shaft Outer rotor Inner rotor Setting pin Attach the oil pump plate to the pump body. Tighten screws. Pump Plate Screw Installation Assemble the oil pump to the R. crank case cover. Install the following parts. - Oil pump drive gear and driven gear - Starter clutch - Starter driven gear and reduction gear - A.C. generator - R. crank case cover - Shroud and cooling fan - Center cover - Body cover - Luggage box Setting bolts 2-6 Lubrication Radiator Removal/Installation Remove the front wheel. Remove the front cover, front side cover and inner box. Loosen the flange bolt(3EA), oil bolt and remove the radiator from the main pipe bracket. Radiator bolts Radiator bracket Radiator collar Radiator Flange bolt 2-7 Lubrication Inspection Check the damage or oil leaks from the radiator. Radiator Installation Assemble the radiator to the main pipe bracket. Tighten the oil bolt. Install the inner box. Install the front side cover. Radiator bolts 2-8 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. grease Front brake lever pivot grease Throttle grip grease Setting head bearing grease Front fork dust seal grease Wheel bearing grease grease Brake caliper bracket grease Side/main stand pivot Wheel bearing /speedometer gear 2-9 MEMO Inspections/Adjustments 3. Inspections/Adjustments Service Information Regular Inspection Schedule Fuel Line Throttle Grip Operation Air Cleaner Spark Plug Valve Tappet Clearance Cylinder Compression Pressure Carburetor Idling Brake Fluid 3-1 3-3 3-4 3-4 3-4 3-5 3-5 3-6 3-6 3-7 Brake Pad Brake System Brake Lever Free Play Headlight Adjustment Side Stand Suspension Bolts and Nuts Wheels/Tires Steering Head Bearing 3-7 3-7 3-8 3-8 3-8 3-9 3-9 3-9 3-10 3 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. NOTES ·For information on engine oil and oil filter, refer to sections 2-3 and 2-4 ·Stand the main stand prior to beginning work. Specifications Throttle grip play Spark plug Spark plug gap Valve clearance IN EX 2­6mm(1/8-1/4 in) CR8EH-9 0.8­0.9mm(0.031-0.035in) 0.12± 0.02mm(0.005±0.001 in) 0.12±0.02mm(0.005±0.001 in) 1,600±100rpm 13.8kg/ Carburetor idle speed Cylinder compression pressure Tires Driver only Cold tire pressure Driver and a passenger Front tire Rear tire Front tire Rear tire Front tire Rear tire Front tire Rear tire 175kPa (1.75kg/) 200kPa (2.00kg/) 225kPa (2.25kg/) 225kPa (2.25kg/) 120/70-13(Tubeless) 130/70-12(Tubeless) 4mm (0.16 in) 7.5mm (0.3 in) Tire size Min,tread depth 3-1 Inspections/Adjustments Torque Values Spark plug Cylinder head cover bolts Valve adjusting nuts Timing hole cap 1.1kg­m, (11N.m, 8ft­lb) 1.0kg­m, (10N.m, 7ft­lb) 1.1kg­m, (11N.m, 8ft­lb) 0.6kg­m, (6N.m, 4.3ft­lb) Tools Wrench, 8×9mm Adjusting wrench Compression gauge 3-2 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 Frequency Item Fuel line(Fuel tube) Fuel filter Throttle grip operation Air cleaner Spark plug Valve clearance Transmission oil Engine oil Engine oil filter element Carburetor idle speed Brake fluid Brake shoe/pad Brake system Brake stop switch Headlight beam distance Side stand Suspension Bolt and nut tightness wheels/tires Steering head bearing Odometer reading(Note 1) 1000km 4000km 8000km 12000km I R I 6 12 I I R R I I C for each 1,000km I R I I R R I I I I I I I I I I R R I I I I I I I I I I 18 I R I Note 2 I I R R R I R I I I I I I I I Remark I R R I Note 3 I I Should be received by an authorized DAELIM dealer, unless the owner has proper tools and service data and not mechanically qualified. In the interest of safety, we recommended these items be served only by an authorized DAELIM dealer. 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 Inspecitions/Adjustments Fuel Line (Fuel Tube) Remove the luggage box ( 4-5) 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. Fuel tube Fuel pump Throttle Grip Operation Check if the throttle grip operates smoothly in any steering position. If the throttle grip does not operate properly, lubricate the throttle cable. If the throttle grip does not operate properly, check the throttle cable for aging, damage or kinking. Check the throttle grip free play. Free play: 2~6mm(1/8~1/4in) Air Cleaner Unlock the system with main key, and open the seat. Loosen the 6 setting screw assembled to the air cleaner case cover. Loosen the 2 setting screw assembled to the air cleaner element. Screw Remove the air cleaner element. Air cleaner element Screw 3-4 Inspecitions/Adjustments Soak the element in solvent, and dry completely. Soak in gear oil (SAE #80-90), and squeeze firmly to remove excessive oil. If the element is excessively contaminated or damaged, replace it. Assemble in the reverse order of the disassembling. Squeeze Dry Squeeze out oil Spark Plug Remove the plug maintenance cover. Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits. If the spark plugs are severely contaminated or damaged, replace with new ones. If the plugs can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plugs. Always use a feeler gauge to check the clearance. Genuine plug: CREH-9 Spark plug clearance: 0.8-0.9mm Torque value: 1.1kg-m(11N.m, 8ft-lb) Oil Wash Gear oil (#80-90) Check gap 0.8~0.9mm Check washer for damage Check for cracks. NOTE ·First, manually tighten the plugs, and use a spark plug wrench to tighten completely. Valve Tappet Clearance Remove the following parts. -- Center cover. ( 4-4) Loosen the 4 cylinder head bolts. NOTE ·Carry out inspection/adjustment when the engine is cold. (35/95F) ·Remove the cylinder head cover. ·Turn the flywheel counterclockwise, and match the "T" mark on the flywheel with the index mark on the R 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 tappet clearance: Intake: 0.12±0.02mm(0.05±0.001in) Exhaust: 0.12±0.02mm(0.05±0.001in) Cylinder head cover "T" mark 3-5 Inspections/Adjustments 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: 1.1kg-m(11N.m,8ft-lb) × Tools: Wrench 8×9mm Adjusting wrench B Measure the valve clearance again. Install the cylinder head cover and tighten the bolts. Torque values: 1.0kg-m(10N.m. 7ft-lb) Feeler gauge Adjusting wrench Cylinder Compression Pressure Start and warm up the engine. Remove the plug maintenance cover. 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: 13.8kg/cm2 If the pressure is low, check the following: - Inadequate valve clearance adjustment - Valve leakage - Leakage from the cylinder had gasket - Piston / cylinder worn If pressure is high, check the following: - Carbon deposits on the piston head, and cylinder head. Spark plug cap Compression gauge Carburetor Idling NOTE ·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. Throttle Stop Screw 3-6 Inspecitions/Adjustments Brake Fluid Front brake fluid Remove the screw rivet and take the front brake fluid maintenance lid off. Check the oil level inside the front brake reservoir. If the oil is near the lower limit line, remove the reservoir diaphragm 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. Rear brake fluid Replenish in the same method as that of front brake fluid replenishment. Front master cylinder Rear master cylinder Brake Pad Front brake pad replacement Check the front brake pads for wear. If the red mark on the pad reaches the brake disk, replace the pads. Front Rear Rear brake pad replacement Replace in the some method as that of front brake pad replacement. NOTE ·Replace the brake pads in sets. Red mark Red mark Brake System Check the front brake hose and the rear brake hose for cracks or damage. If any leaks are found, replace immediately. Check the front brake rod and the rear brake rod for looseness or damage, and replace it if necessary. Front brake hose Front brake caliper Rear brake caliper 3-7 Inspections/Adjustments Brake Lever Free Play Check the free play after pulling the lever. Front:10-20mm Rear:10-20mm FRONT BRAKE REAR BRAKE Headlight Adjustment Adjust the headlight beam level by operating the adjusting screw located on the upper side of the front fender. NOTE ·Adjust the beam level according to local laws and regulations. ·Improper beam level adjustment may blind on coming drivers, or may incorrectly light the road ahead. Adjuster 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. Side stand spring Check the side stand ignition cut-off switch ; -Put the side stand up. -Start the engine. -Lower the side stand. The engine should stop as you put the side stand down. If there is a problem with the system, check the side stand swich. Side stand switch 3-8 Inspections/Adjustments Suspension NOTE ·Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle' safety and s 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 several times to check the operating conditions. Check the rear fork for oil leakage, parts damage or looseness. Bolts and Nuts Tightening Check all nuts and bolts of the frame during the regular maintenance ( 3-3) to check if they meet the prescribed torque value. Check all pins, clips, hose clamps and cable stays. F F 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. Tire pressure gauge Standard Pressure Item Driver only Driver and a passenger kg/(kPa) Front wheel 1.75(175) 2.25(225) Rear wheel 2.00(200) 2.25(225) 3-9 Inspections/Adjustments Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tire. Service limit: 4mm (0.16in) 7.5mm (0.3in) Wear indicator position mark 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. 3-10 External Parts 4. External Parts Service Information 4-1 Maintenance Procedure 4-2 External Parts Removal/Installation 4-3 Muffler Front Fender 4-9 4-10 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 4-1 External Parts Maintenance Procedure Names of frame covers This chart shows arrows connected in the order of disassembling covers. Front cover Floor side cover Luggage box Front handle cover Rear carrier Inner box Rear handle cover Center cover Front side cover Rear under cover Maintenance cover Body cover Rear upper cover Floor panel Tail combination-light 4-2 External Parts Front Cover removal/Installation Loosen the 2 upper screws. Loosen the 2 lower screws. Pull upward and remove the front cover. Install in the reverse order of removal. Front cover Screw Screw Front Side Cover Removal/Installation Remove the front fender. ( 4-10) Remove the front wheel. ( 12-5) Remove the 2 front lower flange bolts and the 2 upper screws. Remove the 2 inner box setting screws. Remove the front side cover. Install in the reverse order of removal. Screw Screw Inner box Bolt Front side cover 4-3 External Parts Inner Box Loosen the 2 bolts installed on the bag holder. Remove the bag holder. Open the inner box lid. Remove the 1 cap nut. Remove the 2 flange bolt installed on the floor panel. Remove the 6 front side cover screws. Remove turn the main key cover slightly to unlock, and remove the main key cover. Remove the charge socket from the inner box. Remove the inner box. Install in the reverse order of removal. Front inner box Screw Nut Charge socket Bolt Radiator Bag holder Center Cover Loosen the 4 setting screws assembled to the body cover. Remove each of the setting screws assembled to the floor panel. Band inwards, and remove the center cover. Install in the reverse order of removal. Screw Center cover Flug maintenance cover Screw 4-4 External Parts Side Cover Remove the floor mat. Loosen the 2 screws on the side of the R/L side covers. Loosen 1 each of the R/L screws assembled to the floor panel. Loosen 3 each of the R/L body cover clips assembled to the floor panel. Remove R/L side covers. Install in the reverse order of removal. Side stand switch Bolt Side cover Luggage Box Unlock the system with the main key, and open the seat. Loosen the 4 cap nuts. Remove the fuel tank cap. NOTE ·Assemble the fuel tank cap after removing the luggage box. Remove the luggage box. Install in the reverse order of removal. Remove the wiring of trunk lamp. Seat Trunk lamp Screw Nut Fuel tank cap Luggage box Hinge pin Bolt 4-5 External Parts Rear Carrier Loosen 1 each of the R/L flange bolt set on the body cover side. Loosen the 2 flange bolts set on top of the body cover. Remove the rear carrier. Install in the reverse order of removal. Body cover clip Rear upper cover Screw Rear carrier Screw Frame body cover Body Cover/Rear Cover Remove the rear carrier. ( 4-6) Remove the luggage box. ( 4-5) Remove the center cover. ( 4-4) Loosen 2 each of the R/L body cover grill screws set with the floor panel. Loosen 1 each of the R/L body cover clips assembled to the rear fender. Loosen 1 each of the R/L flange bolts set on the frame body. Loosen 2 rear under cover setting screws, and remove the rear under cover. Remove the R/L frame body cover. Loosen the 2 rear upper cover setting screws. Install in the reverse order of removal. fuel fiter puel pump 4-6 External Parts Floor Panel/Battery Cover Remove the center cover. ( 4-4) Loosen 2 each of the R/L pillion step cover setting screws of the floor mat, and remove the floor mat. Loosen the 2 battery cover setting screws, and remove the battery cover. Withdraw the battery wiring, and remove the battery. Remove the air cleaner duct. Loosen the 4 setting bolts. Remove the side cover. ( 4-5) Remove the 4 center cover setting screws. Remove the floor panel. Install in the reverse order of removal. Floor mat Bolt Screw Bolt Floor panel Battery cover cover Tail Combination-Light Remove the following parts. - Luggage box. ( 4-5) - Luggage carrier. ( 4-6) Rear under - Body cover. ( 4-6) cover - Rear under cover. ( 4-6) Loosen the 2 bolts assembled Screw to the frame rear part. Loosen the 2 R/L side setting bolts. Remove the tail combinationlight wiring. Remove the tail combinationlight Bolt Install in the reverse order of removal. Bolt 4-7 External Parts Handle Cover Front Handle Cover Loosen the 4 rear handle cover setting screws. (1 each on R/L side, and 2 each on meter side) Loosen 1 front handle cover setting screw. Remove 1 R/L handle side cover lower screw, Screw and 1 each of the special upper side screws. Pull the front handle cover forward, and remove the wiring. Screw Remove the front handle cover. Install in the reverse order of removal. Rear view mirror Bolt Handle side cover Front handle cover Meter Speedometer cable Rear Handle Cover Loosen the 3 screws assembled to the handle bar. Loosen the 3 screws assembled to the meter. Remove the R/L side switch wiring. Remove the rear handle cover. Install in the reverse order of removal. Rear handle cover Screw Rear master cylinder 4-8 External Parts Muffler Removal Loosen the 3 flange nuts securing the EX. pipe comp. Loosen the rear brake hose setting bolt. Loosen the flange bolt securing the rear wheel mud guard. Loosen the 2 flange bolts securing the R. crankcase. Remove the EX. muffler comp. WARNING ·Never perform the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot. EX.pipe Flange bolts EX. Pipe removal Remove the plug maintenance cover. Loosen the 2 flange bolts securing the cylinder comp. Remove the EX. pipe by drawing it to the ground direction. EX.pipe Flange bolts Installation Install the 2 flange bolts after securing the EX. pipe with the stud bolt of the cylinder comp. Install the gasket on the EX. muffler, connect the EX. pipe and install the 2 flange nuts temporarily. Install the 2 flange bolts on the R.crankcase temporarily. Tighten the 3 flange nuts to install the EX. muffler and EX. pipe. Install the flange bolt on the rear wheel mud guard. Tighten the muffler securing 2 flange bolts to install the R. crankcase. Tighten torque of the R. crankcase. Torque: 5.5kg-m(55N.m, 40ft-lb) Tighten the rear brake hose setting bolt. WARNING ·When installing the gasket, replace it with the new one. ·Check to see if there is any evacuation after installing the muffler. EX.pipe Flange nuts 4-9 External Parts Front Fender Loosen the flange bolt connecting the front fender A and B. Bolt Fender A Screw Loosen the 2 setting screws of the front fender A, and remove the front fender A. Fender B Screw Loosen 1 setting screw of the front fender B. Remove the speedometer cable guide. Remove the front fender B. Install in the reverse order of removal. 4-10