HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the S-Five 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 ENGINE 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., ENGINE REMOVAL/INSTALLATION KICK STARTER/ CONTINUOUSLY VARIABLE TRANSMISSION CYLINDER HEAD/CYLINDER/PISTON TRANSMISSION/CRANKSHAFT/CRANK CASE FRONT WHEEL/FRONT FORK/STEERING REAR WHEEL/BRAKE/SUSPENSION BRAKE SYSTEM BATTERY/CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM LIGHTS/METER/SWITCHES WIRING DIAGRAM TROUBLESHOOTING 1. SERVICE INFORMATION GENERAL SAFETY SERVICE RULES CAUTION WHEN WIRING SERIAL NUMBER LOCATION MAINTENANCE INFORMATION 1-1 1-1 1-5 1-9 1-10 TWIST TORQUE SPECIALIZED TOOLS LUBRICATION OIL SYMBOLS WIRING DIAGRAM 1-14 1-16 1-17 1-18 1-19 1 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 SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION 1-9 SERVICE INFORMATION MAINTENANCE INFORMATION SPECIFICATIONS TYPE OF VEHICLE OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE MOTOR TYPE DISPLACEMENT FUEL TYPE FRONT AXLE DRY WEIGHT REAR AXLE TOTAL PASSENGERS FRONT AXLE GROSS WEIGHT REAR AXLE TOTAL GROUND CLEARANCE CASTER TRAIL S-Five 1,795mm 698mm 1,114mm 1,260mm SJ50E 49.5cc UNLEADED GASOLINE 36.5kg 57.5kg 94kg 2(75kg) 58.5kg 100.5kg 159kg 131mm 26 79mm FRAME TYPE BRAKING DISTANCE MIN. REVOLUTION RADIUS COOLING TYPE STARTING MOTOR TYPE UNDER BONE 8.0m(30km/h VELOCITY) 1,800mm AIR-COOLED STARTER MOTOR, KICK 2-CYCLE NO. OF CYLINDERS, MOUNTING 1 CYLINDER, TRANSVERSE VALVE APPARATUS BORE & STROKE COMPRESSION RATIO MAX. OUTPUT MAX. TORQUE PRIMARY SPEED REDUCTION RATIO SECONDARY SPEED REDUCTION RATIO TRANSMISSION TRANSMISSION RATIO 1ST GEAR FRAME NUMBER ENGINE NUMBER READ VALVE PISTON VALVE COMBINATION 39.0X41.4mm 6.8:1 5.1PS/7,000rpm 0.55kgf·m/7,000rpm 4.083 3.615 GEARLESS TRANSMISSION 2.4~0.76 KMYSE1B4S1K000001~ SJ50E3000001~ MAINTENANCE SPECIFICATIONS ITEM LUBRICATION SYSTEM ENGINE OIL TANK CAPACITY RECOMMENDED ENGINE OIL TRANSMISSION OIL CAPACITY RECOMMENDED TRANSMISSION OIL FULL CAPACITY FULL CAPACITY STANDARD 1.2 liters DMC Ultra 2 super oil, 2-Cycle Oil 0.09 liters DMC Pure Mission Oil or SAE 80W/90 Separation Lubrication Current Filtration, Plunger Type USE LIMITS LUBRICATION TYPE OIL FILTER TYPE OIL PUMP TYPE COOLING TYPE COOLING TYPE Air-Cooled 1-10 SERVICE INFORMATION ITEM FUEL SYSTEM FUEL TANK CAPACITY AIR CLEANER TYPE CARBURETOR STANDARD USE LIMITS FULL CAPACITY SETTING MARK VENTURI DIAMETER AIR SCREW OPENING FLOAT LEVEL IDLING RPMS NO. OF JET NEEDLES MAIN JET SLOW JET THROTTLE GRIP CLEARANCE 6 Urethane Foam PB 11P 16.0mm 1 1/4 Rotation 8.0mm 1,800±100rpm 4 #75 #38 2-6mm - CYLINDER HEAD, CYLINDER, PISTON PORT OPEN/CLOSE PERIODS INHALATION CYLINDER HEAD OPEN CLOSE EXHAUST OPEN CLOSE SCAVENGING OPEN CLOSE COMPRESSION PRESSURE Auto Control Auto Control 81.5 BBDC 81.5 ABDC 56.5 BBDC 56.5 ABDC 10kgf/-600rpm - CYLINDER ID MARK LOCATION Side of Cylinder INSIDE DIAMETER CYLINDRICAL DEGREE OUT OF ROUNDNESS ID MARK(A) NO ID MARK 39.000-39.005mm 39.005-39.010mm - 39.05mm 39.05mm 0.10mm 0.10mm PISTON OUTSIDE DIAMETER MEASUREMENT LOCATION OUTSIDE DIAMETER 3mm ID MARK(A) ID MARK(B) NO ID MARK CYLINDER AND PISTON CLEARANCE PISTON PIN HOLE INSIDE DIAMETER PISTON PIN OUTSIDE DIAMETER PISTON AND PISTON PIN CLEARANCE PISTON RING GAP RING MARK CONNECTING ROD SMALL END PORTION DIAMETER TOP SECOND OUTSIDE DIAMETER 38.955-38.960mm 38.965-38.970mm 38.960-38.965mm 0.035-0.050mm 12.002-12.008mm 11.994-12.000mm 0.002-0.014mm 0.10-0.25mm 0.10-0.25mm Turning up 17.005-17.017mm 38.90mm 38.90mm 38.90mm 0.10mm 12.03mm 11.98mm 0.03mm 0.40mm 0.40mm 17.03mm 1-11 SERVICE INFORMATION ITEM CLUTCH CLUTCH AUTOMATIC TYPE CLUTCH OUTER DIAMETER CLUTCH LINING THICKNESS STANDARD Automatic Centrifugal Continuously Variable Transmission 107.0-107.2mm 3.0mm 17.5mm 20.035-20.085mm 20.011-20.025mm 15.920-16.080mm 98.1mm 33.965-33.985mm 34.000-34.025mm USE LIMITS 107.5mm 2.0mm 16.5mm 20.60mm 19.97mm 15.40mm 92.8mm 33.94mm 34.06mm DRIVE BELT WIDTH MOVABLE DRIVE FACE BUSH INSIDE DIAMETER BOSS OUTSIDE DIAMETER WEIGHT ROLLER OUTSIDE DIAMETER DRIVEN PULLEY FACE SPRING FREE LENGTH FACE OUTSIDE DIAMETER MOVABLE FACE INSIDE DIAMETER CRANK SHAFT CRANK SHAFT LARGE END SIDE CLEARANCE CONNECTING ROD LARGE END RIGHT ANGLE DIRECTION CLEARANCE CRANK SHAFT SHAKING A B 0.15~0.55mm 0.010~0.02mm 0.03mm(70mm from center) 0.05mm(40mm from center) 0.60mm 0.04mm 0.15mm 0.10mm FRONT, REAR WHEELS WHEELS RIM RUNOUT AXLE DEFLECTION TYPE TIRE PRESSURE TIRE SIZE RADICAL AXIAL TIRES FRONT REAR FRONT REAR TUBELESS 1.75f/ (2.00f/) 2.00f/ (2.25f/) 120/70-12 58L 130/70-12 62L 2.0mm 2.0mm 0.2mm - SUSPENSION FRONT REAR BRAKES FRONT BRAKE FRONT CUSHION FREE LENGTH REAR CUSHION FREE LENGTH 263.5mm 234.8mm 256.0mm 228.0mm REAR BRAKE LEVER FREE PLAY BRAKE FLUID BRAKE PAD THICKNESS DISK THICKNESS DISK SHAKING DISK WEAR LINE MASTER CYLINDER INSIDE DIAMETER MASTER PISTON OUTSIDE DIAMETER CALIPER CYLINDER INSIDE DIAMETER CALIPER PISTON OUTSIDE DIAMETER LEVER FREE PLAY DRUM INSIDE DIAMETER LINING THICKNESS 10~20mm DOT3 or DOT4 3.5mm 3.0mm 11.000-11.043mm 10.957-10.984mm 30.230-30.280mm 30.148-30.198mm 10~20mm 110mm 4.0mm to wear line 3.0mm 0.3mm 11.05mm 10.91mm 30.29mm 30.14mm 111mm 2.0mm 1-12 SERVICE INFORMATION ITEM IGNITION SYSTEM SPARK PLUG STANDARD PLUG GAP IGNITION TIMING F MARK PEAK VOLTAGE IGNITION COIL(PRIMARY VOLTAGE) EXCITE COIL PULSE GENERATOR IGNITION COIL RESISTANCE VALUES(20) PRIMARY COIL SECONDARY COIL(PLUG CAP CONNECTION) SECONDARY COIL(PLUG CAP DISCONNECTION) EXCITE COIL RESISTANCE VALUE(20) PLUSE GENERATOR RESISTANCE VALUE(20) CHARGING SYSTEM, AC GENERATOR TYPE OUTPUT CHARGING COIL RESISTANCE VALUE(20) LIGHTING COIL RESISTANCE VALUE(20) REGULATOR/RECTIFIER TYPE CONTROL VOLTAGE LAMP SIDE CHARGING SIDE REGISTER RESISTANCE VALUE REGISTER(6.7 5W) REGISTER(5.9 30W) LIGHTS, METER, SWITCHES LIGHTS, BULBS HEADLIGHT TAIL/STOP LIGHT WINKER LIGHTS POSITION LAMP LICENSE LAMP METER LIGHTS HIGH BEAM PILOT OIL PILOT WINKER PILOTS FUSE BATTERY TYPE CAPACITY TERMINAL VOLTAGE(20) CHARGING CURRENT/STANDARD CHARGING CURRENT/RAPID MF BATTERY 12V-3AH 13.0-13.2V 0.4A/5h 4A/0.5h 12V-35/35W 12V-5/21W 12V-16W×2 12V-10W×2 12V-5W 12V-5W 12V-1.7W×2 14V-3W 14V-3W 14V-3W×2 7A AC GENERATOR AC 12V-9.5A/5,000rpm 0.8±20% 0.55±20% Semi-conductor 12.6-13.6V/5,000rpm 14.0-15.0V/5,000rpm 6.3-7.1 5.5-6.5 B8HSA 0.6~0.7mm BTDC 17 /1,800rpm ±2 over 120V over 120V over 1.5V 0.1-0.5 6.5-9.5 2.6±1.25 500±20% 100±20% STANDARD USE LIMITS FRONT REAR 1-13 SERVICE INFORMATION TWIST TORQUE STANDARD TWIST TORQUE TYPE 5mm BOLT, NUT 6mm BOLT, NUT 8mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT TWIST TORQUE 0.5f·m 1.0f·m 2.2f·m 3.5f·m 5.5f·m TYPE 5mm SCREW 6mm SCREW 6mm SCREW FLANGE BOLT, NUT 8mm SCREW FLANGE BOLT, NUT 10mm SCREW FLANGE BOLT, NUT TWIST TORQUE 0.4f m · 0.9f m · 1.2f m · 2.7f m · 4.0f m · Bolts not appearing in the following table are tightened using standard torque. ENGINE PARTS TWIST PART FLY WHEEL NUT DRIVE FACE NUT CYLINDER HEAD BOLT SPARK PLUG DRIVEN FACE NUT CLUTCH OUTER NUT OIL LEVEL CHECK BOLT EXHAUST PIPE JOINT NUT MUFFLER BRACKET BOLT CRANK CASE BOLT NUMBER 1 1 4 1 1 1 1 2 2 6 SCREW DIAMETER (mm) 10 12 6 14 28 10 8 6 8 6 TWIST TORQUE 4.0f m · 5.5f m · 1.0f m · 1.4f m · 5.5f m · 4.0f m · 1.3f m · 1.2f m · 3.3f m · 1.0f m · REFERENCE 1-14 SERVICE INFORMATION FRAME PARTS TWIST PART STEERING STEM LOCK NUT HANDLE POST TWIST NUT FRONT BRAKE LEVER PIVOT BOLT FRONT BRAKE LEVER PIVOT NUT REAR BRAKE LEVER PIVOT SCREW REAR BRAKE LEVER PIVOT NUT MASTER CYLINDER HOLDER BOLT MASTER CYLINDER COVER SCREW BRAKE HOSE BOLT CALIPER MOUNT BOLT CALIPER BREATHER VALVE CALIPER PAD PIN CALIPER SLIDE PIN BOLT BRAKE SWITCH SCREW STEERING STEM BOLT(FRONT FORK SIDE) FRONT AXLE NUT REAR AXLE NUT SPEEDOMETER CABLE SETTING SCREW REAR BRAKE ARM BOLT FRONT BRAKE DISK BOLT REAR CUSHION UPPER BOLT REAR CUSHION LOWER BOLT ENGINE HANGER BRACKET NUT (FRAME SIDE) EXHAUST PIPE JOINT NUT MUFFLER BRACKET BOLT EXHAUST PIPE PROTECTOR SCREW 3 2 4 6 8 6 NUMBER SCREW DIAMETER 1 1 1 1 1 1 2 2 2 2 1 2 1 1 4 1 1 1 1 3 1 1 2 10 6 6 5 5 6 4 10 8 8 10 8 4 10 12 14 4 6 8 10 10 10 TWIST TORQUE 7.0f·m 5.0f·m 1.0f·m 1.0f·m 0.3f·m 0.4f·m 1.2f·m 0.2f·m 3.5f·m 2.7f·m 0.6f·m 1.8f·m 2.3f·m 0.12f·m 3.5~4.5f·m 6f·m 11.0f·m 0.2f·m 0.6f·m 3.9f·m 4.0f·m 4.0f·m 5.0f·m (7.3f·m) 1.2f·m 3.3f·m 0.5f·m REFERENCE 1-15 SERVICE INFORMATION SPECIALIZED TOOLS TOOL NAME FLOAT LEVEL GAUGE BEARING DIRVER BEARING REMOVER REMOVER HANDLE REMOVER WEIGHT DRIVER HANDLE A OUTER DRIVER 24×26mm CLUTCH SPRING COMPRESSOR SOCKET WRENCH 39mm CLUTCH CENTER HOLDER UNIVERSAL HOLDER CRANK ASSEMBLY DRIVER HANDLE A OUTER DRIVER 37×40mm DRIVER PILOT, 17mm UNIVERSAL BEARING PULLER CRANK CASE PULLER CRANK ASSEMBLY OUTER DRIVER 52×55mm DRIVER PILOT 20mm DRIVER HANDLE A CRANK ASSEMBLY LOCK NUT WRENCH A LOCK NUT WRENCH B BALL RACE REMOVER OUTER DRIVER, 42×47mm DRIVER HANDLE A SHOCK ABSORBER COMPRESSER COMPRESSER SCREW ASS' Y SPRING COMPRESSER ATTACHMENT SPRING COMPRESSER ATTACHMENT UNIVERSAL HOLDER A.G.G ROTOR PULLER TOOL NO. 07401-001000 07945-GC80000 07936-3710300 07936-3710100 07741-0010201 07749-0010000 07746-0010700 07960-KM10000 0723-03900 07724-0050001 07725-0030000 0740-00001 0749-0010000 07746-0010200 07746-0040400 0755-00001 0751-00003 0740-00001 07746-0010400 07746-0040500 07749-0010000 0740-00001 07916-1870101 07916-KM10000 07946-GA70000 07746-0010300 07749-0010000 07GM-0010000 079GME-0010100 07967-GA70102 07JME-GW20100 07725-0030000 0750-00006 Disassembly/Assembly of Fly Wheel Disassembly of Fly Wheel 13 Disassembly/Assembly of Rear Cushion 11 Assembly of Ball Race 10 Assembly of R/L Crank Shaft Oil Seal Disassembly of Top Cone Race Disassembly of Crank Shaft Bearing Disassembly of R/L Crank Case, Crank Shaft Disassembly of R.Crank Case, Crank Shaft Assembly of Crank Shaft Bearing 9 Disassembly/Assembly of Driven Pulley/Driven Face Disassembly/Assembly of Clutch/Driven Pulley Assembly of Drive Shaft Assembly of Drive Shaft Bearing Disassembly/Assembly of Clutch/Driven Face Assembly of Driven Face Needle Bearing 7 USAGE Carburetor Oil Level Measurement Change of Driven Face Outer Bearing Disassembly of Driven Face Needle Bearing CHAPTER 5 1-16 SERVICE INFORMATION LUBRICATION OIL ENGINE PARTS APPLICATION AREAS CRANK CASE JOINING FACE CRANK CASE REVOLUTION PART CYLINDER BIG REVOLUTION PART, FRICTION PART TRANSMISSION(FINAL REDUCTION) KICK SPINDLE BUSH STARTER PINION STARTER DRIVE GEAR OPERATION PART MOVEABLE DRIVEN FACE (DRIVEN FACE OPERATION PART) OIL PUMP DRIVE GEAR Molybdenum Grease Capacity : 5.0~5.6g Multi-Purpose Grease Capacity : 0.09 CAUTIONARY SUGGESTIONS OIL TYPE Gasket Fluid(TB 1215) Ultra-2 Super, 2-Cycle Oil (Separation Lubrication Use) SAE 80W/90 FRAME PARTS APPLICATION AREAS FRONT WHEEL DUST SEAL EDGES FRONT PIVOT ARM BUSH FRICTION FACE FRONT PIVOT ARM SEAL EDGES REAR BRAKE CAM AXLE PART, CAM PART WHOLE AREA OF REAR BRAKE CAM DUST SEAL REAR BRAKE ANCHOR PIN AXLE PART FRONT BRAKE OIL SEAL EDGES FRONT BRAKE CAM AXLE PART, CAM PART WHOLE AREA OF FRONT BRAKE CAM DUST SEAL SPEEDOMETER GEAR/PINION INSIDE DIAMETER PART, AXLE PART, GEAR TEETH PART BALL RACE, BEARING REVOLUTION PART HANDLE GRIP INSIDE AXLE PART Adhesives ROYAL BOND 1300 CAUTIONARY SUGGESTIONS OIL TYPE Multi-Purpose Grease 1-17 SERVICE INFORMATION SYMBOLS The following symbols appear in this manual and offer cautionary suggestions which need to be heeded when performing maintenance work on the vehicle. SYMBOL CAUTION SYMBOL CAUTION Indicates an important step or operation. Indicates special caution needed. WARNING Possibility of resulting in serious malfuctioning of vehicle if ignored. NOTE CAUTION Possibility of resulting in minor malfuctioning or damage to part if ignored. Indicates general caution. Caution needed to be taken when performing the maintenance operation or in the handling of part. The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance. SYMBOL CAUTION Indicates needed application of oil. When a designated brand is not listed, use the designated or suggested engine oil when this symbol appears. Indicates needed application of a molybdenum solution. The molybdenum solution is made by mixing molybdenum grease with engine oil at a 1:1 ratio. Indicates needed application of a multi purpose grease. (NLG 1 #2 using a lithium soap base) Example brand: Shell Albania EP-2(Fire-proof Shell Oil) Indicates needed application of molybdenum grease. (containing over 3% of emulsified molybdenum, NCG 1 #2) Indicates needed application of molybdenum paste. (containing over 40% of emulsified molybdenum, NLG 1 #2) Indicates needed application of silicon grease. Indicates needed application of an antilock substance. When a designated brand is not listed, use a medium-strength brand. Indicates needed application of a sealant. Indicates new part needed every time when disassembled. Indicates brake fluid needed. Use recommended DOT3 or DOT4 brake fluid. Use recommended cushion oil. Use Specialized Tool. Use Option Tool. These tools are needed for the part, see part list for tool number. ( 3-1) Indicates reference page. This particular symbol indicates chapter 3 page 1. Special grease, etc. that do not correspond to the above are indicated without using symbols. 1-18 SERVICE INFORMATION WIRING DIAGRAM PRESS TO ATTACH THE SEL. SECTION TO THE PIPE. LIGHTING S/W UNIT STARTER S/W UNIT WINKER REALY SPEEDOMETER ASS'Y DIMMER S/W UNIT WINKER S/W UNIT HORN S/W UNIT THROTTLE CABLE FR. BRAKE HOSE SPEEDOMETER CORD RR. BRAKE CABLE SPEEDOMETER CABLE THROTTLE CABLE RR.STOP S/W CONNECTOR FR. BRAKE HOSE HAZARD S/W UNIT RR. STOP S/W CONNECTOR RR. BRAKE CABLE SPEEDOMETER CABLE SPEEDOMETER CORD HORN COMP SEAT LOCK CABLE COMBI LOCK S/W FRAME EARTH TIGHT AT THE SAME TIME WITH THE HORN. RESISTOR 30W 5.6 FUEL UNIT CONNECTING COUPLER R/L TAIL STOP RR. WINKER FUEL TANK OIL TANK CDI UNIT ASS'Y COMBI LOCK S/W HORN COMP FRAME EARTH TIGHT AT THE SAME TIME WITH THE HORN. RESISTER CONNECTING COUPLER AUTO BY STARTER 5W 6.7 HEADLIGHT TIE-DOWN COUPLER ROLL THE HES. CLAMP WITH THE CORD SECURELY. REGULATE RECTIFIER ROLL THE HES. CLAMP SEAT LOCK CABLE WITH THE CORD SECURELY. COMBI LOCK S/W STARTER REALY ASS' Y CONNECTING COUPLER I/G COIL ROLL THE HES. CLAMP WITH THE CORD SECURELY. WIRE HARNESS BATTERY ASS'Y BE TU S LE S TIR E AP PL. KO RE A A.C.GENERATOR THIS SECTION SHOULD NOT BE PROJECTED THAN THE FRONT OF THE FRAME AND NOT HAVE ANY LOOSENESS. 1-19 SERVICE INFORMATION ROLL THE HES. CLAMP WITH THE CORD SECURELY. HEADLIGHT CONNECTING COUPLER FRAME EARTH TERMINAL RESISTER CONNECTING CONNECTOR AUTO BY STARTER S/W CORD 5W 6.7 REGULATE RECTIFIER TIE-DOWN COUPLER COMBI LOCK S/W TIE-DOWN COUPLER WIRE HARNESS LIGHT COMP. CONNECTING CONNECTOR SPEEDOMETER CORD FUEL VENT TUBE FUEL STRAINER FUEL AUTO COCK ASS'Y FUEL TUBE RESISTER 30W 5.6 RESISTER AUTO BY STARTER 5W 6.7 FR. BRAKE HOSE ROLL THE HES. CLAMP WITH THE CORD SECURELY. THROTTLE CABLE BATTERY ASS'Y NEGATIVE PRESSURE TUBE AUTO BY STARTER CORD THROTTLE CABLE OIL TUBE SEAT LOCK CABLE THROTTLE CABLE OIL PUMP CABLE RR. BRAKE CABLE SEAT LOCK CABLE I V SIDE STAND SWITCH THIS SECTION SHOULD NOT BE PROJECTED THAN THE FRONT OF THE FRAME AND NOT HAVE ANY LOOSENESS. OIL PASS TUBE RR. BRAKE CABLE 1-20 SERVICE INFORMATION RR. BRAKE CABLE THROTTLE CABLE SEAT LOCK CABLE WIRE HARNESS BATTERY ASS'Y HIGH TENSION CORD PRESS TO ATTACH THE SEL. SECTION TO THE PIPE. STARTER MOTOR ENGINE EARTH TIGHT AT THE SAME TIME WITH THE STARTING MOTOR. OIL PUMP CABLE THROTTLE CABLE OIL PASS TUBE ROLL THE HES. CLAMP WITH THE CORD SECURELY. I/G COIL ACG. CORD CLAMP ROLL THE WHITE TAPE AREA OF ACG CORD CLAMP IN THE POSITION OF THE CLAMP FIRMLY. I/G COIL ACG. CONNECTING COUPLER STARTER REALY ASS'Y OIL TUBE AUTO BY STARTER CORD FUEL TUBE NEGATIVE PRESSURE TUBE FUEL AUTO COCK ASS'Y FUEL STRAINER FUEL TANK TAIL LIGHT CONNECTING CONNECTOR FUEL VENT TUBE SEAT LOCK CABLE AUTO BY STARTER CONNECTING COUPLER ROLL THE HES. CLAMP WITH THE CORD SECURELY. OIL LEVEL S/W CDI.UNIT ASS'Y FUEL UNIT TAIL LIGHT ASS'Y LH. RR. WINKER LIGHT RH. RR. WINKER LIGHT 1-21 MEMO 2. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION REGULAR INSPECTION SCHEDULE FUEL LINE (FUEL TUBE) FUEL LINE FOR CLOGGING THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG CYLINDER COMPRESSION PRESSURE CARBURETOR IDLING AIR SCREW ADJUSTMENT 2-1 2-2 2-3 2-3 2-3 2-4 2-5 2-5 2-6 2-6 BRAKE FLUID BRAKE PAD/SHOE BRAKE SYSTEM HEADLIGHT ADJUSTMENT SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING BATTERY 2-6 2-7 2-7 2-8 2-8 2-9 2-9 2-9 2-10 2-10 2 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. NOTE ·Stand the main stand prior to beginning work. SPECIFICATIONS ITEM THROTTLE GRIP FREE PLAY SPARK PLUG SPARK PLUG GAP CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE STANDARD VALUE 2-6mm B8HSA 0.60.7mm 1,800±100rpm 10f/ - 600rpm REFERANCE TORQUE VALUES SPARK PLUG CYLINDER HEAD COVER BOLTS 1.4f·m 1.0f·m 2-1 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 ODOMETER READING(NOTE 1) x 1000Km 1 4 6 8 12 12 18 REMARK FREQUENCY ITEM MONTH FUEL LINE(FUEL TUBE) THROTTLE GRIP OPERATION OIL PUMP, OIL LINE CARBURETOR CHOKE AIR CLEANER SPARK PLUG CARBON REMOVAL I I I I C I I I I I I C I I I I I C I I R I I I I I I I I I I NOTE 3 NOTE 2 CARBURETOR IDLE SPEED TRANSMISSION OIL BRAKE SHOE/PAD WEAR BRAKE SYSTEM Every 8,000 : C 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 BRAKE STOP SWITCH HEADLIGHT ADJUSTMENT CLUTCH SHOE WEAR SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING I I DRIVE BELT WEIGHT ROLLER SLIDE PIECE 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. 2-2 INSPECTIONS/ADJUSTMENTS FUEL LINE(FUEL TUBE) Remove the luggage box.( 3-3) 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. FUEL TUBE FUEL AUTO COCK FUEL LINE FOR CLOGGING NOTE ·Refer to section 2 for fuel filter inspection. Check the fuel tank cap and/or fuel tank breather tube for clogging. Visually inspect the fuel strainer for contamination. Check the fuel flow with the fuel strainer installed and with the strainer removed. Replace the fuel strainer if it is excessively contaminated or if the fuel flow is not smooth. FUEL TANK FUEL STRAINER CAUTION ·Note the installation direction of the fuel strainer. Be sure to install it as shown in the drawing, i.e., with the cup facing down. Fuel flows even though the strainer is installed upside down, but it contaminates the inner wall of the strainer and prevents visual inspection of the strainer. Remove the fuel valve lock nut and check the fuel strainer screen for contamination. Tighten the lock nut to the specified torque. (Inner walls get contaiminated, making visual inspection difficult.) 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 2-3 INSPECTIONS/ADJUSTMENTS For adjustment, loosen the lock nut and turn adjuster. After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play. LOCK NUT ADJUSTER AIR CLEANER Loosen the 5 setting screw assembled to the air cleaner case cover, and then remove the air cleaner case cover. AIR CLEANER COVER Remove the air cleaner element. Wash away any accumulated dust or dirt, by gently squeezing it in non flammable or high flash point solvent. WASHER SCREW WARNING ·Using gasoline or low flash point solvents for cleaning parts may result in a fire or explosion. CAUTION ·Cleaning the element with gasoline or any acid, alkaline, or organic, volatile type oil may cause improper ignition, deterioration of the element, or a loosening of the element adhesive. Be sure to allow the element to dry thoroughly before applying oil. Otherwise, the oil will be diluted by the and the filtering ability of the filter will be much less effective. Spread clean #80~90 gear oil on the element, rubbing inthoroughly over the surface with both hands, and then squeeze out any excess oil. AIR CLEANER ELEMENT CAUTION ·Using air filter oil when riding in extremely dusty conditions prevents premature engine wear due to dust/dirt drawn into the engine. Apply air filter oil to the entire surface of the element and rub it with both hands to saturate the element with oil. Squeeze out excess oil. 2-4 INSPECTIONS/ADJUSTMENTS SPARK PLUG Remove the plug maintenance cover. Remove the spark plug cap and disassemble the plug. SPARK PLUG CAP PLUG MAINTENANCE COVER Check the plug for damage, contamination or deposits. If the spark plugs are severely contaminated or damaged, raplace 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 gap. SPARK PLUG GAP : 0.6~0.7mm CAUTION ·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, hand-tighten the spark plug before using a wrench to tighten to the specified torque.(torque : 14kgf·m) ·Do not overtighten the spark plug. 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. 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: -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. TOOL : COMPRESSION GAUGE 2-5 INSPECTIONS/ADJUSTMENTS CARBURETOR IDLING Stand the vehicle on the main stand. Heat the engine to make accurate idling inspection and adjustment. Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. Turn the throttle stop screw and make adjustments to prescribed idling speed. THROTTLE STOP SCREW AIR SCREW ADJUSTMENT NOTE ·The air screw is factory pre-set. Adjustment is not necessary unless the carburetor is overhauled or a new air screw is installed. ·Tightening the air screw against its seat will damage the seat. Turn the air screw clockwise until it seats lightly then back it out to the specification given. This is an initial setting prior to the final air screw adjustment. Rev the engine up slightly from the idle speed and make sure that engine speed rises and returns smoothly. Adjust by turning the air screw in or out within a 1/4 turn if necessary. If the engine cannot be adjusted by turning the air screw within a 1/4 turn, check for other engine problems. AIR SCREW THROTTLE STOP SCREW CAUTION ·Excessive air screw adjustment may cause the engine sticking and deteriorate the starting performance. 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 CAUTION ·Brake fluid will damage painted, plastic or rubber parts. ·Mixing incompatible fluids can impair braking efficiency. ·Foreign materials can clog the system, causing a reduction or complete loss of braking ability. ·A leak in the brake system can lead to reduced braking effiency and possible loss of braking ability. 2-6 INSPECTIONS/ADJUSTMENTS 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 BRAKE LEVER FREE PLAY Check the free play after pulling the lever. FRONT : 10~20mm REAR : 10~20mm FREE PLAY 2-7 INSPECTIONS/ADJUSTMENTS 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 NUT 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 oncoming drivers, or may incorrectly light the road ahead. ADJUSTER LEVER 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 switch. 2-8 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'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, NUTS, FASTENERS 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 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. STANDARD PRESSURE f/ (kpa) ITEM FRONT WHEEL REAR WHEEL DRIVER ONLY 1.75(175) 2.00(200) DRIVER AND A PASSENGER 2.00(200) 2.25(225) TIRE PRESSURE GAUGE 2-9 INSPECTIONS/ADJUSTMENTS Check the tread depth at the tire center. If the tread depth has reached the service limit, replace the tire. SERVICE LIMIT : 4.0mm 7.5mm 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 hadle moves satisfactorily, adjust the steering head bearing. BATTERY Remove a tapping screw securing the battery cover from the floor panel. Check if the terminal is loose. If the terminal is loose, check and clean the contacting surface and then tighten it. Apply grease thinly after tightening. If the terminal is rusted, remove the battery, pour warm water and clean with the wire brush. - FULL CHARGING VOLTAGE : 13.0~13.2V - LOW CHARGING VOLTAGE : LESS THAN 12.3V BATTERY COVER TAPPING SCREW NOTE ·Check the charging condition using the voltmeter. ·Pay attention not to transform the battery terminal. ·Never remove the filler cap. DIGTAL TESTER 2-10 3. EXTERNAL PARTS SERVICE INFORMATION MAINTENANCE PRECEDURE LUGGAGE BOX PLUG MAINTENANCE COVER/CENTER COVER REAR CARRIER BODY COVER TAILLIGHT BASE FLOOR SIDE COVER FLOOR PANEL ENGINE HANGER SIDE COVER 3-1 3-2 3-3 3-3 3-3 3-3 3-4 3-4 3-4 3-5 FRONT COVER FRONT FENDER INNER BOX FRONT UNDER COVER FRONT HANDLE COVER REAR HANDLE COVER MUFFLER REAR FENDER REAR WHEEL MUD GUARD UNDER COVER 3-5 3-5 3-5 3-6 3-6 3-6 3-7 3-7 3-8 3-8 3 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. 3-1 EXTERNAL PARTS MAINTENANCE PROCEDURE NAMES OF FRAME COVERS 14 15 4 10 1 5 11 12 8 2 3 6 13 7 9 This chart shows arrows connected in the order of disassembling covers. LUGGAGE BOX FLOOR SIDE COVER FRONT COVER FRONT HANDLE COVER REAR HANDLE COVER PLUG MAINTENANCE COVER CENTER COVER FLOOR PANEL FRONT FENDER ENGINE HANGER SIDE COVER INNER BOX REAR CARRIER FRONT UNDER COVER BODY COVER TAILLIGHT BASE 3-2 EXTERNAL PARTS LUGGAGE BOX Release the seat lock using the main key to open the seat. Loosen 4 washer bolts and 2 flange bolts. Remove the oil tank cap and the fuel tank cap. WASHER BOLT FLANGE BOLT NOTE ·Luggage box can be removed with the seat. Remove the luggage box. Install in the reverse order of removal. CAUTION ·Install the oil tank cap and the fuel tank cap temporarily to prevent the foreign material from entering after removing the luggage box. TAPPING SCREW PLUG MAINTENANCE COVER/CENTER COVER Release the seat lock using the main key to open the seat. Loosen the washer bolt securing the luggage box. Loosen the special screw to remove the plug maintenance cover. Loosen 2 tapping screw securing the floor panel. Loosen 2 special screw (R/L) securing the body cover. Remove the center cover. SPECIAL SCREW SPECIAL SCREW CAUTION ·If removal is difficult, recheck each connection and then try removing again. Install in the reverse order of removal.