User manual DAELIM SL125 - SERVICE MANUAL

HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the SL125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 3). Sections 1 through 3 provide information on overall vehicle; section 4, assembly and disassembly procedures for external components, and section 5 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 20: Troubleshooting. CONTENTS SERVICE INFORMATION GENERAL LUBRICATION INSPECTIONS / ADJUSTMENTS EXTERNAL PARTS FUEL SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 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 LH.CRANK CASE COVER / KICK STARTER / CONTINUOUSLY VARIABLE TRANSMISSION A.C.GENERATOR / STARTER CLUTCH CYLINDER HEAD / VALVE CYLINDER / PISTON TRANSMISSION/CRANKSHAFT/CRANK CASE FRONT WHEEL / FRONT FORK / STEERING REAR WHEEL / BRAKE / SUSPENSION / REAR SWING ARM BRAKE SYSTEM CHARGING SYSTEM / BATTERY IGNITION SYSTEM STARTER SYSTEM LIGHTS/METER/SWITCHES WIRING DIAGRAM TROUBLESHOOTING 1. SERVICE INFORMATION GENERAL SAFETY ········ · SERVICE RULES·········· CAUTION WHEN WIRING ····· SERIAL NUMBER LOCATION ··· 1-1 1-1 1-5 1-9 SPECIFICATIONS ········· 1-10 · TORQUE VALUES········· 1-12 SYMBOLS / ABBREVIATIONS ··· 1-14 WIRING DIAGRAM ········ 1-15 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 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 / REAR BRAKE PARKING BRAKE FUEL TANK CAPACITY CASTER ANGLE TRAIL FRONT FORK OIL CAPACITY TYPE CYLINDERS / ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY 1,965 mm 690 mm 1,230 mm 1,350 mm 780 mm 120 mm 125 kg 255 kg Underbone Telescopic / 77mm Swing arm / 66mm 120 / 70 - 12 53k / Tubeless 130 / 70 - 12 62k / Tubeless 2.00 Kgf / (200 kPa) 2.00 Kgf / (200 kPa) 2.00 Kgf / (200 kPa) 2.25 Kgf / (225 kPa) Hydraulic disk Drum brake 8.0 1.7 25 86 mm 90 Oil cooled / air cooled 4 cycle SOHC engine 1(Single cylinder), front angle 80 56×50.7 mm 124.9 10.8 : 1 SOHC chain drive 1.1After disassembly 0.75After Oil change 0.8After Oil filter change 0.9After Oil change with Oil in the Oil hose removed Forced pressure splash type Wet sump 14.0 kgf / (550 rpm) 5 BTDC 14 ABDC 18 BBDC 1 BTDC 0.12±0.12 mm 0.12±0.12 mm SPECIFICATIONS DIMENSIONS FRAME FRONT REAR FRONT REAR FULL CAPACITY RESERVE CAPACITY ENGINE LUBRICATION SYSTEM AIR CLEANER TYPE CYLINDER COMPRESSION INTAKE VALVE OPEN CLOSED EXHAUST VALVE CLOSED CLOSED VALVE CLEARANCE (COOLING-OFF PERIOD) INTAKE EXHAUST 1-10 SERVICE INFORMATION ITEM TYPE / VENTURI BORE MODEL MARK CHOKE TYPE MAIN JET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING AC GENERATOR CAPACITY BATTERY TYPE / CAPACITY SPARK PLUG SPARK PLUG GAP FUSE CAPACITY STARTING SYSTEM HEADLIGHT ( HIGH / LOW ) POSITION LIGHT WINKER LIGHTS ( FR / RR ) TAIL / STOP LIGHT HIGH-BEAM PILOT WINKER PILOT METER LIGHTS TRUNK LAMP LICENSE LAMP PARKING BRAKE PILOT SPECIFICATIONS CV type ( vacuum ) 24.2 mm BDS 26 - 112 Auto-bystarter # 95 1 and ½ trust out 13 mm 1.800±100 ( rpm ) Automatic Transmission 3.231 (42/13) 2.786 (39/14) C.D.I Ignition 15 BTDC / 1.800 ( rpm ) 12V 10A / 5,000 ( rpm ) Closed type (MF) 12V 8AH CR8EH - 9 (NGK) 0.8 - 0.9 mm 15A Kick / starter motor 12V 60 / 55W 12V 5W 12V 10W×4 12V 21 / 5W 14V 3W 14V 3W×2 12V 1.7W×2 14V 1.4W 12V 5W 14V 3W CARBURETOR DRIVE TRAIN F MARK ELECTRICAL SYSTEM 1-11 SERVICE INFORMATION TORQUE VALUES ENGINE ITEM OIL FILTER CAP OIL DRAIN PLUG BOLT VALVE ADJUST SCREW LOCK NUT CYLINDER HEAD BOLT FLYWHEEL BOLT DRIVE FACE NUT CLUTCH OUTER BOLT CAM CHAIN TENSIONER PIVOT BOLT SPARK PLUG DRIVE PLATE CAM SHAFT HOLDER NUT CAM CHAIN TENSIONER FLANGE BOLT CAM CHAIN TENSIONER PAN SCREW CYLINDER HEAD COVER BOLT MISSION COVER BOLT MISSION COVER DRAIN BOLT MISSION COVER CHECK BOLT COOLING FAN BOLT STARTING CLUTCH NUT STARTER MOTOR FLANGE BOLT RADIATOR OIL BOLT OIL PUMP FLAT SCREW OIL PUMP DRIVEN GEAR NUT Q'TY 1 1 4 2 1 1 1 1 1 1 4 2 1 4 8 1 1 3 1 2 4 3 1 THREAD DIA (mm) 20 12 5 6 12 12 12 8 12 30 8 6 6 6 6 8 8 6 22 6 12 6 6 TORQUE VALUE 1.1 kgf·m 2.5 kgf·m 0.8 kgf·m 1.0 kgf·m 5.5 kgf·m 7.5 kgf·m 5.5 kgf·m 1.0 kgf·m 1.2 kgf·m 5.5 kgf·m 2.0 kgf·m 1.0 kgf·m 0.4 kgf·m 0.9 kgf·m 1.2 kgf·m 1.0 kgf·m 0.9 kgf·m 1.0 kgf·m 9.5 kgf·m 0.9 kgf·m 3.2 kgf·m 1.0 kgf·m 1.0 kgf·m REFERENCE Apply engine oil FRAME ITEM STEERING STEM NUT STEERING TOP THREAD NUT HANDLE POST NUT FRONT FORK BOTTOM BRIDGE BOLT FRONT FORK SOCKET BOLT FRONT AXLE NUT FRONT BRAKE DISK BOLT REAR BRAKE DISK BOLT REAR AXLE NUT ENGINE HANGER NUT MAIN STAND BOLT SIDE STAND PIVOT BOLT Q'TY 1 1 1 4 2 1 3 3 1 2 2 1 THREAD DIA (mm) 26 26 10 10 8 12 8 8 14 10 10 10 TORQUE VALUE 7.0 kgf·m 0.20 kgf·m 6.0 kgf·m 7.5 kgf·m 2.0 kgf·m 5.0~7.0 kgf·m 4.0~4.5 kgf·m 4.0~4.5 kgf·m 6.0~8.0 kgf·m 4.5 kgf·m 4.0 kgf·m 1.5 kgf·m REFERENCE Initial torque Apply locking agent 1-12 SERVICE INFORMATION ITEM SIDE STAND PIVOT NUT FRONT / REAR BRAKE CALIPER BRACKET BOLT FRONT / REAR BRAKE CALIPER BLEEDER VALVE FRONT / REAR BRAKE CALIPER SLIDE PIN FRONT / REAR BRAKE CALIPER BRACKET PIN BOLT FRONT / REAR BRAKE HANGER PIN FRONT / REAR MASTER CYLINDER RESERVOIR CAP SCREW FRONT / REAR BRAKE HOSE OIL BOLT FRONT / REAR MASTER CYLINDER LEVER PIVOT BOLT FRONT / REAR MASTER CYLINDER LEVER PIVOT LOCK NUT REAR BRAKE ARM FLANGE BOLT SPEEDOMETER GEAR BOX OVAL SCREW REAR CUSHION UPPER BOLT REAR CUSHION LOWER BOLT REAR CUSHION DAMPER ROD LOCK NUT Q'TY 1 2/2 1/1 1/1 1/1 2/2 2/2 2/2 1/1 1/1 1 1 1 1 1 THREAD DIA (mm) 10 8 8 8 8 8 4 10 6 6 6 5 10 10 10 TORQUE VALUE 4.5 kgf·m 2.7 kgf·m 0.6 kgf·m 2.3 kgf·m 1.8 kgf·m 1.8 kgf·m 0.15 kgf·m 3.0 kgf·m 1.0 kgf·m 1.0 kgf·m 10 kgf·m 0.4 kgf·m 4.0 kgf·m 4.0 kgf·m 4.0 kgf·m REFERENCE Apply locking agent Apply locking agent Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table. SH (Small Head) : Indicates 6mm bolt of 8mm flange head. ITEM 5mm BOLT, NUT 6mm BOLT, NUT 8mm BOLT, NUT 10mm BOLT, NUT 12mm BOLT, NUT TORQUE VALUE 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 1-13 SERVICE INFORMATION SYMBOLS / ABBREVIATIONS The following symbols are used in this manual to represent job-related warnings or cautions. SYMBOL MEANING SYMBOL MEANING Indicates important work. Minor injury or Indicates dangerous area. Serious WARNING accident may result if instructions are not followed. NOTE CAUTION 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 1-14 SERVICE INFORMATION WIRING DIAGRAM A.P. WINKER RELAY SOCKET COMP. LIGHTING S/W UNIT HEAD PIPE THROTTLE CABLE PRESS TO ATTACH THE SEL. SECTION TO THE PIPE FR. BRAKE HOSE SPEEDOMETER CABLE RR. BRAKE HOSE THROTTLE CABLE CABLE GUIDE STARTER S/W UNIT FR. STOP S/W CONNECTOR FR. BRAKE HOSE Y CABLE GUIDE SPEEDOMETER DIMMER S/W UNIT WINKER S/W UNIT HORN S/W UNIT HAZARD S/W UNIT RR. STOP S/W CONNECTOR RR. BRAKE HOSE LH. FR. WINKER LIGHT CONNECTING CONNECTOR CABLE GUIDE HORN COMP. RESISTOR 30W 5.9 SPEEDOMETER CABLE CABLE GUIDE FRONT FENDER MAIN S/W SEAT OPEN CABLE REG. RECTIFIER FRAME EARTH CONNECTOR (TIGHT AT THE SAME TIME WITH THE REG. REC.) FR. BRAKE HOSE FULE TUBE(CARB) BREATHER TUBE PLUNGER ASS'Y. CORD CLIP FULE TUBE(INSU) DRAIN TUBE THROTTLE CABLE DETAIL OF "Z" STARTER MOTOR CABLE STARTER MAGNETIC S/W PLUNGER ASS'Y HIGH TENTION CORD RR. BRAKE HOSE B WIRE CLIP I/G. COIL WIRE HARNESS WIRE CLIP HOSE CLAMP RH. RR. WINKER LIGHT RH. RR. WINKER CORD WIRE CLIP TAIL LIGHT CORD LICENSE LIGHT CORD BATTERY EARTH CABLE STARTER MAGNETIC BATTERY + CABLE RR. BRAKE HOSE B WIRE HARNESS RH. RADIATOR HOSE RR. BRAKE HOSE B BATTERY WIRE CLIP HOSE CLAMP LH. RADIATOR HOSE FUSE BREATHER TUBE FUEL UNIT CORD THROTTLE CABLE BREATHER TUBE DRAIN TUBE(CARB.) AIR CLEANER INLET DUCT TUBE CLAMP SEAT LOCK CABLE CABLE CLIP FUEL TANK FUEL UNIT FUEL TUBE LH. RR. WINKER CORD LH. RR. WINKER LIGHT CABLE SETT. PIPE FUEL PUMP 1-15 SERVICE INFORMATION MASTER CYLINDER ASS'Y FR. BRAKE HOSE SPEEDOMETER CABLE THROTTLE CABLE MAIN S/W SEAT LOCK CABLE WIRE HARNESS REGULATE RECTIFIER I/G. COIL STARTER MOTOR CABLE TRUNK LAMP AIR CLEANER TRUNK LAMP S/W PARKING BRAKE CABLE RR. BRAKE HOSE B BLEEDER TUBE STARTER MAGNETIC BATTERY +CABLE BATTERY EARTH CABLE HIGH TENSION CORD THROTTLE CABLE WIRE HARNESS SPEEDOMETER CABLE HEADLIGHT WIRE HARNESS FUEL TANK TAIL LIGHT CDI UNIT RH. RR. WINKER LIGHT LICENSE LIGHT RH. RADIATOR HOSE RR. BRAKE HOSE B SOCKET COMP. CHARGE SOCKET ASS'Y WIRE HARNESS HEAD LIGHT CORD INNER BOX MASTER CYLINDER ASS'Y RR. BRAKE HOSE A SPEEDOMETER CABLE HORN COMP. RESISTOR 30W 5.9 SPEEDOMETER CABLE HEAD LIGHT CONNECTING COUPLER(4P. FEMAIL) HEADLIGHT SOCKET COMP. WIRE CLAMP (SOCKET COMP.) SEAT LOCK CABLE THROTTLE CABLE WIRE CLAMP WIRE HARNESS VIEW "X" DETAIL OF "A" FUEL PUMP ASS'Y CABLE SETTING PIPE FUEL TUBE(INSU.) FUEL TUBE(CARB') A THROTTLE CABLE AIR CLEANER X RR. BRAKE HOSE B BREATHER CABLE SEAT LOCK CABLE THROTTLE CABLE RR. BRAKE HOSE B CABLE CLAMP BREATHER TUBE LICENSE LIGHT FUEL STRAINER COMP. FUEL TUBE(TANK) TAIL LIGHT LH. RR. WINKER LIGHT RH. RADIATOR HOSE LH. RADIATOR HOSE SPEEDOMETER CABLE DRAIN TUBE SIDE STAND S/W PARKING BRAKE CABLE 1-16 2. LUBRICATION SERVICE INFORMATION ··· 2-1 · TROUBLESHOOTING ····2-2 ENGINE OIL LEVEL INSPECTION · 2-3 · ENGINE OIL CHANGE···· 2-3 OIL FILTER ELEMENT CHANGE · 2-4 OIL PUMP ········· · RADIATOR········· · TRANSMISSION OIL INSPECTION LUBRICATION POINTS ··· 2-4 2-7 2-8 2-9 2 SERVICE INFORMATION GENERAL SAFETY WARNING 1. The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. 2. Used engine oil may cause skin cancer if repeatedly left in 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 1.1 (After disassembly) 0.9 (After Oil change with Oil in the Oil hose removed) OIL CAPACITY 0.8 (After Oil filter change) 0.75 (After Oil change) API service classification : SE, SF, SH grade Viscosity : SAE10W-30 RECOMMENDED (Use appropriate type of oil with viscosity satisfying OIL the atmospheric temperature In your riding area based on the table shown on the right side.) -10 0 10 20 30 40 TRANSMISSION OIL OIL CAPACITY RECOMMENDED OIL 0.15 (Full capacity) 0.14 (After oil change) DMC Pure mission oil or SAE 80W/90 TORQUE VALUES OIL FILTER SCREEN CAP OIL FILTER COVER BOLT OIL PUMP MOUNTING BOLT OIL DRAIN PLUG BOLT 1.5f·m 1.1f·m 1.1f·m 2.5f·m 2-1 LUBRICATION 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. 2-2 LUBRICATION 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. UPPER LINE PROPER LINE LOWER LINE SIGHT GLASS ENGINE OIL CHANGE NOTE ·To completely and rapidly drain engine oil, warm up engine and erect the motorcycle on its side stand. Loosen the oil drain plug bolt and drain engine oil. Operate the kick starter arm several times to remove the remaining oil from the engine. Tighten the oil drain plug bolt. TORQUE VALUE : 2.0-3.0 kgf·m OIL DRAIN PLUG CAUTION ·It is extremely important to replace oil filter or clean the oil filter screen at the first maintenance interval (after 1,000Km). ·Clean the oil filter screen every 4,000Km. ·Clean the filter screen with fresh cleaning oil. ·Check the hole cap O-ring for satisfactory condition. ·Tighten the hole cap with specified tightening torque. TORQUE VALUE : 1.5 kgf·m TAPPET ADJUSTING HOLE CAP OIL PICK UP COLLAR OIL FILTER SCREEN Loosen the special screw, remove the plug maintenance cover. Fill the recommended oil after opening oil filter cap of cylinder head cover. OIL CAPACITY : 1.1(After disassembly) 0.9(After Oil change with Oil in the Oil hose removed) 0.8(After Oil filter change) 0.75(After Oil change) API service classification : SE, SF, SH grade. Start the engine and keep it idle for a few minutes. Stop the engine and check the oil level. If the oil level is low, add the recommended engine oil. Check on oil leaks. OIL FILTER CAP 2-3 LUBRICATION OIL FILTER ELEMENT CHANGE Drain engine oil. (2-3) Loosen the 3 flange bolts securing the oil filter cover, remove the oil filter cover. Remove the oil filter element and oil filter spring. OIL FILTER COVER Change the oil filter element with a new one. Check if the oil filter seal is in good condition. Assemble the filter element spring and filter cover, and tighten bolts. TORQUE VALUE : OIL FILTER COVER 1.1kgf·m ELEMENT NOTE ·Always use a genuine oil filter element. ·Be sure to replace the oil filter seal when removing oil filter element. ·Be careful not to lose the oil filter spring when assembling the oil filter element. OIL FILTER SEAL OIL PUMP REMOVAL Remove the following parts : -Rear cushion lower bolt (13-7) -Muffler (4-12) -Rear swing arm (13-8) -Rear caliper (14-6) -Shroud (8-2) -Cooling fan (8-2) -A.C. generator (8-2) -RH. crankcase cover (8-4) -Starter driven gear (8-6) -Reduction gear (8-5) -Starting clutch assembly (8-6) Loosen the oil pump driven gear setting nut. Remove the oil pump driven gear. Remove the oil pump drive gear. Loosen the 3 flat screws securing the oil pump. Remove the oil pump. DRIVE GEAR DRIVEN GEAR NUT FLAT SCREW 2-4 LUBRICATION OIL PUMP DISASSEMBLY Loosen the screw securing the oil pump plate. Remove the oil pump body and the oil pump plate. Clean the oil pump body, inner and outer rotors with fresh cleaning oil. PUMP PLATE PUMP BODY INNER ROTOR PUMP SHAFT OUTER ROTOR ROLLER2.5x11.8 OIL PUMP INSPECTION Assemble the inner and outer rotors to the oil pump body. Measure the pump body clearance. SERVICE LIMIT : 0.23mm TOOL : FEELER GAUGE FEELER GAUGE Measure the rotor tip clearance. SERVICE LIMIT : 0.18mm INNER ROTOR OUTER ROTOR Measure the pump side clearance SERVICE LIMIT : 0.12mm 2-5 LUBRICATION OIL PUMP ASSEMBLY Clean all parts with fresh cleaning oil. PUMP PLATE PUMP BODY INNER ROTOR PUMP SHAFT OUTER ROTOR ROLLER2.5x11.8 Install the inner and outer rotors to the pump body. Assemble the pump shaft with setting pin. INNER ROTOR OUTER ROTOR Install the oil pump plate to the pump body. Tighten the pan screw. NOTE ·After installing, check the oil pump to operate smoothly. PUMP PLATE PAN SCREW OIL PUMP INSTALLATION Install the oil pump to the RH. crankcase. Install the following parts. -Oil pump drive gear and driven gear. -Starting clutch assembly. (8-8) -Starter driven gear and reduction gear (8-6) -A.C. generator (8-2) -RH. crank case cover (8-6) -Shroud and cooling fan (8-2) -Rear swing arm (13-8) -Rear caliper (14-6) -Muffler (4-12) FLAT SCREW 2-6 LUBRICATION RADIATOR REMOVAL Remove the front cover. (4-3) Remove the front wheel. (12-5) Loosen the 2 oil bolts and the 4 drain cock packings from the main pipe bracket. Loosen the 3 flange bolts securing the radiator. Remove the radiator. FLANGE BOLT CAUTION ·Be careful not to damage the radiator when removing it. ·Pay attention not to turn over the vehicle. RADIATOR INSPECTION Check the oil line connections for leaks. Check the oil cooler for bent or collapsed fins. Straighten the bent or collapsed fins with a suitable, small, blade-type screw driver if necessary. Check the air passages for clogging or restriction. Blow dirt out from between core fins with compressed air or wash off dirt with water. After installing, start the engine and check for leak. Stop the engine and check the oil level. FIN OIL RADIATOR RADIATOR RUBBER RADIATOR COLLAR FLANGE BOLT 2-7 LUBRICATION RADIATOR INSTALLATION Tighten the 3 radiator setting flange bolts to the main pipe bracket. FLANGE BOLT RADIATOR Tighten the drain cock packings and oil bolts. TORQUE VALUE : 3.2kgf·m Install the front wheel. (12-9) Install the front cover. (4-3) CAUTION ·Pay attention not to turn over the vehicle. ·When installing the radiator, tighten the oil bolts with specified tightening torque. OIL BOLT TRANSMISSION OIL INSPECTION Remove the LH. crankcase cover. (7-2) Check the body and the connection of each engine component for any leak. Remove the oil check bolt and check to see if the oil overflows from the oil check hole. If only the small amount of oil overflows. fill the recommended transmission oil through the oil filler hole gradually. OIL CHECK BOLT NOTE ·Oil level inspection must be performed in the flat ground with the vehicle being straight by raising the main stand. RECOMMENDED OIL : SAE 80W/90 Tighten the oil check bolt. TORQUE VALUE : 0.9 kgf·m A.C.GENERATOR CAP Start the engine and check for leak. Install the LH. crankcase cover. (7-2) BREATHER TUBE 2-8 LUBRICATION LUBRICATION POINTS Unless specifically designated, use general grease to lubricate the lubrication points. For sliding parts not shown here, add oil or grease. CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable, and apply oil. If the cable has expanded, replace it. FRONT BRAKE LEVER PIVOT THROTTLE GRIP STEERING HEAD BEARING FRONT FORK DUST SEAL WHEEL BEARING BRAKE CALIPER BRACKET SIDE/MAIN STAND PIVOT WHEEL BEARING/SPEEDOMETER GEAR 2-9 MEMO 3. INSPECTIONS/ADJUSTMENTS SERVICE INFORMATION ··· 3-1 MAINTENANCE SCHEDULE ·· 3-3 FUEL LINE (FUEL TUBE) ··· 3-4 · THROTTLE GRIP OPERATION·· 3-4 AIR CLEANER ······· 3-4 SPARK PLUG ······· 3-5 VALVE CLEARANCE ···· 3-5 CYLINDER COMPRESSION PRESSURE · 3-6 · CARBURETOR IDLE SPEED · 3-6 · BRAKE FLUID········3-7 · BRAKE PAD/SHOE····· BRAKE SYSTEM ······ · BRAKE LEVER FREE PLAY· · HEADLIGHT AIM······ · SIDE STAND········ SUSPENSION ······· BOLTS, NUTS, FASTENERS · · · WHEELS/TIRES······· · STEERING HEAD BEARING· 3-7 3-7 3-8 3-8 3-8 3-9 3-9 3-10 3-10 3 SERVICE INFORMATION WARNING The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time. NOTE ·For information on engine oil and oil filter, refer to sections 2-3 and 2-4 ·Stand the main stand prior to beginning work. SPECIFICATIONS THROTTLE GRIP PLAY SPARK PLUG SPARK PLUG GAP VALVE CLEARANCE IN EX 2- 6mm CR8EH-9 0.8-0.9mm 0.12±0.02mm 0.12±0.02mm 1,800±100rpm 14±2kgf/ ( 550rpm ) CARBURETOR IDLE SPEED CYLINDER COMPRESSION PRESSURE TIRES COLD TIRE PRESSURE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 200kPa (2.00kgf/ ) 200kPa (2.00kgf/ ) 200kPa (2.00kgf/ ) 225kPa (2.25kgf/ ) 120/70 - 12 53k(Tubeless) 130/70 - 12 62k(Tubeless) 0.5mm 0.5mm 3-1 TIRE SIZE MIN, TREAD DEPTH "" INSPECTIONS / ADJUSTMENTS TORQUE VALUES SPARK PLUG CYLINDER HEAD COVER BOLTS VALVE ADJUSTING NUTS TIMING HOLE CAP 1.1kgf·m 1.0kgf·m 1.1kgf·m 0.6kgf·m TOOLS WRENCH 8X9mm ADJUST WRENCH COMPRESSION GAUGE 3-2 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 These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart. FREQUENCY ITEM ODOMETER READING(NOTE 1) x 1000Km 1 4 6 8 12 12 18 REMARK MONTH I R I I I R R I I I I FUEL LINE(FUEL TUBE) FUEL FILTER THROTTLE GRIP OPERATION AIR CLEANER SPARK PLUG I R I I R I I R I NOTE 2 I I R NOTE 3 R R I I I I I I I I I I I I I C L NOTE 3 Every 1,000 : C I I I R R I I I I I I I I I R R I I I I I I I I I I I I I I I C L I I I I C L VALVE CLEARANCE TRANSMISSION OIL ENGINE OIL ENGINE OIL FILTER CARBURETOR IDLE SPEED BRAKE FLUID BRAKE SHOE/PAD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT ADJUSTMENT SIDE STAND SUSPENSION BOLTS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING I I DRIVE BELT WEIGHT ROLLER SLIDE PIECE OIL FILTER SCREEN MOVABLE DRIVE FACE INNER PART 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. 3-3 INSPECTIONS / ADJUSTMENTS FUEL LINE(FUEL TUBE) Remove the luggage box.(4-4) Check the fuel tube of the fuel pump connected to the fuel tank and carburetor. If the fuel tube is cracked, damaged or leaks, replace it. FUEL PUMP FUEL TUBE 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 adjustment, loosen the lock nut and turn adjuster. After adjusting, tighten lock nut. After adjustment is completed, recheck the throttle grip free play. AIR CLEANER Release the seat lock by turning the main switch key to open the seat. 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. Remove the air cleaner trap comp. Wash away any accumulated dust or dirt, by gently squeezing it in non flammable or high flash point solvent. SCREW WARNING ·Using gasoline or low flash point solvents for cleaning parts may result in a fire or explosion. AIR CLEANER ELEMENT AIR CLEANER TRAP 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. SCREW 3-4 INSPECTIONS / ADJUSTMENTS 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. 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. SPARK PLUG Remove the plug maintenance cover. Remove the spark plug cap and disassemble the plug. Check the plug for damage, contamination or deposits. If the spark 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 : CR8EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE VALUE : 1.1 kgf·m CHECK GAP, DEPOSITS 0.8mm~0.9mm CHECK WASHER FOR DAMAGE CHECK FOR CRACKS 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. VALVE CLEARANCE Remove the following parts. -Luggage box. (4-4) -Center cover. (4-5) Loosen the 4 cylinder head bolts. CYLINDER HEAD COVER NOTE ·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 : 0.12±0.02mm Exhaust : 0.12±0.02mm TIMING CHECKING RH. SHROUD 3-5 INSPECTIONS / ADJUSTMENTS Loosen the lock nut with a valve wrench, and set valve clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench. After setting clearance to the prescribed level, hold the adjuster screw with a valve adjusting wrench, and tighten the lock nut. TORQUE VALUES : 1.1kgf·m TOOLS : WRENCH 8X9mm ADJUSTING WRENCH B FEELER GAUGE ADJUSTER WRENCH 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 NOTE ·The maximum reading is usually reached within 4~7 seconds. COMPRESSION PRESSURE : 13.8 kg/cm2 SPARK PLUG 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. COMPRESSION GAUGE CARBURETOR IDLE SPEED Remove the plug maintenance cover. (4-5) Check the idle speed and adjust if necessary by turning the throttle stop screw. THROTTLE STOP SCREW NOTE ·Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. ·Heat the engine to make accurate idling inspection and adjustment. Stand the vehicle on the main stand. ·Turn the throttle stop screw and make adjustments to prescribed idling speed. 3-6 INSPECTIONS / ADJUSTMENTS BRAKE FLUID Loosen the 3 screen setting screws securing the wind screen. Remove the oil cup cap covers. Check the oil level inside the front/rear brake reservoirs. If the oil level is near the lower limit line, remove the reservoir diaphragms 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. FRONT MASTER CYLINDER REAR 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. WEAR LIMIT LINE WEAR LIMIT LINE BRAKE PAD/SHOE BRAKE PAD REPLACEMENT Check the brake pads for wear. If the red mark on the pad reaches the brake disk, replace the pads.