How to use this manual General This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO., LTD. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule(Section 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co.,Ltd., Contents Service Information Inspections / Adjustments External Parts Lubrication System EMS(Engine Management System) Fuel System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Engine Removal / Installation Engine Frame Electrical LH, Crank Case Cover Continuously Variable Transmission A.C Generator / Starter Clutch Cylinder Head / Valves Cylinder Head / Piston Transmission / Crank Shaft Crank Case Front Wheel / Front Fork / Steering / Brake Rear Wheel / Rear Brake / Suspension / Rear Swing Arm Charging System Ignition System Starter System Lights / Switches / Horn Wiring diagram SERVICE INFORMATION 1 1-1 SERVICE INFORMATION 1-2 SERVICE INFORMATION 1-3 SERVICE INFORMATION 1-4 SERVICE INFORMATION 1-5 SERVICE INFORMATION 1-6 SERVICE INFORMATION 1-7 SERVICE INFORMATION 1-8 SERVICE INFORMATION 1-9 SERVICE INFORMATION 145kg 306.9kg 11.5 2.2 stroke SOHC ATDC 1-10 SERVICE INFORMATION , 30A LED LED LED 1-11 SERVICE INFORMATION 1-12 SERVICE INFORMATION 1-13 SERVICE INFORMATION 1-14 SERVICE INFORMATION 1-15 SERVICE INFORMATION 1-16 SERVICE INFORMATION BATTERY + CABLE START-MAGNET SW. ASS'Y. START MOTOR CABLE TO. CARBULATOR TUBE CLIP FUEL PUMP TUBE CLIP TUBE CLIP TO. FUEL TANK TO. INSULATOR WIRE CLIP BATTERY EARTH CABLE ACG. WIRE START-MAG. SW. CORD ACG. CORD 1-17 MEMO INSPECTIONS/ADJUSTMENTS 2 2-1 INSPECTIONS/ADJUSTMENTS 2-2 INSPECTIONS/ADJUSTMENTS 2-3 INSPECTIONS/ADJUSTMENTS 2-4 INSPECTIONS/ADJUSTMENTS 2-5 INSPECTIONS/ADJUSTMENTS 2-6 INSPECTIONS/ADJUSTMENTS 2-7 INSPECTIONS/ADJUSTMENTS 2-8 INSPECTIONS/ADJUSTMENTS 2-9 INSPECTIONS/ADJUSTMENTS 2-10 EXTERNAL PARTS 3 3-1 EXTERNAL PARTS 3-2 EXTERNAL PARTS 3-3 EXTERNAL PARTS 3-4 EXTERNAL PARTS UPPER UPPER HANDLE COVER HANDLE COVER UNDER UNDER HANDLE COVER HANDLE COVER FRONT COVER FRONT COVER 3-5 EXTERNAL PARTS FRONT UNDER FRONT UNDER COVER A COVER A 3-6 EXTERNAL PARTS 3-7 EXTERNAL PARTS 3-8 LUBRICATION SYSTEM 4-1 4-2 4-3 4-3 4-4 4-4 4-7 4-8 4-9 4 4-1 LUBRICATION SYSTEM 4-2 LUBRICATION SYSTEM 4-3 LUBRICATION SYSTEM 4-4 LUBRICATIONSERVICE SYSTEM 4-5 LUBRICATION SYSTEM 4-6 LUBRICATION SYSTEM 4-7 LUBRICATION SYSTEM 4-8 LUBRICATION SYSTEM 4-9 MEMO EMS(Engine Management System) 5. EMS(Engine Management System) 1. CAUTION WHEN REPAIRING THE EMS PARTS 2. THE COMPONENT PARTS OF THE EMS 3.TERMINAL ARRANGEMENT OF THE ECU 4. WIRING DIAGRAM OF THE ECU 5. SELF-DIAGNOSTIC FUNCTION BY MIL(Malfunction Indicator Lamp) - Self diagnostic function - Fail safe function - How to check the fault code - How to show the fault code - How to read the fault code - Fault code table - How to remove the fault code - EMS trouble shooting 6. INJECTOR 7. MAPAT 8. TPS 9. ETS 10. ISA 11. O2(Oxygen) SENSOR 12. CHECKING OF MIL CIRCUIT 13. ECU (Electronic control unit) 14. IGNITION COIL/SPARK PLUG 15. CPS 16. FUEL PUMP 17. THROTTLE BODY 18. HOW TO USE THE SCAN WHEN THE ECU IS INITIALIZED 19. HOW TO USE THE SCAN WHEN THE ISA PWM IS ADJUSTING 20. HOW TO USE THE SCAN WHEN THE IGNITION TIMING IS CHECK 21. HOW TO USE THE SCAN WHEN ENGINE REVOLUTION IS CHECKING 5-2 5-3 5-4 5-4 5-5 5-5 5-6 5-7 5-8 5-8 5-9 5-10 5-10 5-11 5-14 5-17 5-20 5-23 5-26 5-29 5-30 5-31 5-32 5-33 5-36 5-41 5-43 5-44 5-45 5-1 EMS(Engine Management System) 1.CAUTION WHEN REPAIRING THE EMS PARTS. If the fuse is short-circuited, findout the cause and repair. Replace with the fuse having the specified capacity. Do not use the electlic wires or others instead of the fuse. Do not drop or throw the EMS parts because these parts may be damaged by the impact of the drop. Do not touch the ECU terminal, because it may be damaged by the static. The ignition key off when assembly and disassembly of the ECU coupler. otherwise, it might be damage to ECU. Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts While engine operating, do not disassembly the battery terminal. otherwise, it might cause damaged the EMS parts. Use the specitied voltmeter and resistance meter. 5-2