User manual DAELIM NS125III - SERVICE MANUAL

SERVICE MANUAL SERVICE MANUAL HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997 SM37-0211-01E Engine How to use this manual This manual describes effective maintenance procedure for the NS125 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 Frame Electrical System Lubrication Inspections/Adjustments External Parts Fuel System Engine Removal/Installation L. Crank Case Cover / Kick Starter / Continuously Variable Transmission Generator/Starter Clutch Cylinder Head/Valve Cylinder/Piston 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 Service Rules Caution when Wiring Identification Numbers 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 Identification Numbers Frame serial number Engine serial number FARME SERIAL NUMBER LOCATION The frame serial number is stamped on the front central part of the frame. ENGINE SERIAL NUMBER LOCATION The engine serial number is stamped on the central part of the left crankcase. 1-9 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 0.12 0.02 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 filter change 0.8 After Oil change 0.9 After Oil change with Oil in the Oil hose removed Forced pressure splash type Wet sump 13.8kg/ Open 5 BTDC Closed 14 ABDC Closed 18 BBDC Closed 1 ATDC 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 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 -112 Autoby-starter #95 1 and 1/2 trust out 13 mm 1,800 100(rpm) Automatic Transmission 3.231(42/14) 2.786(39/14) C.D.I. lgnition 15 BTDC/1,800(rpm) 19 125W/5,000(rpm) Closed type (MF)12V 8AH 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 1-11 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 1-12 Service Information 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) 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 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 1-13 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 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 1-14 Service Information Wiring Diagram Front brake master cylinder Winker relay Rear brake cable Speedometer Cable Front winker connector Main switch Resister(excepted some countries) Front brake hose Stop switch connector Front winker connector Packing lever Horn Radiator Front brake hose Throttle cable Radiator hose Rear brake cable Speedometer cable 1-15 Service Information CDI unit Ignition coil Radiator hose CDI unit Ignition coil Throttle cable Fuel filter Fuel pump Rear brake cable 1-16 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 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 Oil capacity 1.1 (After disassembly) 0.75 (After Oil filter change) 0.8 (After Oil 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 0.08 0.17(0.003-0.007) 0.03 0.13(0.001-0.005) 0.04 0.09(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 Oil drain plug bolt 1.5kg 1.1kg 1.1kg 2.5kg m, (15N m, 11ft m, (11N m, 8ft m, (11N m, 8ft m, (25N m, 18ft Ib) Ib) Ib) Ib) 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 grease Front brake lever pivot 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/Shoe 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 3-10 3-10 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 Carburetor idle speed Cylinder pressure IN EX 2 6mm(1/8-1/4 in) CR8EH-9 0.8 0.9mm(0.031-0.035in) 0.12 0.02mm(0.005 0.001 in) 0.12 0.02mm(0.005 0.001 in) 1,800 100rpm 13.8kg/ 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/ ) 280kPa (2.80kg/ ) 120/70-13(Tubeless) 130/60 13(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 1.1kg 1.0kg 1.1kg 0.6kg m, (11N.m, 8ft m, (10N.m, 7ft m, (11N.m, 8ft m, (6N.m, 4.3ft lb) lb) lb) lb) 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 Oil Dry Squeeze out oil Wash Gear oil (#80-90) 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) 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 Remove the brake fluid cover. Check the oil level inside the front brake reservoir. If the oil level 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. Brake hose bolt Master cylinder Brake Pad/Shoe Brake pad replacement Check the brake pads for wear. If the red mark on the pad reaches the brake disc, replace the pads. NOTE Replace the brake pads in sets. Red Mark Brake Shoe Replacement If the arrow mark of the wear limit aligns with the mark when the rear brake lever is fully pressed, it indicates the brake lining has reached the service limit. Replace the brake shoes. ` ' mark Brake System 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 hose Brake caliper 3-7 Inspections/Adjustments Brake Lever Free Play Check the free play after pulling the lever. Front:10-20mm Rear:10-20mm Rear Brake Free Play Adjustment Turn the adjuster nut to adjust the free play. After initial adjustment, check the operation of the rear brake light switch. Make additional adjustments, if necessary. Adjuster 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 3-8 Inspections/Adjustments 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 Suspension NOTE Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle s safety and operation efficiency. Front wheel Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions. 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 3-9 Inspections/Adjustments 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) 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. 4-1 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 inner box Install in the reverse order of removal. Front inner box Screw Nut 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