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 insula ...