User manual DAELIM VL125E - SERVICE MANUAL

How to use this manual General This manual explains how to maintain the Daystar of the DAELIM MOTOR CO., LTD. Follow the maintenance schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Section 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, grouped according to location. Most sections start with an assembly or system illustration, service information and trouble shooting for the section. The subsequent pages give detailed procedures. If you don't know the source of the trouble, go to section 20, trouble shooting. All information, illustrations, directions and specificiations included in this publication are based on the latest product information avaliable at the time of approval for printing. DAELIM reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced wihtout written permission. Some drawings of this manual can be slightly different from actual specification of model. Contents General Information Lubrication Maintenance Fuel System EMS(Engine Management System) Engine Removal / Installation Clutch / Gearshift Engine Frame Electrical A.C. Generator / Starter Clutch Cylinder Head / Valve Cylinder / Piston Crankcase / Transmission / Crankshaft Cooling System Seat / Exhaust Muffler Front Wheel / Front Fork / Steering Rear Wheel / Rear Brake / Suspension Hydraulic Brake Charging System / Battery Ignition System Electric Starter Lights / Switches / Horn / Fuel Unit Wiring diagram Troubleshooting General Information 1. General Information General Safety Service Rules Model Identification Specification 1-1 1-1 1-2 1-3 Torque Values Safety Notice Tools / Tester gauge / Valve Seat Cut Cable & Harness Routing 1-5 1-7 1-8 1-10 General Safety ! WARNING 1. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. 2. The battery contains sulfuric acid(electrolyte) Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water. If electrolyte gets on your eyes, flush with water and call physician. Electrolyte is poisonous. Keep out of reach of children. 3. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in your working area. 4. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged period. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. Service Rules 1. Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents. 2. Use the special tools designed for this product. 3. Install new gaskets, o-ring, piston pins, clips, cotter pins, etc. When reassembling. 4. When tightening a series of bolt or nuts, begin with the larger-diameter of inner bolts first, and tighten to the specified torque diagonally, in incremental steps unless a particular sequence is specified. 5. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. 6. Clean parts in cleaning solvent upon disassembly. Remove the cleanser with compressed air. 7. Lubricate any sliding surface before reassembly with recommended grease. 8. After reassembly, check all parts for proper installation and operation. 1-1 General Information Model Identification Frame No Frame No Frame No Engine No Engine No Engine No 1-2 General Information Specifications Item Overall Length Overall Width Overall Height Wheel Base Seat Height Ground clearance Dry Weight Curb Weight Type Front Suspension Stroke Rear Suspension Stroke Front Tire Size Rear Tire Size Tire Pressure 1 Person Front Rear 2 Person Front Rear Front Brake Rear Brake Fuel Capacity Fuel Reserve Capacity Caster Angle Trail Length Front Fork Oil Capacity Type Cylinder Number, arrangement Bore and Stroke Displacement Comparison Ratio Valve Train Oil Capacity 2,240mm 860mm 1,140mm 1,505mm 720mm 135mm 147.5kgf 344.9kgf Double Cradle Telescopic fork 140mm Swingarm 35mm 90/90 - 18 (Tubeless) 130/90 - 15 (Tubeless) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) Hydraulic Disk Drum Brake 16.8 4.3 32 147mm 280cm3 Oil / Air Cooled 4-stroke SOHC Engine 1 Cylinder, 15 56.5 X 49.5mm 124.1cm3 11.5:1 SOHC Chain Drive 1.2 After Disassembly 1.15 After Draining and Oil Filter Change 1.1 After Draining Forced Pressure Splash Type Viscose Oil Wet Filter 14kgf/cm2 (550rpm) 6 BTDC 22 ABDC at 1.12mm Lift 24 BBDC 4 BTDC at 1.12mm Life 0.12 0.02mm(0.005 0.001 in) 0.12 0.02mm(0.005 0.001 in) 32.3kg Specifications Dimensions Frame Engine Lubrication System Air Cleaner Cylinder compression Intake Value Opens Closes Exhaust Value Opens Closes Valve Clearance Intake (a cooling-off period) Exhaust Engine Dry Weight 1-3 General Information Item Clutch Transmission Type Primary Reduction Secondary Reduction Gear Ratio 1st Gear Ratio 2nd Gear Ratio 3rd Gear Ratio 4th Gear Ratio 5th Gearshift Pattern Specifications Hydraulic, Multi-plate Constant Mesh Transmission 3.650(73/20) 3.214(45/14) 3.083(37/12) 1.882(32/17) 1.380(29/21) 1.095(23/21) 0.923(24/26) Left foot operated return system 1-N-2-3-4-5 TRANSISTER BTDC 18 2 /1,600 150(rpm) 12V 10AH CR9EH - 9 0.8 - 0.9mm 30A, 15A Starter Motor 12V 60W/55W 12V 10W 4 12V 5W/21W 12V 3W/3.4W(1.7W 2) 12V 1.7W 12V 1.7W 12V 1.7W Drive Train Electrical Ignition Ignition Timing "F" Mark Battery Capacity Spark Plug Spark Plug Gap Fuse Capacity Starting System Headlight (High/Low Beam) Winker Tail/Stop Lights Meter Light Neutral Indicator Lamp High Beam Pilot Lamp Malfunction Indicator Lamp 1-4 General Information Torque Values Engine Item Oil Filter Screen Cap Oil Filter Relief Valve Oval Screw Oil Filter Cover Socket Bolt Oil Pump Mounting Bolt Valve Adjusting Screw Lock Nut Drive Sprocket Engine Hanger Bolt(Front) Engine Hanger Bolt(Front 1, Rear 2) Clutch Lock Nut Drum Stopper Arm Bolt Primary Drive Gear Bolt R Crank Case Cover Bolt Gear Change Arm Bolt Flywheel Bolt Starter Clutch Socket Bolt Cam Chain Tensioner Pivot Bolt Spark Plug Cam Shift Holder 8mm nut Cam Chain Tensioner Mounting Bolt Cam Chain Tensioner Sealing Screw Cylinder Head Cover Bolt Crank Shaft Hole Cap Timing Hole Cap L Crank Case Cover Bolt Main Shaft Bearing Setting Plate Crank Case Bolt Starter Motor Terminal Nut Cylinder(Oil Through Bolt) Radiator(Oil Through Bolt) Q'ty 1 1 3 2 4 2 2 3 1 1 1 11 1 1 3 1 1 4 2 1 2 1 1 7 2 11 1 2 2 Thread dia (mm) Torque kgf.m,(N.m) Remark 36 10 6 6 5 6 8 10 16 6 16 6 6 10 8 8 10 8 6 6 6 30 14 6 6 6 6 12 12 1.5(15) 1.2(12) 1.1(11) 1.1(11) 1.1(11) 1.2(12) 2.7(27) 4.9(49) 6.5(65) 1.2(12) 6.5(65) 1.1(11) 1.2(12) 5.5(55) 3.2(32) 1.1(11) 1.1(11) 2.0(20) 1.2(12) 0.4(4) 1.0(10) 0.8(8) 0.6(6) 1.1(11) 1.2(12) 1.1(11) 1.2(12) 3.2(32) 3.2(32) Apply Engine Oil Apply Engine Oil Apply Engine Oil Apply a locking nut agent Apply Engine Oil Apply a locking nut agent Frame Item Handle Holder Bolt Steering Stem Nut Steering top Thread Nut Front Fork Top Bridge Bolt Front Fork Bottom Bridge Bolt Front Fork Socket Bolt Front Fork Tube Cap Front Axle Nut Front Wheel Stud Bolt Ignition Switch Bolt Front Brake Disk Nut Q'ty 2 1 1 2 2 2 2 1 5 2 6 Thread dia (mm) Torque kgf.m,(N.m) Remark 10 22 22 7 8 8 26 14 6 8 8 2.6(26) 7.4(74) 1.8(18) 0.3(3) 1.1(11, 8) 3.3(33) 2.0(20) 2.3(23) 5.9(59) 0.6(6, 4.3) 3.3(33) 4.2(42) With a Starting torque With a Finishing torque Apply a locking nut agent Apply a locking nut agent Self lock nut 1-5 General Information Item Brake Caliper Bracket Bolt Brake Caliper Bleed Valve Brake Pad pin Bolt Master Cylinder Reservoir Cap Screw Brake Hose Bolt Brake Lever Pivot Bolt Brake Lever Pivot Lock Nut Rear Axle Nut Final Driven Sprocket Nut Rear Brake Arm Bolt Rear Shock Absorber Upper Bolt Rear Shock Absorber Lower Bolt Rear Fork Pivot Bolt Rear Brake Pedal Bolt Chain Tensioner Flange Nut Q'ty 2 1 2 2 2 1 1 1 4 1 1 1 1 1 1 Thread dia (mm) Torque kgf.m,(N,m) Remark 8 8 8 4 10 6 6 14 10 6 10 10 12 8 8 3.0(30) 0.6(6) (1.8, 13) 0.13(1.3) 3.4(34) 1.0(10, 7) 1.0(10, 7) 8.8(88) 5.9(59) 1.0(10) 3.4(34) 3.4(34) 4.5(45) 2.2(22) 3.6(36) Self lock nut Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below. SH(Small Head): 6mm Bolt of 8mm Flange Head. Type 15mm Bolt, nut 16mm Bolt, nut 18mm Bolt, nut 10mm Bolt, nut 12mm Bolt, nut Torque kgf-m 0.45~6 0.8~1.2 1.8~2.5 3.0~4.0 5.0~6.0 N.m 4.5~6 8~12 18~25 30~40 50~60 Type 5mm Screw 6mm Screw&Flange bolt (SH TYPE) 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut Torque kgf-m N.m 0.35~0.5 0.7~1.1 1.0~1.4 2.4~3.0 3.5~4.5 3.5~5 7~11 10~14 24~30 35~45 1-6 General Information Safety Notices Following marks indicate some warnings and caution against some specific service methods. Mark ! Meaning Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed ! Mark CAUTION Meaning Indicates a possibility of personal injury or equipment damage if instructions are not followed. Gives helpful information WARNING NOTE The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance Symbol Caution Use recommended engine oil, unless otherwise specified Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1) Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) Symbol Caution Apply sealant Replace the parts with new ones before assembly Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified. CUSHION OIL Use Forkor Suspension Fluid S TOOL Use special tool Use silicone grease Apply a locking agent. Use the agent of the middle strength, unless otherwise specified O.P. TOOL Use optional tool. These tools are obtained as you order parts Indicates reference page. (Example: Refer to page 3-1) Special greases, etc. that do not correspond to the above are indicated without using symbols. 1-7 General Information Tools Special Description Clutch Center Holder Flywheel Puller Lock Pin Puller Set Sliding shaft Sliding Weight Valve Guide Reamer Universal Bearing Puller Bearing Remover Set, 15mm Remover Assy, 15mm Remover Shaft, 15mm Remover Head Sliding Weight Thread Adopter Assembly Shaft Crank Case Assembly Color Ball Race Driver Steering Stem Driver Fork Seal Driver Steering Stem Socket Snap Ring Pliers Reference section 6 7 8 8 8 8 10 10 10 10 10 10 10 10 10 13 13 13 13 15 Common Description Wrench, 8 9mm Adjusting Wrench, B Float Level Gauge Lock Nut Wrench, 20 24mm Extension Bar Fly Wheel Holder Valve Spring Compressor Driver Attachment, 32 35mm Attachment, 42 47mm Attachment, 62 68mm Attachment, 72 78mm Pilot, 15mm Pilot, 20mm Pilot, 35mm Pilot, 28mm Lock Nut Wrench, 30 32mm Attachment, 37 40mm Pilot, 12mm Fork Seal Driver Body Remover Head, 12mm Bearing Remover Shaft Remover Head, 15mm Rear Cushion Compressor Attachment Reference section 3 3 4 6 6, 13 6, 7 8 10, 13, 14 10, 14 10, 13, 14 10 10 10, 14 10 10 10 13 13 13 13 13 13, 14 14 14 14 1-8 General Information Tester, Gauge Description Compression Gauge Digital Circuit Tester Circuit Tester Inspecion Adapter Spark Adapter Reference section 3 16, 17 16, 17 17 17 Remark Valve Seat Cut Description Valve Seat Cutter 45 Valve Seat Cutter 35 Valve Seat Cutter 35 Valve Seat Cutter 60 Cutter Holder 5mm Reference section 8 8 8 8 8 Remark 24.5mm IN, EX 23mm IN 20mm EX 22mm IN, EX Use with Valve Seat 1-9 General Information Cable & Harness Routing Note the following when routing cables and wire harnesses: A loose wire, harness or cable can be safety hazard. After clamping, check each wire to be sure it is secure. Do not squeeze wires against the weld or its clamp. Secure wires and wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses. Route harnesses so they are neither pulled tight nor have excessive slack. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. Do not use a wire or harnesse with a broken insulator. Repair by wrapping then with protective tape or replace them. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. Keep wire harnesses away from the exhaust pipes and other hot parts. Be sure grommets are seated in their grooves properly. After clamping, check each harness to be certain that it is not interfering with any moving or sliding parts. After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched by or interfere with adjacent or surrounding parts in all steering positions. Do not bend or twist the control cables. Damaged control cables will not operate smoothly and may stick or bind. : CORRECT : INCORRECT 1-10 General Information 1-11 General Information 1-12 General Information 1-13 MEMO Lubrication 2. Lubrication Service Information Specifications Troubleshooting Engine Oil Level Check 2-1 2-1 2-2 2-3 Engine Oil Change Engine Oil Filter Element Change Oil Pump Lubrication Points 2-3 2-4 2-4 2-7 Service Information ! WARNING If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged. Although it is unlikely to happen unless you handle used oil on a daily basis, it is still advisable to wash your hands thoroughly with soap and water as soon as possible after handling used oil. The oil pump can be serviced with the engine installed in the frame. Specifications Engine oil Oil Capacity 1.2 (all capacity) 1.15 (after oil filter change) 1.1 (after oil change) API Service Classification:SE or SH Viscosity:SAE10W-30 (Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range.) 10W Oil Recommendation 10 0 10 20 30 40 Oil Pump Item Pump Body clearance Rotor end clearance Pump side clearance Standard Value 0.15~0.20(0.006~0.008) 0.15(0.006) 0.05~0.09(0.002~0.004) Unit : mm(in) Service Limit 0.25(0.010) 0.20(0.008) 0.12(0.005) Torque Valves Oil Filter Screen Cap Oil Filter Relief Valve Oval Screw Oil Filter Cover Socket Bolt Oil Pump Mounting Bolt 1.5kgf-m(15N.m) 1.2kgf-m( 9N.m) 1.1kgf-m(11N.m) 1.1kgf-m(11N.m) 2-1 Lubrication Troubleshooting Low oil pressure Oil level low Pressure relief valve stuck open Plugged oil pick-up screen Oil pump worm External oil leaks High oil pressure Pressure relief valve stuck closed Plugged oil filter, gallery, or metering orifice In correct oil being used No oil pressure Oil level low Oil pump drive gear broken Oil pump faulty Internal oil leakage 2-2 Lubrication Engine Oil Level Check Run the engine and allow it to idle for few minutes. Stop the engine and place the motorcycle on its center stand. After 2-3 minutes, check the oil level with the filler cap/dipstick. Do not screw it in when making this check. If the oil level is below or near the lower level mark on the dipstick, add the recommended oil up to the upper level line. Oil Level Gauge Oil Level Gauge Oil Level Gauge Engine Oil Change ! CAUTION Change engine oil with engine warm and the motorcycle on its side stand to assure complete and rapid draining. Remove the oil filter cap. Remove the oil filter cap, spring, and screen. Drain the oil from the engine. Clean the filter screen with clean wash. check that the oil filter screen and O-ring of the screen cap are in good condition. Assemble filter screen, spring and cap. Torque : 1.5kgf-m(15N.m) Fill the crankcase with recommended engine oil. Oil Capacity : 1.2 (After disassembly) 1.15 (After Oil filter change) 1.1 (After oil change) Oil Recommendation : DAELIM genuine oil API service classification : SE or SH Viscosity : SAE 10W-30 Install the oil level gauge. Start the engine and let it idle for a few minutes. Stop the engine and check that the oil level is at the upper level mark. If the oil level is below or near the lower level mark, add the recommended oil up to the upper level mark, Make sure if there is no oil leak. Oil Filter Cap Oil Filter Cap Oil Filter Cap Gear Change Gear Change Gear Change Pedal Bolt Pedal Bolt Pedal Bolt Filter Screen Filter Screen Filter Screen Filter Screen 2-3 Lubrication Engine Oil Filter Element Change Remove the drain plug and drain the oil. ( 2-3) Remove the oil filter cover bolt, filter cover, filter element and spring. Replace the oil filter element with a new oil filter. Check the operation of the relief valve. If the relief valve is fully opened when released, it is in good condition. Check if the oil filter seal is in good condition. Install the filter element spring and filter cover, and tighten the socket bolt. Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw : 1.2kgf-m(12N.m) Oil Filter Cover Oil Filter Cover Oil Filter Cover Filter Element Filter Element Filter Element Oil Pump Removal Remove the right crank case cover. ( 6-3) Remove the oil pump mounting bolts, oil pump, pump plate, and lock pin. Clean the oil pump body, inner and outer rotors with cleaning solvent. Mount Bolt Mount Bolt Mount Bolt Inspection Install the inner and outer rotor into the oil pump body. Measure the pump body clearance. Service Limit : 0.25mm(0.010 in) Oil Pump Oil Pump Oil Pump Outer Rotor Outer Rotor Outer Rotor Inner Rotor Inner Rotor Inner Rotor 2-4 Lubrication Measure the rotor end clearance. Service Limit : 0.20mm(0.008 in) Measure the pump side clearance. Service Limit : 0.12mm(0.005 in) Disassembly / Assembly Remove the inner and outer rotor from pump body. Remove the setting ring, spacer, oil seal and pump shaft. Clean each parts with cleaning solvent. Setting Ring Setting Ring Setting Ring Connect the pump shaft, oil seal, and spacer, then install into the setting ring. Install the inner and outer rotors. Inner Rotor Inner Rotor Inner Rotor Pump Shaft Pump Shaft Pump Shaft Outer Rotor Outer Rotor Outer Rotor Pump Body Pump Body Pump Body Spacer Spacer Spacer Spacer Setting Setting Setting Ring Ring Ring Oil Seal Oil Seal Oil Seal 2-5 Lubrication Remove the oval screw, sealing washer, spring and relief valve from oil filter cover. Remove the oil filter element from R. crank case cover. Blow the oil path way of crank case cover with compressed air, and clean. Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw: 1.2kgf-m(12N.m) Install the dowel pins and oil pump plate into the pump body. Dowel Pin Dowel Pin Dowel Pin Dowel Pin Oil Pump Plate Oil Pump Plate Oil Pump Plate Install the oil pump into the right crank case cover and tighten the bolt. Torque : 1.1kgf-m(11N.m, 8ft-lb) Install the right crank case cover Mount Bolt Mount Bolt Mount Bolt Oil Pump Oil Pump Oil Pump 2-6 Lubrication Lubrication points if there is no specific indication of oil, use general grease to lubricate the lubrication parts. Lubricate the other operation parts which are not shown below with oil or grease. Control Cable Lubrication Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. Check the cable for loose, replace them if necessary. Clutch Lever Pivot Brake Lever Pivot Throttle Grip Throttle Cable, Choke Cable Speedometer Cable, Clutch Cable Steering Head Bearing Front Fork Dust Seal Main Stand Pivot Side Stand Pivot Wheel Bearing Drive Chain Brake Pedal Pivot Wheel Bearing Speedometer Gear Brake Caliper 2-7 MEMO Maintenance 3. Maintenance Service Information Maintenance Schedule Fuel Line Throttle Grip Operation Air Cleaner Spark Plug Valve Clearance Cylinder Compression Pressure Drive Chain Battery Brake Fluid Brake Pad / Shoe 3-1 3-3 3-4 3-4 3-5 3-6 3-6 3-7 3-8 3-10 3-10 3-10 Brake System Brake Stop Switch Headlight Adjustment Clutch Side Stand Suspension Bolts, Nuts Fasteners Wheels / Tires Steering Head Bearings 3-11 3-12 3-12 3-12 3-13 3-13 3-14 3-14 3-15 Service Information NOTE If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area. Engine oil and oil filter see page 2-3, 2-4 Before working, stand the main stand. Specifications 2 6mm(0.078~0.236 in) CR9EH 9 0.8 0.9mm(0.031-0.035in) IN) 0.12 0.02mm(0.005-0.001in) EX) 0.12 0.02mm(0.005-0.001in) Cylinder compression: 14 f/ (550rpm) Drive chain free play: 50~60mm(1.968~2.362 in) Rear brake pedal free play: 20~30mm(0.787~1.181 in) Clutch lever free play: 10~20mm(0.393~0.787 in) Throttle grip free play: Spark plug: Spark plug gap: Valve clearance: Tires Driver only Cold tire pressure Driver and a passenger Tire size Tire part minimum-depth Front Rear Front Rear Front Rear Front Rear 200kPa (2.00kgf/ 200kPa (2.00kgf/ 200kPa (2.00kgf/ 200kPa (2.00kgf/ 90/90 -18 130/90 -15 4mm (0.16 in) 8.5mm (0.3 in) ) ) ) ) 3-1 Maintenance Torque Values Spark Plug Cylinder Head Cover Bolt Valve Adjusting Nut Timing Hole Cap Crankshaft Hole Cap Rear Axle Nut 1.1 kgf-m( 11N.m) 1.0 kgf-m( 10N.m) 1.1 kgf-m( 11N.m) 0.6 kgf-m( 6N.m) 0.8 kgf-m( 8N.m) 8.8kgf-m(88N.m) Tools Common Tool Wrench, 8 9 mm Adjuster Wrench Compression Gauge 3-2 Maintenance Maintenance Schedule Perform the Pre-ride inspection in the Owner's manual at each scheduled maintenance period. I : Inspect and clean, adjust, lubricate or replace if necessary R : Replace L : Lubricate C : Clean Frequency Item Fuel Line Throttle Grip Operation Air Cleaner Spark Plug Valve Clearance Engine Oil Engine Oil filter Element Drive Chain Brake Fluid Brake Shoe/Pad Brake System Brake Stop Switch Head Light Aim Clutch System Side Stand Suspension Bolt, Nut Fastener Wheels/Tires Steering Head Bearing Odometer Reading (NOTE 1) 1,000km I 4,000km 8,000km 6 12 I I I I R R I R I I R R R R 1,000km : I,L I I I I I I I I I I I I I I I I I I I I 12,000km 18 I I R I I R R I I I I I I I I I Refer to Page 3-4 3-4 3-5 3-6 3-6 2-3 2-4 3-10 3-10 3-11 3-12 3-12 3-12 3-13 3-13 3-14 3-14 3-15 Remark NOTE 2 I R R 3-8 NOTE 3 I I I I Should serviced by an authorized DAELIM dealer, unless the owner has proper tools and service date and is mechanically qualified. In the interest of safety, we recommended these items be serviced only by an authorized DAELIM dealer. NOTES: 1. After high odometer reading 12,000km(7,500mi), repeat at the frequency interval established here. 2. Service more frequently when riding in unusual wet or dustry areas 3. Replace every 2 years. In case of replacing, proper skills are needed. 3-3 Maintenance Fuel Line Check the fuel lines for deterioration, damage, or leakage. Replace the fuel lines. Fuel Cock Fuel Cock Fuel Cock Fuel Tube Fuel Tube Fuel Tube Choke Cable Choke Cable Choke Cable Throttle Grip Operation Check the throttle grip for smooth operation. Complete opening and automatic closing in all steering positions. Lubricate the throttle cables if throttle operation is not smooth ( 2-7) Make sure if there is no deterioration, damage, or kinking in the throttle cables. Measure the throttle grip free play at the throttle grip flange. Free Play : 2~6mm(0.078~0.236in) Adjust the free play by loosening the lock nut and turning the adjuster. Tighten the lock nut. Recheck the throttle free play. Adjuster Adjuster Adjuster Lock Nut Lock Nut Lock Nut 3-4 Maintenance Air Cleaner Loosen the four screw, and remove the air cleaner case cover. Loosen the three screw, and remove the air cleaner element. 3-5 Maintenance Make sure if there is no deterioration and damage in the air cleaner element. Replace damaged parts. NOTE Element Element Element The element is a viscous type which contains oil. Therefore do not use compressed air to clean the air cleaner element. Assemble the Air cleaner element in the reverse order of removal Spark Plug Remove the spark plug cap and spark plug. Check any dirt, damage from around the spark plug bases. If necessary, clean away the dirt from around the spark plugs with a plug cleaner or a wire brush. Measure the new spark plug using a wire-type feeler gauge. Adjust the gap by bending the side electrode carefully. Pure Plug : CR9EH-9 Spark Plug Gap : 0.8~0.9mm NOTE Check the Plug for Clearance, Contamination Deposit 0.8~0.9mm Check the Washer For damage Check the Plug for Cracks Install the plug by turning with finger. Tighten it with plug wrench. Torque: 1.1kgf.m(11N.m) Install the spark plug caps Valve Clearnance NOTE A.C Generator Cap A.C Generator Cap A.C Generator Cap Perform valve inspection/adjustment with the engine at normal operating temperature (Below 35 / 95 ) Remove the cylinder head cover. Align the "T" mark on the flywheel with the index mark on the left crank case cover, turning the flywheel to the left. At this time, the piston should be placed on the groove of the compression stroke. 3-6 Maintenance Measure the valve clearance with filler gauge. Valve Clearance: Intake: 0.12 0.02mm(0.05 0.001in) Exhaust: 0.12 0.02mm(0.05 0.001in) Loosen the lock nut with a valve wrench, and adjust the adjuster screw to the standard clearance using a valve adjusting wrench. When the standard clearance is done, hold the adjuster screw with a valve adjusting wrench. And then tighten the lock nut. Torque : 1.1kgf-m(11N.m) Tools : Wrench 8 9mm Adjusting wrench Measure the valve clearance again. After connecting the cylinder head cover, tighten the bolt. Torque : 1.0kgf-m(10N.m) Install the timing hole cap and crank case hole cap. Timing Hole Cap : 0.6kgf-m(6N.m) Crank Case Hole Cap : 0.8kgf-m(8N.m) Filler Gauge Filler Gauge Filler Gauge Adjusting Wrench Adjusting Wrench Adjusting Wrench Cylinder Compression Pressure Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and spark plug. Install the compression gauge. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. Tool: Compression gauge NOTE Cylinder Head Cover Bolt Cylinder Head Cover Bolt Cylinder Head Cover Bolt The maximum reading is usually reached within 4~7 seconds. Compression Pressure : 14.0 f/ (550rpm) If compression is low, check the following: Incorrect valve clearance adjustment Valve for leakage Exposed cylinder head from the gasket Worn piston/cylinder If compression is high, check the following: Carbon deposits on the piston head, cylinder head Compression Gauge Compression Gauge Compression Gauge 3-7 Maintenance Drive Chain NOTE Stop the engine to inspect the drive chain, otherwise fingers can be caught in the drive chain while the drive chain is operating. Chain Free Play Adjustment Stop the engine and shaft the gear into neutral, support the motorcycle on a level surfase. Remove the chain tensioner. Move the position of chain tensioner roller up and down with hands to check if the chain free play is within recommended range. Free Play: 50~60mm If necessary, adjust the drive chain free play. Adjust by loosening the axle nut and lock nuts in the right/left chain adjusters and turning the adjusting nut. NOTE 50~60mm Adjust the chain adjuster reading scale into the same place in the right and left sides. Tighten the axle nut Torque: 88kgf-m(88N.m) Retainer Clip Retainer Clip Retainer Clip Removal/Inspection Inspect the drive chain for contamination. 3-8 Maintenance Inspect the drive chain for adherence and damaging. Remove the contamination with a cleaner. After drying completely, coat the chain with #80-90 gear oil. Wipe any excessive oil off the chain, check the drive chain for wear and damage, replace it if necessary. Check the drive sproket for wear and damage. Replace it if necessary. NOTE Dry Gear Oil(#80-90) New motocycle adapts endless-type drive chain (end-type for after-sales service purpose) After once disassembling chain, chain clip can be accidentally removed, so even change new one after disassembling chain once. If the chain or sprocket requires replacement, the chain and sproket must be replaced as a set. Inspect the rollar for wear and damage, and remove the chain tensioner Service limit: 30.5mm RR. Brake Pedal Return Spring Chain Tensioner Rollar RR. Brake Pedal Return Spring Chain Tensioner Rollar RR. Brake Pedal Return Spring Chain Tensioner Rollar Installation After assembling the chain tensioner, keep the upper part of bracket which is holding chain tensioner-roller to the underline of rear swing arm under pipe. NOTE Flange Bolt Flange Bolt Flange Bolt Chain Tensioner Braket Chain Tensioner Braket Chain Tensioner Braket Install the drive chain with the closed area of the clip facing to the proceeding direction. While driving, master link will be removed suddenly when facing to the opposite direction. Check for the master link-to-retainer clip clearance. Chain tensioner 3-9 Maintenance Battery Remove the right side cover. ! CAUTION The battery contains sulfuric acid(electrolyte). Contact with skin or eyes may cause severe burns. If electrolyte gets on your eyes, flush with water for at least 15 minutes and call a physician. Brake Fluid Check the fluid level of the front brake reservoir. If the level nears the lower level, remove the cover set plate and diaphram. Fill the reservoir to the upper level with DOT 3 or DOT 4 fluid from a sealed container. Check the system for leaks. ! Master Cylinder Master Cylinder Master Cylinder CAUTION Do not allow dust or water to enter the system when filling the reservoir. Do not remove the reservoir cover until the reservoir is level. Avoid spilling the fluid on painted, plastic, or rubber parts. Brake Pad/Shoe Brake Pad Replacement Check the brake pads for wear. Replace the brake. If the red marks in the pads reach to the brake.( 15-4) ! Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt "UP" Mark "UP" Mark "UP" Mark Pad Mark Pad Mark Pad Mark CAUTION Always replace the brake pads as a set to assure even disc pressure. 3-10 Maintenance Brake Shoe Replacement Replace the brake shoes if the arrow on the brake arm aligns with the reference mark on full application of the rear brake pedal. Mark Mark Mark Arrow Arrow Arrow Brake System Inspect the front brake hoses for deterioration, cracks. If there are signs of leakage, replace them as soon as possible. Replace hoses as required. Inspect the rear brake pedal and brake rod for looseness or damage. Tighten any loose fittings. Replace them if necessary. Brake Caliper Brake Caliper Brake Caliper Brake Hose Brake Hose Brake Hose Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Pedal Height Perform brake pedal clearance adjustment after adjusting brake pedal height. Free play: 20~30mm(0.787~1.181in) If adjustment is necessary, use the rear brake adjusting nut. after adjusting the brake pedal free play, check the rear brake light switch operation and adjust it if necessary. Adjusting Nut Adjusting Nut Adjusting Nut 3-11 Maintenance Height Adjustment Adjust the brake pedal height to 10-20mm. ! CAUTION The adjustment faulty of height may caused that the brake runs in state of operation. Loosen the lock nut, and then adjust the height by turning the brake pedal stoper bolt. After adjusting, tighten the lock nut securely. Stoper Bolt Stoper Bolt Stoper Bolt After adjusting the brake pedal height, inspect the operation of rear brake light switch and brake pedal, and adjust them if necessary. Stop Switch Stop Switch Stop Switch Brake Stop Switch Adjust the brake light switch so that the brake light may come on, when the brake pedal is depressed, and brake engagement begin. Hold the switch body and turn the adjusting nut. Adjust Nut Adjust Nut Adjust Nut Headlight Adjustment Adjust the headlight beam by turning the case adjustment screw. NOTE Adjust the headlight beam as specified by local laws and regulations. ! CAUTION An improperly adjusted headlight may blind on coming drivers, or it may fail to light a road for a safe distance. Bolt Bolt Bolt Clutch Measure the clutch system free play at the end of clutch lever. Free Play: 10~20mm(0.393~0787 in) 3-12 Maintenance Perform the light adjustment by loosening the lock nut from the handle and turning the adjuster. Adjuster Adjuster Adjuster Lock Nut Lock Nut Lock Nut Perform the main adjustment by loosening the lock nut from the engine and turning the adjusting nut. Tighten the lock nut. Inspect the clutch operation. Lock Nut Lock Nut Lock Nut Adjust Nut Adjust Nut Adjust Nut Side Stand Set up the main stand. Check of smooth operation, when pulling the low end part of the side stand. If the side stand is hard, coat the pivot with grease. If the side stand moves too freely, inspect the side stand spring. Make sure that the side stand is not bent. Suspension ! CAUTION Do not ride a vehicle with a faulty suspension. Loose, worn or damaged suspension parts impair vehicle stability and control. Front Check the action of the fork by compressing the front suspension several times. Check the entire fork assembly for leaks, damage, or looseness. 3-13 Maintenance Rear Check the action of the rear cushion by compressing them several times. Check the rear cushion for leaks, damage, or looseness. Support the motorcycle with a main stand. Check for worn rear fork bush by attempting to move the wheel side to side. Replace the bearings if any looseness is noted. Tighten all nuts and bolts of the rear suspension. Bolts, Nuts Fasteners Check that all nuts and bolts are tightened to correct torque values. Check that all cotter pins, safety clips, hose clamps and cable stays are in place. ( 3-3) Wheels/Tires NOTE Tire pressure should be checked when the tires are cold. Check the tires for cuts, embedded nails, or other damage. Replace them if necessary. Recommended Tire Pressure: Front 1 Person 2.00(200) 2 Person 2.00(200) kgf/cm2(kPa) Rear 2.00(200) 2.00(200) 3-14 Maintenance Measure the tread depth at the center of the tire. Replace the tire when the tread depth reaches the following limits: Minimum Tread Depth: 4mm (0.16 in) 8.5mm (0.3 in) Steering Head Bearings NOTE Check that the control cables do not interfere with handle bar rotation. Raise the front wheel off the ground. Check that the handle bar moves freely from side to side. If the handle bar moves unevenly, bends, or has vertical movement, inspect the cables and electric code wires. If the handle bar moves too freely, adjust the steering head bearings. 3-15 Fuel System 4-0 Fuel System 4. FUEL SYSTEM Service Information Troubleshooting 4-1 4-2 Fuel Tank Air Cleaner Case 4-3 4-4 Service Information General ! WARNING Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refuelled. If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area. ! CAUTION Bending or twisting the control cables will impair smooth operation and may cause the cables stick or blind to result in loss of vehicle control. When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on assembly. The float bowls have drain screws that can be loosened to drain residual gasoline. Specifications Fuel Tank Capacity NOTE 16.8 Reserve Fuel Capacity 4.3 If the vehicle is to be stored for more than one month, drain the float chambers. Fuel left in the float chambers may cause clogged jet to result in hard starting or poor drive ability 4-1 Fuel System Torque Air cleaner case cover screw 0.43kg-m (4.3N.m, 3.1ft-lb) Tools Float level gauge Troubleshooting Engine cranks but won t start No fuel in tank Engine flooded with fuel Clogged air cleaner No spark at plug(Ignition system faulty) Rough idle, hard starting or stalling starting Incorrect idle ring adjustment Lean mixture, rich mixture Clogged air cleaner Faulty air cut off valve Clogged fuel system Lean mixture Clogged injector Clogged fuel tank breather Clogged fuel strainer screen Restricted fuel tube Fuel filter 4-2 Fuel System Fuel Tank Removal ! WARNING Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled. Loosen the speedometer cable screw. Remove the L. front side cover. Remove the seat.( 12-2) Turn the fuel cock OFF and remove the fuel Remove a fuel tank mounting bolt. Remove fuel unit wire coupler. Remove the fuel tank. Fuel Tank Fuel Tank Fuel Tank Bolt Bolt Bolt