User manual DAELIM S2-250 - SERVICE MANUAL

HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the S2-250 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, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 18: Troubleshooting. CONTENTS GENERAL SERVICE INFORMATION INSPECTIONS/ADJUSTMENTS EXTERNAL PARTS LUBRICATION SYSTEM FUEL SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ENGINE ELECTRICAL SYSTEM FRAME 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., COOLING SYSTEM ENGINE REMOVAL/INSTALLATION LH.CRANK CASE COVER/TRANSMISSION A.C. GENERATOR/STARTING CLUTCH CYLINDER HEAD/VALVE CYLINDER/PISTON CRANK SHAFT/CRANK CASE FINAL REDUCTION FRONT WHEEL / FRONT FORK / STEERING / BRAKE REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM LIGHTS / SWITCHES / HORN WIRING DIAGRAM 1. SERVICE INFORMATION GENERAL SAFETY SERVICE RULES CAUTION WHEN WIRING SERIAL NUMBER LOCATION SPECIFICATIONS 1-1 1-1 1-5 1-9 1-10 TORQUE VALUES STANDARD TORQUE VALUES SYMBOLS LUBRICATION OIL WIRING DIAGRAM 1-12 1-13 1-13 1-14 1-15 1 GENERAL SAFETY 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 chassis. 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 be 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 expended when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine. ·Prior to using the tester, please read the manual carefully and understand the contents. ·When testing the resistance of the tester, the zero adjustment must be performed before testing. Is this measurement range or configuration in accord with the manual? ·Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop. 1-8 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION 1-9 SERVICE INFORMATION SPECIFICATIONS ITEM OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE / TYPE REAR TIRE SIZE / TYPE TIRE PRESSURE 1 PERSON 2 PERSON FRONT BRAKE REAR BRAKE FUEL TANK CAPACITY 2,110 mm 745 mm 1,356 mm 1,481 mm 760 mm 121 mm 164 kg 294 kg Underbone Telescopic Swing arm 120 / 70 - 12 / Tubeless 140 / 60 - 13 / Tubeless 2.00 Kgf / 2.00 Kgf / 2.00 Kgf / 2.25 Kgf / Hydraulic disk Hydraulic disk 11 2.8 27 87.1 mm 100/65 Water cooled 4 cycle SOHC engine 1(Single cylinder), front angle 80 72.7×60 mm 249 10.3 : 1 SOHC chain drive 1.1After disassembly 0.95After Oil filter change 0.9After Oil change Forced pressure splash type Paper Filter 15 kgf / (600 rpm) 8 BTDC 42 ABDC 33 BBDC 1 ATDC 0.1 mm 0.1 mm SPECIFICATIONS DIMENSIONS FRAME FRONT REAR FRONT REAR FULL CAPACITY RESERVE CAPACITY CASTER ANGLE TRAIL FRONT FORK /REAR 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 OPEN CLOSED EXHAUST VALVE OPEN CLOSED VALVE CLEARANCE (COOLING-OFF PERIOD) INTAKE EXHAUST 1-10 SERVICE INFORMATION ITEM TYPE / VENTURI BORE CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING BATTERY TYPE / CAPACITY SPARK PLUG SPARK PLUG GAP STARTING SYSTEM HEADLIGHT ( HIGH / LOW ) POSITION LIGHT WINKER LIGHTS ( FR / RR ) TAIL / STOP LIGHT HIGH-BEAM PILOT SPEEDOMETER LAMP WINKER PILOT TRUNK LAMP LICENSE LAMP SPECIFICATIONS CVK type/30 mm Butterfly # 102 2½ 18.5 mm 1,700±100 rpm Automatic Transmission 2.8 (42/15) 2.79 (39/14) Full-Transistor BTDC 5 1,700 ( rpm ) / 12V 10AH (MF type) NGK DPR 7EA-9 0.9 mm Starter motor 55/ 55W 5W 10W×2/10W×2 5/21W 3W 1.7W×2 3W×2 1.4W×1 5W×1 LG-Caltex Oil CX AF EQUIV/40% 1.4/ 1.0 80 2 C 0.9 0.15kgf/cm2 Motor / 90 3 C 43km/ (50km/h) 22PS/7000rpm 2.2kgf m SAE:15W 40# or 10W 30, API:SJ Triple phase wave 100 5dB CARBURETOR DRIVE TRAIN F MARK ELECTRICAL SYSTEM COOLING SYSTEM COOLANT/MIXTURE RATIO COOLANT CAPACITY RADIATOR AND ENGINE/AT REPLACING THERMOSTAT VALVE OPEN RADIATOR CAP VALVE OPEN PRESSURE COOLING FAN DRIVING METHOD/OPERATING TEMPERATURE FUEL CONSUMPTION RATIO ENGINE MAXIMUM POWER ENGINE MAXIMUM TORQUE ENGINE OIL GENERATOR TYPE HORN THE OTHERS 1-11 SERVICE INFORMATION TORQUE VALUES ENGINE ITEM CYLINDER HEAD BOLT A CYLINDER HEAD BOLT B OIL FILTER SCREEN CAP EXHAUST MUFFLER JOINT LOCK NUT CYLINDER HEAD CAP NUT VALVE ADJUST LOCK NUT CAM CHAIN TENSIONER SLIPER BOLT OIL BOLT CLUTCH OUTER NUT CLUTCH DRIVE PLATE NUT FLYWHEEL NUT OIL PUMP BOLT CYLINDER HEAD COVER BOLT SPARK PLUG WATER PUMP IMPELLER CAM CHAIN TENSIONER BOLT MUFFLER TORQUE BOLT Q'TY 2 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1 2 1 THREAD DIA (mm) 8 8 30 8 8 5 6 12 12 12 14 5 6 10 6 8 8 10 TORQUE VALUE 3.0 kgf·m 3.0 kgf·m 1.47 kgf·m 2.2 kgf·m 2.45 kgf·m 1.1 kgf·m 1.0 kgf·m 1.27 kgf·m 5.5 kgf·m 5.5 kgf·m 5.88 kgf·m 0.5 kgf·m 1.18 kgf·m 1.72 kgf·m 1.18 kgf·m 1.18 kgf·m 2.8 kgf·m 4.0 kgf·m REFERENCE FRAME ITEM STEERING STEM NUT STEERING TOP THREAD NUT FORK PIPE BOTTOM BRIDGE HANDLE POST FRONT AXLE NUT FRONT CALIPER BRACKET BOLT FRONT MASTER CYLINDER HOLDER BOLT FRIBT DISK PLATE BOLT REAR AXLE NUT REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER BOLT REAR DISK PLATE BOLT SPEEDOMETER GEARBOX SCREW FRONT FORK BOLT REAR CUSHION UPPER BOLT REAR CUSHION UNDER BOLT REAR CUSHION LOCK NUT ENGINE HANGER UPPER BOLT ENGINE HANGER LOWER BOLT MAINSTAND BOLT SIDESTAND PIVET SEREW SIDESTAND PIVET NUT Q'TY 1 1 1 2 1 2 2 3 1 2 2 3 1 2 2 2 2 2 1 2 1 1 THREAD DIA (mm) 26 26 10 10 12 8 6 8 16 8 6 8 5 22 10 10 10 12 10 10 10 10 TORQUE VALUE 7.0 kgf·m 0.25 kgf·m 7.5 kgf·m 6.0 kgf·m 6.0 kgf·m 3.1 kgf·m 1.2 kgf·m 4.25 kgf·m 12.5 kgf·m 3.1 kgf·m 1.2 kgf·m 4.25 kgf·m 0.43 kgf·m 2.25 kgf·m 4.0 kgf·m 4.0 kgf·m 3.5 kgf·m 5.25 kgf·m 4.5 kgf·m 4.0 kgf·m 1.5 kgf·m 4.5 kgf·m REFERENCE Initial torque Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table. 1-12 SERVICE INFORMATION STANDARD TORQUE VALUES ITEM 5mm BOLT, NUT 6mm BOLT, NUT 8mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT TORQUE VALUE 0.5 kgf·m 1.0 kgf·m 2.2 kgf·m 3.5 kgf·m 5.5 kgf·m ITEM 5mm SCREW 6mm SCREW 6mm FLANGE BOLT, NUT 8mm FLANGE BOLT, NUT 10mm FLANGE BOLT, NUT TORQUE VALUE 0.4 kgf·m 0.9 kgf·m 1.2 kgf·m 2.7 kgf·m 4.0 kgf·m SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious accident may result if instructions are not followed. vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures. The following symbols indicate oil adding, oil change, or parts. SYMBOL MEANING OIL GREASE (3-1) Add oil. If there is no specific oil indicated, use the designated or recommended engine oil. Apply grease Indicates reference page. (example : Refer to page 3-1) The following abbreviations are used in this manual. ASS'Y ASSEMBLY LH. RH. Left Right 1-13 SERVICE INFORMATION LUBRICATION OIL ENGINE LUBRICATION POINTS VALVE GUIDE/VALVE STEM OPERATING PARTS CAM SHAFT CONTACT AREA CAM SHAFT DRIVE CHAIN CYLINDER LOCK BOLT AND NUT PISTON AROUND AND PISTON RING GROOVE PISTON PIN AROUND CONNECTING ROD, PISTON PIN HOLE CONNECTING ROD BIG END CRANK SHAFT CRANK SHAFT ONE-WAY CLUTCH OPERATING PARTS OIL PUMP DRIVE CHAIN STARTER REDUCTION GEAR PARTS COUNTER SHAFT GEAR PARTS FINAL GEAR PARTS BEARING OPERATING PARTS O-RING SURFACE OIL SEAL RIP STARTER IDLE GEAR FRICTION SPRING OPERATING PARTS/SHAFT OPERATING PARTS SHAFT OPERATING PARTS STARTER SPINDLE OPERATING PARTS STARTER ONE-WAY CLUTCH THREAD A.C. GENERATOR CONNECTOR TRANSMISSION CASE BLEEDER TUBE LOCTITE APPLIES HEAT-RESISTANT GREASE REFERENCE SAE15W-40 or SAE10W 30# API SE, SF or SG GLUE 1-14 SERVICE INFORMATION WIRING DIAGRAM WATER PASS TUBE A HOSE CLIP WATER PASS TUBE C E.M.I. UNIT COMP. RADIATOR HOSE A HORN FUEL NECK EARTH WIRE WATER PASS TUBE A E.M.I. CORD (WIRE) E.M.I. CORD (FAN MOTOR) WATER PASS TUBE B FUEL BREATHER TUBE L. SEAT LOCK CABLE I.G COIL AUTO CHOCK COUPLER SIDE STAND SWITCH COUPLER THROTTLE POSITION SENSER COUPLER TRANK LAMP WIRE BATTERY (12V 10AH) RESISTER COMP. HEATER CONTROLLER IGNITION UNIT COMP. FUEL UNIT COUPLER DRAIN TUBE AIR CLEANER TUBE(AIR CLEANER) THEROMO SWITCH WIRE WATER PASS TUBE A REGULATOR RECTIFIER HEADLIGHT CONTROL UNIT STARTER MAGNETIC SWITCH FUEL TUBE (CARBURETOR) FUEL TUBE (FUEL TANK) FUEL TUBE (INSULATOR) RADIATOR HOSE A RADIATOR HOSE B FUEL STRAINER SPEEDOMETER CABLE FR. BRAKE HOSE RADIATOR CAP HOSE LICENSE LAMP WIRE A.C.G. COUPLER STARTER MAGNETIC SWITCH WIRE EARTH CABLE RR. BRAKE HOSE STARTER MOTOR CABLE A.C.G CORD RR. STAY WATER PIPE A WATER PIPE B WATER HOSE A WATER HOSE B WATER HOSE C 1-15 SERVICE INFORMATION E.M.I. UNIT COMP. HORN WIRE E.M.I. CORD(WIRE HARNESS) WATER PASS TUBE A E.M.I. CORD(FAN MOTOR) WATER PASS TUBE B THROTTLE CABLE WATER PASS TUBE A RADIATOR CAP HOSE RADIATOR HOSE A THERMO SWITCH WIRE SEAT LOCK CABLE SEAT LOCK CABLE COMB METER COUPLER THERMO SWITCH WIRE RADIATOR HOSE B RADIATOR HOSE A WATER PASS TUBE B WATER PIPE A WATER PIPE B WATER PASS TUBE B RR. BRAKE HOSE PIPE LH. SEAT LOCK CABLE RH. SEAT LOCK CABLE FUEL TUBE (INSULATOR) FUEL TUBE (INSULATOR) FUEL TUBE FUEL STRAINER COMP. FUEL WATER PASS TUBE B FUEL TUBE (FUEL TANK) TUBE CLIP WATER HOSE B WATER HOSE A WATER HOSE CLAMP RR. STAY WATER PIPE A WATER PIPE B RR. BRAKE HOSE PIPE WATER PASS TUBE B 1-16 SERVICE INFORMATION HEAD LIGHT RELAY THERMO SWITCH RELAY WINKER RELAY EARTH CABLE BATTERY BOX COUPLER *NOTE - WHITE COLOR : EXPORT USE ONLY - BLACK COLOR : DOMESTIC USE ONLY HEAD LIGHT CONTROLLER REGULATOR RECTIFIER START MAGNETIC SWITCH REGULATOR COUPLER 2EA BATTERY EARTH CABLE HEADLIGHT CONTROLLER CODE 1-17 SERVICE INFORMATION WINKER RELAY THERMO SWITCH RELAY HEADLIGHT RELAY FUSE BOX ASS'Y BATTERY BOX HEADLIGHT RELAY BATTERY EARTH CABLE RESERVE FUSE BATTERY BOX FUSE BOX 1-18 SERVICE INFORMATION FUEL TUBE (INSULATOR) FUEL TUBE (FUEL TANK) FUEL TUBE (CARBURETOR) TRUNK LAMP WIRE RR. BRAKE HOSE THERMO SENSOR WIRE WATER HOSE B WATER HOSE A NOISE SUPPRESSOR CAP AUTO CHOCK CORD I.G. COIL SIDE STAND SWITCH COUPLER THROTTLE POSITION COUPLER AIR CLEANER BREATHER TUBE (AIR CLEANER) CARBURETOR DRAIN TUBE CARBURETOR BREATHER TUBE CARBURETOR HEATER CORD START MAGNETIC SWITCH START MOTOR CABLE FUEL PUMP 1-19 MEMO 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION ··· 2-1 · MAINTENANCE SCHEDULE·· 2-3 · FUEL LINE········· 2-4 · THROTTLE GRIP OPERATION··2-4 AIR CLEANER ······· 2-5 · SPARK PLUG··········2-5 · VALVE CLEARANCE······2-5 CYLINDER COMPRESSION PRESSURE ·2-6 CARBURETOR IDLING ···· 2-6 · FINAL REDUCTION GEAR OIL··2-6 · GEAR OIL REPLACEMENT···2-7 · DRIVE BELT·········· 2-7 COOLING LEVEL INSPECTION · 2-8 · COOLANT REPLACEMENT··2-8 · BRAKE FLUID········· 2-9 · BRAKE PAD·········· 2-9 BRAKE SYSTEM ········ 2-9 · SIDE STAND·········· 2-9 · SUSPENSION········· 2-10 · BOLTS, NUTS, FASTENERS·· 2-10 · WHEELS / TIRES········ 2-11 · STEERING HEAD BEARING·· 2-11 2 SERVICE INFORMATION ·The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. ·Refer to 2~3, 2~4 with respect to Engine oil and oil filter. ·Stand the main stand prior to beginning work. SPECIFICATIONS THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE ENGINE OIL GEAR OIL RADIATOR CAPACITY COOLANT CAPACITY RESERVE TANK CAPACITY DISASSEMBLY REPLACE DISASSEMBLY REPLACE IN EX 2- 6mm DPR7EA-9 0.9mm 0.1mm 0.1mm 1,700±100rpm 15±2kgf/ 1.1 0.9 0.2 0.18 1,000 20cc 1,400 20cc 400 20cc 2-1 INSPECTIONS / ADJUSTMENTS TIRES COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 2.00kgf/ 2.00kgf/ 2.00kgf/ 2.25kgf/ 120/70 - 12 (Tubeless) 140/60 - 13 (Tubeless) TIRE SIZE 2-2 INSPECTIONS / ADJUSTMENTS MAINTENANCE SCHEDULE Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner's manual. I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN ODOMETER READING(NOTE 1) FREQUENCY ITEM 1,000Km 1MONTH R(Brand new) 300Km 4,000Km R I 8,000Km 12,000Km 16,000Km R I R R R I R R I R R I I I I I I I I I I I I I I I R I I I I I I REMARK 6MONTH 12MONTH 18MONTH 24MONTH ENGINE OIL ENGINE OIL FILTER SCREEN FUEL FILTER GEAR OIL VALVE CLEARANCE CARB. IDLE AIR CLEARER SPARK PLUG BRAKE SYSTEM DRIVE BELT SUSPENSION NUTS, BOLTS, FASTENERS TIRE STEERING HEAD BEARING BRAKE FLUID RADIATOR COOLANT RADIATOR CORE RADIATOR CAP BRAKE LEVER BRAKE PAD WEAR R R(Brand new) 300Km R I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Daily check priorto driving I I I I R I I I I I I I I I I I I I I If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections. To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops, dealers or other designated repair shops. NOTE 1. After the odometer reading exceeds 12,000km, repeat maintenance service at intervals indicated in the table. 2. After riding in areas with high humidity or pollution, carry out maintenance service more frequently. 3. Replace every 2 years. Proper technology is required for this job. 2-3 INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) Remove the luggage box. Check the fuel tube of the fuel auto cock connected to the fuel tank and carburetor. If the fuel tube is cranked, damaged or leaks, replace it. THROTTLE GRIP OPERATION Check if the throttle grip operates smoothly in any steering position. If the throttle grip does not operate properly, 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 For main adjustment, loosen the lock nut and turn adjuster. After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play. ADJUSTRING NUTS ADJUSTRING NUTS ADJUSTRING NUTS LOCK NUTS LOCK NUTS LOCK NUTS For simple adjustment, use the adjuster under the throttle grip. RH. Remove the Rubber. Loosen the lock nut and turn the adjuster. 2-4 INSPECTIONS / ADJUSTMENTS AIR CLEANER Loosen the 6 screws securing the air cleaner case cover, remove it. Loosen the 2 screws securing the air cleaner element holder, remove it. Remove the air cleaner element. Wash away any accumulated dust or dirt, by gently squeezing it in non flammable or high flash point solvent. ·Using gasoline or low flash point solvents for cleaning parts may result in a fire or explosion. CHECK GAP, DEPOSITS SPARK PLUG 0.6 ~ 0.7mm CHECK WASHER FOR DAMAGE CHECK FOR CRACKS 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 plug is severely contaminated or damaged, raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug. Always use a feeler gauge to check the gap. GENUINE PLUG : DPR7EA9 SPARK PLUG : 0.9~1.0mm TORQUE VALUE : 1.47~1.96kgf·m ·Make sure there is no dirt or debris on the seat of the spark plug hole before inserting the spark plug. ·To prevent damage to the cylinder head, handtighten the spark plug before using a wrench to tighten to the specified torque. ·Do not overtighten the spark plug. VALVE CLEARANCE Remove the cylinder head cover. 2-5 INSPECTIONS / ADJUSTMENTS ·Inspect and adjust the valve clearance when the engine is cool. (under 35 ° / 95 ° C F) ·Remove the cylinder head cover. ·Turn the flywheel counterclockwise, and align the "T" mark on the flywheel with the index mark on the RH. crank case cover. ·The piston at this time must be at the top dead center of the compression stroke. Measure valve clearance with a feeler gauge. VALVE CLEARANCE : Intake : 0.1mm Exhaust : 0.1mm Loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut. TORQUE VALUES : 1.1kgf·m TOOLS : WRENCH 8X9mm ADJUSTING WRENCH B FEELER GAUGE Measure the valve clearance again. Install the cylinder head cover and tighten the bolts. TORQUE VALUES : 1.0 kgf·m 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 ·The maximum reading is usually reached within 4~7 seconds. COMPRESSION PRESSURE : 15±2 kgf/cm2 If the pressure is low, check the following: -Inadequate valve clearance adjustment -Valve leakage -Leakage from the cylinder head gasket -Piston/cylinder worn If pressure is high, check the following: -Carbon deposits on the piston head, and cylinder head. 2-6 INSPECTIONS / ADJUSTMENTS CARBURETOR IDLE SPEED Remove the plug maintenance cover. ·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. IDLING SPEED: 1,700±100rpm OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT FINAL REDUCTION GEAR OIL ·Erect the main stand prior to beginning work. Erect the main stand prior to beginning work. Stop the engine and remove the oil check bolt. Check the oil level through the oil check hole. If the oil level is below, fill the oil (SAE90#). Install and tighten the oil check bolt. ·Make sure that the sealing washer is good condition. GEAR OIL REPLACEMENT Remove the oil check bolt. Remove oil drain bolt and drain oil completely. Install and tighten the oil drain bolt. TORQUE VALUE : 0.98kgf·m ·Make sure that the sealing washer is good condition. Fill the recommended oil(SAE90#). OIL DRAIN BOLT OIL DRAIN BOLT OIL DRAIN BOLT OIL DRAIN BOLT GEAR OIL CAPACITY At disassembling: 200cc At replacing: 180cc DRIVE BELT Remove the L.crankcase cover. Check the drive belt for wear or damage. Check scheduled maintenance period, replace the new drive belt if possible. 2-7 INSPECTIONS / ADJUSTMENTS COOLANT LEVEL INSPECTION Erect the main stand prior to beginning work. Check the coolant level of the reserve tank. The level should be between the "UPPER" and "LOWER" level lines. Fill the coolant with the reserve tank up to the "F" (upper level). ·Unless the coolant is refilled or replaced, the engine temperature too high or low. ·Fill to the "F"(UPPER LEVEL) line. COOLANT REPLACEMENT Remove the drain bolt and drain the coolant. (Tilt the vehicle to the right in order to assure complete and rapid draining.) Remove the radiator cap. Install the drain bolt. Fill the radiator with new coolant. COOLANT CAPACITY : 1,400±20cc RADIATOR CAPACITY : 1,000±20cc RESERVE TANK CAPACITY : 400±20cc Start the engine. Bleed air from the coolant and check the level of coolant. Install the radiator cap. Fill the coolant with the reserve tank up to the upper level. 2-8 INSPECTIONS / 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 fluid will damage painted, plastic or rubber parts. ·Mixing incompatible fluids can impair braking efficiency. ·A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability. BRAKE PAD/SHOE BRAKE PAD REPLACEMENT Check the brake pads for wear. If the red mark on the pad reaches the brake disc, replace the pads. ·Replace the brake pads in sets. 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 LEVER FREE PLAY Check the free play after pulling the lever. FRONT : 10~20mm REAR : 10~20mm 2-9 INSPECTIONS / ADJUSTMENTS 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. 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 switch. SIDE STAND SWITCH SUSPENSION ·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. 2-10 INSPECTIONS / ADJUSTMENTS BOLTS, NUTS, FASTENERS F Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value. Check all pins, clips, hose clamps and cable stays. WHEELS/TIRES ·Check the tire pressure when the tires have been cooled off. Check the tread (the part making contact with the road surface) and side for wear, cracks or damage. Replace damaged tires. STANDARD PRESSURE f/ (kpa) ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 2.00(200) 2.00(200) DRIVER AND A PASSENGER 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 : 0.5mm STEERING HEAD BEARING ·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 hadle moves satisfactorily, adjust the steering head bearing. 2-11 MEMO 3. EXTERNAL PARTS · SERVICE INFORMATION··· 3-1 · SEAT·············· 3-2 · PILLION SEAT········· 3-2 · LUGGAGE BOX TOP COVER·· 3-2 · REAR GRIP·········· 3-2 · LUGGAGE BOX········ 3-3 · CENTER COVER······· 3-3 · BODY SIDE COVER····· 3-3 · BODY COVER········· 3-4 · REAR FENDER········ 3-4 · FLOOR SIDE COVER····· 3-4 · FLOOR PANEL········ 3-4 · UNDER COVER········ 3-5 · HANDLE COVER······· 3-5 · FRONT COVER········ 3-5 · WINDSCREEN········ 3-6 · FRONT UNDER COVER A·· 3-6 · FRONT UNDER COVER B·· 3-6 · INNER COVER········ 3-7 · SPEEDOMETER COVER·· 3-7 · FRONT FENDER······· 3-8 · REAR WHEEL MUDGUARD· 3-8 · MUFFLER··········· 3-8 · EX. PIPE············ 3-8 3 SERVICE INFORMATION 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. 3-1 EXTERNAL PARTS SEAT Release the seat lock by turning the main switch key to open the seat. Loosen the flange nuts and remove the seat. Install in the reverse order of removal. PILLION SEAT Release the seat lock by turning the main switch key to open seat. Pull the pillion seat forward and remove it. Install in the reverse order of removal. LUGGAGE BOX TOP COVER Loosen the 5 Tapping screws and remove the top cover. Install in the reverse order of removal. REAR GRIP Remove the rear grip cap (R.L) Loosen the 4 special bolts. Install in the reverse order of removal. 3-2 EXTERNAL PARTS LUGGAGE BOX Remove the seat. Remove the pillion seat. Remove the luggage box top cover. Loosen the screws on the seat catch. Loosen the open stay nuts. Loosen the washer bolts. Remove the wire for the trunk lamp. Install in the reverse order of removal. CENTER COVER Remove the floor mat. Loosen the 2 washer screws and 1 special screw. Install in the reverse order of removal. BODY SIDE COVER Remove the center cover. Loosen the 2 washer screws. Loosen the 2 tapping screws securing the body side cover on the inside of the body cover. Install in the reverse order of removal. ·Remove the air duct cover in dissembling LH. body side cover. 3-3 EXTERNAL PARTS BODY COVER Remove the Rr. Grip R/L Remove the following parts - Seat - Luggage box - Center cover - Body side cover Loosen the special screw Loosen the body cover clip (R/L) Remove the wire for the tail light and pull the body cover backward. Install in the reverse order of removal REAR FENDER Remove the body cover Loosen the 4 washer bolts and remove the Rr. fender Install in the reverse order of removal FLOOR SIDE COVER Remove the center cover Loosen the 3 body cover clips, 2 washer screws and 1 tapping screw in back side of left Remove the floor mat Install in the reverse order of removal FLOOR PANEL Remove the floor side cover Loosen the 6 washer bolts Pull the floor panel backward to remove it Install in the reverse order of removal 3-4 EXTERNAL PARTS UNDER COVER Loosen the 4 special screws (R/L, 2Ea for each) to remove the under cover Install in the reverse order of removal HANDLE COVER Loosen the washer screw and tapping screw securing the under handle cover Loosen the screw in the top of the upper handle cover Remove the under handle cover Loosen the 2 screws (R/L) in the upper handle cover securing the steering handle Install in the reverse order of removal FRONT COVER Loosen the 2 tapping screws securing the fornt cover Loosen the 2 tapping screws securing the inner cover Install in the reverse order of removal 3-5 EXTERNAL PARTS WINDSCREEN Remove the front cover Loosen the 4 washer bolts and remove the windscreen Install in the reverse order of removal FRONT UNDER COVER A Remove the front cover and windscreen Loosen the 7 tapping screws securing the inner cover Install in the reverse order of removal Loosen the 2 washer bolts in the top of the front under cover Loosen the 2 tapping screws FRONT UNDER COVER B Loosen the 2 flange bolts Loosen the 4 tapping screws securing the inner cover 3-6 EXTERNAL PARTS Loosen the 4 tapping screws securing the inner cover INNER COVER Remove the front cover and windscreen Remove the coolant reserve tank Remove the fuel tube clip Remove the breather tube Loosen the 3 screws securing the inner cover Remove the bag holder Loosen the 2 tapping screws securing the speedometer cover Install in the reverse order of removal SPEEDOMETER COVER Remove the speedometer cable Remove the coupler and wire Loosen the 2 tapping screws secring the speedometer cover Install in the reverse order of removal 3-7 EXTERNAL PARTS FRONT FENDER Loosen the 4 screws (R/L, 2Ea for each) Install in the reverse order of removal REAL WHEEL MUDGUARD Loosen the 2 flange bolts of RH. Loosen the flange bolt securing the air cleaner and mudguard Remove the air cleaner Loosen the washer bolt securing the mudguard Install in the reverse order of removal MUFFLER Loosen the muffler flange bolt securing Ex. pipe comp. Loosen the 3 bolts securing the Rr. Fork Remove the Ex. muffler comp. ·Never performing the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot. EX. PIPE Loosen the 2 cap nuts securing the cylinder comp. Pull the Ex. Pipe comp. downward to remove it Install in the reverse order of removal ·Replace the packing when assemblying the muffler and Ex. pipe comp. 3-8 MEMO LUBRICATION SYSTEM ROCKER ARM SHAFT CRANK SHAFT OIL FILTER SCREEN OIL PUMP 4-0 4. LUBRICATION SYSTEM SERVICE INFORMATION ····4-1 · TROUBLESHOOTING····· 4-2 ENGINE OIL LEVEL INSPECTION ·4-3 · ENGINE OIL CHANGE····· 4-3 OIL PUMP ··········· 4-4 · OIL PUMP ASS'Y ASSEMBLY· 4-6 SERVICE INFORMATION GENERAL SAFETY 4 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 contect 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) 0.9 (After Oil change) 0.95 (After Oil filter change) API service classification : SJ grade Viscosity : SAE10W-30/15W 40# RECOMMENDED (Use appropriate type of oil with viscosity satisfying the atmospheric temperature OIL In your riding area based on the table shown on the right side.) -10 0 10 20 30 40 4-1 LUBRICATION SYSTEM TROUBLESHOOTING Oil level low ·Oil consumption. ·External oil leaks. ·Worn piston ring or incorrect piston ring installation. ·Worn valve guide or seal. Oil contamination ·Oil or filter not changed often enough. ·Faulty head gasket. ·Worn piston rings. Low or no oil pressure ·Clogged oil orifice. ·Incorrect oil being used. 4-2 LUBRICATION SYSTEM OIL LEVEL GAUGE OIL LEVEL GAUGE OIL LEVEL GAUGE ENGINE OIL LEVEL INSPECTION Erect the motorcycle on the main stand. Warm up the engine to heat the engine oil to an appropriate level. Stop the engine, and check the oil level line on the sight-glass installed on the LH. crank case cover. If the oil level is between the lower and higher sightglass oil level line, oil level is satisfactory. If the oil level is below or near the lower level mark, add the recommended engine oil. ENGINE OIL CHANGE ·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. Tighten the oil drain plug bolt. TORQUE VALUE : 1.4 kgf·m