How to use this manual General This manual explains how to maintain procedure for the S2-125 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 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. 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., Contents Service Information Inspections / Adjustments External Parts Lubrication System EMS(Engine Management System) Fuel System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Engine Removal / Installation Engine Frame Electrical LH, Crank Case Cover Continuously Variable Transmission A.C Generator / Starter Clutch Cylinder Head / Valves Cylinder Head / Piston Transmission / Crank Shaft Crank Case Front Wheel / Front Fork / Steering / Brake Rear Wheel / Rear Brake / Suspension / Rear Swing Arm Charging System Ignition System Starter System Lights / Switches / Horn Wiring diagram SERVICE INFORMATION 1 1-1 SERVICE INFORMATION 1-2 SERVICE INFORMATION 1-3 SERVICE INFORMATION 1-4 SERVICE INFORMATION 1-5 SERVICE INFORMATION 1-6 SERVICE INFORMATION 1-7 SERVICE INFORMATION 1-8 SERVICE INFORMATION FRAME SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION 1-9 SERVICE INFORMATION 1,965mm 743mm 1,120mm 1,350mm 770mm 126mm 127kg 277kg 60 1.75 2.25 9.6 2.2 25 80 90/70 stroke SOHC 13.8 380 ATDC 1-10 SERVICE INFORMATION , 30A LED LED LED 1-11 SERVICE INFORMATION 1-12 SERVICE INFORMATION 1-13 SERVICE INFORMATION SEAT LOCK CABLE HORN COMP. THROTTLE CABLE HAZARD RELAY SEAT LOCK CABLE BATTERY + CABLE EARTH CABLE Y HEAD LIGHT (COUPLER) RR.BRAKE HOSE A RR. BRAKE HOSE PIPE FR.BRAKE HOSE C THROTTLE CABLE SEAT LOCK CABLE FUEL BREATHER TUBE FUEL SUPPLY TUBE LH. RADIATOR HOSE THROTTLE CABLE BREATHER TUBE ECU UNIT FRM.EARTH CORD SIDE STAND SW.ø¨·OE COUPLER FUEL HOSE(TO. INJECTOR) FUEL PUMP(TO. INJECTOR) RADIATOR ASS'Y. BRAKE HOSE CLAMP FR.BRAKE HOSE C FR. BRAKE HOSE SIDE STAND SW. DRAIN TUBE(AIR CLEANER) SPEEDOMETER CABLE SEAT LOCK CABLE HORN COMP. TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER COUPLER ACG. & CPS CORD X TRUNK LAMP COUPLER IGNITION COIL EARTH CORD EARTH CABLE BATTERY + CABLE RR. BRAKE HOSE PIPE RADIATOR ASS'Y. MAIN WIRE HARNESS FUEL SUPPLY TUBE FUEL BREATHER TUBE CHARGE SOCKET COUPLER JUNCTION VALVE FR. BRAKE HOSE RR.BRAKE HOSE START MOTOR CABLE 1-14 Z HARNESS POSITION CLAMP HIGH TENSION CORD NOISE SUPPRESSOR CAP THROTTLE CABLE FUEL HOSE(TO. INJECTOR) FUEL PUMP(TO. INJECTOR) FRAME EARTH RH. RADIATOR HOSE SPEEDOMETER CABLE O2 SENSOR COUPLER SERVICE INFORMATION 12V 10AH BATTERY(MF) ECU UNIT FRM.EARTH CORD SEAT LOCK CABLE REGULATE RECTIFIER SIDE STAND SWICH COUPLER THROTTLE CABLE RH/LH RADIATOR HOSE FUEL PUMP(TO. INJECTOR) FUEL SUPPLY TUBE FUSE MAIN WIRE HARNESS FUEL BREATHER TUBE RR. BRAKE HOSE PIPE O2 SENSOR COUPLER FUEL HOSE(TO. INJECTOR) FUEL PUMP RELAY RR.BRAKE HOSE TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER COUPLER ACG. & CPS CORD START MOTOR CABLE IGNITION COIL CORD IGNITION COIL EARTH CORD CAN(ÎøÎ) CORD ¡Ê«,¿OE WIRING¿ª ««" Õ. HIGH TENSION CORD START-MAG. SW. COUPLER TRUNK LAMP COUPLER IGNITION COIL SPEEDO METER ASS'Y A.P. WINKER RELAY LIGHTING S/W UNIT STARTER S/W UNIT DIMMER S/W UNIT WINKER S/W UNIT HORN S/W UNIT RR. STOP SW. HAZARD S/W UNIT FR. STOP SW. THROTTLE CABLE SEAT LOCK CABLE HORN COMP. COMB. & LOCK SW. HAZARD RELAY RR.BRAKE HOSE A FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3. SPEEDO METER EARTH CHARGE SOCKET FR. BRAKE HOSE HEAD LIGHT (·º±øÎ COUPLER) FR.BRAKE HOSE C SPEEDOMETER CABLE 1-15 SERVICE INFORMATION SEAT LOCK CABLE THROTTLE CABLE RR.BRAKE HOSE A THROTTLE CABLE FR. BRAKE HOSE COMB.METER SOCKET COMB. & LOCK SW. FUEL SUPPLY TUBE HEAD LIGHT (·º±øÎ COUPLER) JUNCTION VALVE RR. BRAKE HOSE PIPE FUEL BREATHER TUBE HARNESS ~x_1~/_5 ^!`'|(^-`%|5^R`-|P CLAMP MAIN WIRE HARNESS FR.BRAKE HOSE C VIEW Y SPEEDO METER ASS'Y A.P. WINKER RELAY FR. BRAKE HOSE RR.BRAKE HOSE A THROTTLE CABLE SPEEDOMETER CABLE COMB. & LOCK SW. SEAT LOCK CABLE VIEW X HORN COMP. 1-16 SERVICE INFORMATION THROTTLE CABLE RH/LH RADIATOR HOSE FUEL PUMP(TO. INJECTOR) FUEL HOSE(TO. INJECTOR) RR. BRAKE HOSE PIPE MAIN WIRE HARNESS FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3. O2 SENSOR COUPLER O2 SENSOR CORD DETAIL OF O2 SENSORS PART INJECTOR ISA MAPAT COUPLER ECU UNIT FRM.EARTH CORD THROTTLE CABLE FUEL HOSE(TO. INJECTOR) BATTERY + CABLE START-MAGNET SW. ASS'Y. MAIN WIRE HARNESS ACG. & CPS CORD BREATHER TUBE START MOTOR CABLE RR.BRAKE HOSE TPS VIEW Z DETAIL OF SENSORS PART 1-17 MEMO INSPECTIONS/ADJUSTMENTS 2 2-1 INSPECTIONS/ADJUSTMENTS 2-2 INSPECTIONS/ADJUSTMENTS 2-3 INSPECTIONS/ADJUSTMENTS NUTS NUTS NUTS 2-4 INSPECTIONS/ADJUSTMENTS 2-5 INSPECTIONS/ADJUSTMENTS TIMINCT HOlLE CAP TIMINCT HOlLE CAP TIMINCT HOlLE CAP COOLING FAN COOLING FAN COOLING FAN ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH FEELER GAUGE FEELER GAUGE FEELER GAUGE TAPPET ADJUST SCREW TAPPET ADJUST SCREW TAPPET ADJUST SCREW SPARK PLUG CAP SPARK PLUG CAP SPARK PLUG CAP COMPRESSION GAUGE COMPRESSION GAUGE COMPRESSION GAUGE 2-6 INSPECTIONS/ADJUSTMENTS OIL CHECK HOLE OIL CHECK HOLE OIL CHECK HOLE OIL SIGHT GRASS OIL SIGHT GRASS OIL SIGHT GRASS UPPER UPPER UPPER UPPER UPPER UPPER MIDDIE MIDDIE MIDDLE MIDDIE MIDDIE MIDDIE MIDDIE LOWER LOWER LOWER LOWER LOWER LOWER DRIVE FACE DRIVE FACE DRIVE FACE DRIVE BELT DRIVE BELT DRIVE BELT DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY 2-7 INSPECTIONS/ADJUSTMENTS 0IL CUP CAP 0IL CUP CAP 0IL CUP CAP BRAK 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 diaphrag mand fill DOT3 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 FLUID BRAKE FLUID BRAKE FLUID CHECK WINDOW CHECK WINDOW CHECK WINDOW BRAKE PAD/SHOE ROD MARK ROD MARK BRAKE PAD REPLACEMENT Check the brake pads for wear. If the rod mark on the pad reaches the brake disc, replace the pads. BRAKE PAD BRAKE PAD DUBLE BRAKE HOSE DUBLE BRAKE HOSE DUBLE BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE REAR BRAKE HOSE 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. REAR CALLIPE REAR CALLIPE REAR CALLIPE FRONT CALLIPE FRONT CALLIPE FRONT CALLIPE FRONT BRAKE HOSE FRONT BRAKE HOSE FRONT BRAKE HOSE DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER BRAKE LEVER FREE PLAY Check the free play after pulling the lover. FRONT:10~20mm REAR:10~20mm 2-8 INSPECTIONS/ADJUSTMENTS SIDE STAND SIDE STAND SIDE STAND SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH 2-9 INSPECTIONS/ADJUSTMENTS TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GAUGE GANGE 2-10 EXTERNAL PARTS 3 3-1 EXTERNAL PARTS TAPPING SCREN TAPPING SCREN TAPPING SCREN FRONT COVER Loosen the 4tapping screws securing the front cover TNNER BOX TNNER BOX TNNER BOX Loosen the tapping screw securing the front cover Disconnect the headlight wiring and winker 00wiring0right and left) ( Install in the reverse order of removal SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW ERONT COVER FRONT COVER ERONT COVER ERONT ERONT FENER FRONT FENER ERONT FENER ERONT FRONT COVER Disconnect the wire grommet Disconnect the front fender Install in the reverse order of removal FRONT UNDER COVER A WIRE GROMMET WIRE GROMMET WIRE GROMMET TNNER BOX TNNER BOX TNNER BOX FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW FRONT PORK FRONT PORK FRONT PORK Remove - Front fender - Front wheel - The 4 tapping screw securing the underside of inner box - The 2 flange bolts and 2 special screw securing front under cover - The screw (right and left) securing the front side of floor side cover - Front under cover - Install in the reverse order of removal 3-2 EXTERNAL PARTS FRONT HANDLE COVER Remove the front cover Loosen the 2 tapping screw securing the front handle cover B and remove the handle cover B HANDIL COVER B HANDIL COVER B HANDIL COVER B TAPPING SCREN TAPPING SCREN TAPPING SCREN TAPPING SCREN TAPPING SCREN TAPPING SCREN TAPPING SCREN Loosen the 5 tapping screw and remove the handle cover Loosen the 1 tapping screw securing front handle cover and 2 tapping screw securing rear handle cover Remove the front handle cover Install in the reverse order of removal WASHER WASHER WASHER WASHER TAPPING SCREN TAPPING SCREN TAPPING SCREN SPEEDO MATER SPEEDO MATER SPEEDO MATER SPEEDO MATER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDLE COVER Loosen the 2 washer bolt securing front under cover and the 2 tapping screw underside STEERING HANDIL STEERING HANDIL STEERING HANDIL 3-3 EXTERNAL PARTS FLANGE NET FLANGE NET FLANGE NET LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW LUGGAGE BOX Release the seat lock. Release the seat . Loosen the special screw and remove the battery cover. BATTERY COVER BATTERY COVER BATTERY COVER OPEN SRAY NUTS OPEN SRAY NUTS OPEN SRAY NUTS SPECIAL SCREW 2EA SPECIAL SCREW 2EA SPECIAL SCREW 2EA CENTER COVER Release the seat lock by turning the main key. Loosen the special screw. Remove the center cover. Install in the reverse order of removal. 3-4 EXTERNAL PARTS REAR CARRIER Loosen the washer bolt(4). Remove the rear carrier. Install in the reverse order of removal. BODY COVER UPPER UPPER HANDLE COVER HANDLE COVER Loosen the 2 tapping screw securing RH/LH body side cover and 2 special screw UNDER UNDER HANDLE COVER HANDLE COVER BODY COVER BODY COVER BODY COVER Loosen the body cover clip(R/L). Disconnect the rear winker wiring and the body cover opens with right and left and pull to backside and remove it. Install in the reverse order of removal FRONT COVER FRONT COVER REAR FENDER 4WASHER BOLTS 4WASHER BOLTS 4WASHER BOLTS 4WASHER BOLTS Remove - Luggage box. - Body cover. - Loosen the 4 washer bolts. - Rear fender. - Tail right wiring. Install in the reverse order of removal. REAR FENDER REAR FENDER REAR FENDER 3-5 EXTERNAL PARTS FLOOR SIDE COVER Loosen the screw(R/L) in the floor side cover. Remove the floor side cover(R/L). Install in the reverse order of removal. FLOOR SIDE COVER FLOOR SIDE COVER FLOOR SIDE COVER CENTER COVER CENTER COVER CENTER COVER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANER Remove - Center cover. - Body cover. - Floor panel cap. - Floor side cover. - 4 washer bilts. - pull the floor panel backward to remove it. - Install in the reverse order of removal. FLOOR SIDE COVER FLOOR SIDE COVER FLOOR SIDE COVER INTER BOX TAPPING SCREN TAPPING SCREN TAPPING SCREN FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL SUPPLY TUBE FUEL SUPPLY TUBE FUEL SUPPLY TUBE Remove - Front fender. - Front wheel. - Front under cover. - Floor side cover. - Floor panel. Loosen. - 4 tapping screw securing fuel cap neck. 3-6 EXTERNAL PARTS CHARGE SOCKER CAP CHARGE SOCKER CAP CHARGE SOCKER CAP Loosen the special screw securing back holder. Remove the charge socket cap by turing the socket cap to loosen the lock securing mainkey. Remove the inner box. Install in the reverse order of removal. BACK HOLDER BACK HOLDER BACK HOLDER UNDER COVER Remove the floor side cover. Loosen the special screw (R/L) and remove the under cover. Install in the reverse order of removal. UNDER COVER UNDER COVER UNDER COVER SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW REAR WHEEL MUD GUARD REAR WHEEL GUARD REAR WHEEL GUARD REAR WHEEL GUARD REAR WHEEL GUARD Loosen the brake hose clamp and washer bolt securing. Remove the air cleaner and washer bolt. securing mud guard. Remove the rear wheel mud guard. Install in the reverse order of removal. SPEEDO METER SPEEDO METER SPEEDO METER SPEEDO METER Remove - The speedometer. - Coupler and wire. - Rear handle cover. 3-7 EXTERNAL PARTS FIANGE BOLT FIANGE BOLT FIANGE BOLT FIANGE BOLT MUFFLER MUFFLER MUFFLER EX.CAP NUT EX.CAP NUT EX.CAP NUT FIANGE NUTS FIANGE NUTS FIANGE NUTS EX.PIPE CAMP EX.PIPE CAMP EX.PIPE CAMP 3-8 LUBRICATION SYSTEM 4-1 4-2 4-3 4-3 4-4 4-4 4-7 4-8 4-9 4 4-1 LUBRICATION SYSTEM 4-2 LUBRICATION SYSTEM OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS UPPER UPPER UPPER UPPER UPPER MIDDLE MIDDLE MIDDIE MIDDLE MIDDLE MIDDLE MIDDLE LOWER LOWER LOWER LOWER LOWER LOWER OIL DRAIN PLUG BOLT OIL DRAIN PLUG BOLT OIL DRAIN PLUG BOLT TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP OIL FILTER SCREN OIL FILTER SCREN OIL FILTER SCREN 4-3 LUBRICATION SYSTEM FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL SEAL OIL SEAL OIL SEAL START DRIVEN GEAR START DRIVEN GEAR START DRIVEN GEAR OIL PUMP OIL PUMP OIL PUMP FLAT SCEWS FLAT SCEWS FLAT SCEWS 4-4 LUBRICATIONSERVICE SYSTEM 4-5 LUBRICATION SYSTEM OUTER ROTOR OUTER ROTOR OUTER ROTOR INNER ROTOR INNER ROTOR INNER ROTOR PUMP BODY PUMP BODY PUMP BODY OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT ROLLER ROLLER ROLLER U NUT U NUT U NUT DRIVEN GEAR DRIVEN GEAR DRIVEN GEAR OIL PUMP OIL PUMP OIL PUMP 4-6 LUBRICATION SYSTEM 4-7 LUBRICATION SYSTEM RADIATOR RADIATOR RADIATOR OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT AC GENERATOR CAP AC GENERATOR CAP AC GENERATOR CAP 4-8 LUBRICATION SYSTEM REAR VIEW MIRROR BATTERY FR. BRAKE LEVER BAG HOLDER MUFFLER TIRE REAR BRAKE DISK PILLION STEP 4-9 MEMO