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DAELIM S-FIVE - Service Manual

Other manuals for S-FIVE -: Specification, Manual

Summary of S-FIVE -

  • Page 2: Contents

    How to use this manual this manual describes effective maintenance procedure for the s-five manufactured by daelim motor co., ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (section 2). Sections 1 through 2 p...

  • Page 3: 1. Service Information

    1-1 1. Service information general safety 1-1 service rules 1-1 caution when wiring 1-5 serial number location 1-9 maintenance information 1-10 twist torque 1-14 specialized tools 1-16 lubrication oil 1-17 symbols 1-18 wiring diagram 1-19 general safety warning 1. Do not run the engine for a long ti...

  • Page 4

    1-2 service information 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. 7. A...

  • Page 5

    1-3 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 ...

  • Page 6

    1-4 service information 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...

  • Page 7: Caution When Wiring

    1-5 service information •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 . •...

  • Page 8

    1-6 service information •insert the lock of the coupler until the lock is fully secured. •turn off the main switch before connecting/dis- connecting. •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...

  • Page 9

    1-7 service information •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. •insert the connector until the vinyl cover is fully inserted into the terminal. •...

  • Page 10

    1-8 service information •if necessary, lock the wire harness properly. •when mounting parts, make sure that the wire harness is not pressed by the parts. •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 ...

  • Page 11: Serial Number Location

    1-9 service information serial number location engine serial number location frame serial number location.

  • Page 12: Maintenance Information

    1-10 service information maintenance information specifications maintenance specifications type of vehicle overall length overall width overall height wheel base motor type displacement fuel type front axle rear axle total passengers front axle rear axle total ground clearance caster trail s-five 1,...

  • Page 13

    1-11 service information item standard fuel system fuel tank capacity full capacity air cleaner type carburetor setting mark venturi diameter air screw opening float level idling rpms no. Of jet needles main jet slow jet throttle grip clearance cylinder head, cylinder, piston port open/close periods...

  • Page 14

    1-12 service information item standard clutch clutch automatic type clutch outer diameter clutch lining thickness drive belt width movable drive face bush inside diameter boss outside diameter weight roller outside diameter driven pulley face spring free length face outside diameter movable face ins...

  • Page 15

    1-13 service information item standard b8hsa 0.6~0.7mm btdc 17。 ±2。 /1,800rpm over 120v over 120v over 1.5v 0.1-0.5Ω 6.5-9.5 ㏀ ㏀ 2.6±1.25㏀ ㏀ 500Ω±20% 100Ω±20% ac 12v-9.5a/5,000rpm 0.8Ω±20% 0.55Ω±20% semi-conductor 12.6-13.6v/5,000rpm 14.0-15.0v/5,000rpm 6.3-7.1Ω 5.5-6.5Ω 12v-35/35w 12v-5/21w 12v-16w...

  • Page 16: Twist Torque

    1-14 service information twist torque standard twist torque engine parts type 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut twist torque 0.5㎏f·m 1.0㎏f·m 2.2㎏f·m 3.5㎏f·m 5.5㎏f·m type 5mm screw 6mm screw 6mm screw flange bolt, nut 8mm screw flange bolt, nut 10mm screw flange ...

  • Page 17

    1-15 service information frame parts twist part steering stem lock nut handle post twist nut front brake lever pivot bolt front brake lever pivot nut rear brake lever pivot screw rear brake lever pivot nut master cylinder holder bolt master cylinder cover screw brake hose bolt caliper mount bolt cal...

  • Page 18: Specialized Tools

    1-16 service information specialized tools tool name float level gauge bearing dirver bearing remover remover handle remover weight driver handle a outer driver 24×26mm clutch spring compressor socket wrench 39mm clutch center holder universal holder crank assembly driver handle a outer driver 37×40...

  • Page 19: Lubrication Oil

    1-17 service information lubrication oil engine parts application areas crank case joining face crank case revolution part cylinder big revolution part, friction part transmission(final reduction) kick spindle bush starter pinion starter drive gear operation part moveable driven face (driven face op...

  • Page 20: Symbols

    Symbol caution note symbol 1-18 service information symbols the following symbols appear in this manual and offer cautionary suggestions which need to be heeded when performing maintenance work on the vehicle. Caution indicates special caution needed. Possibility of resulting in serious malfuctionin...

  • Page 21: Wiring Diagram

    1-19 service information wiring diagram tubeless tire appl. Korea fuel unit connecting coupler r/l tail stop rr. Winker auto by starter 5w 6.7Ω oil tank fuel tank wire harness a.C.Generator this section should not be projected than the front of the frame and not have any looseness. Battery ass'y rol...

  • Page 22

    1-20 service information frame earth terminal headlight connecting coupler tie-down coupler tie-down coupler light comp. Connecting connector resister connecting connector auto by starter s/w cord 5w 6.7Ω regulate rectifier combi lock s/w wire harness speedometer cord oil pump cable throttle cable a...

  • Page 23

    1-21 service information rr. Brake cable throttle cable seat lock cable high tension cord starter motor oil pump cable throttle cable oil pass tube oil tube auto by starter cord fuel tube negative pressure tube fuel auto cock ass'y fuel strainer fuel tank fuel vent tube seat lock cable lh. Rr. Winke...

  • Page 24: Memo

    Memo.

  • Page 25: 2. Inspections/adjustments

    2-1 2. Inspections/adjustments 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. Specifications torque values spark plug 1.4㎏f·m cylinder head cover bolts 1.0㎏f·m 2 service informatio...

  • Page 26: Regular Inspection Schedule

    2-2 inspections/adjustments regular inspection schedule carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s manual. I : inspect and clean, adjust, lubricate or replace if necessary. R : replace l : lubricate c : clean ＊ if there are no...

  • Page 27: Fuel Line(Fuel Tube)

    Fuel line(fuel tube) ● remove the luggage box .( 3-3) ● check the fuel tube of the fuel auto cock connected to the fuel tank and carburetor. If the fuel tube is cranked, damaged or leaks, replace it. Fuel line for clogging note •refer to section 2 for fuel filter inspection. ● check the fuel tank ca...

  • Page 28: Air Cleaner

    ● 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 ● loosen the 5 setting screw assembled to the air cleaner case cover, and then remove the air cleaner case cover. ● remove the...

  • Page 29: Spark Plug

    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 plugs are severely contaminated or damaged, raplace with new ones. If the plugs can be reused after removing only the carbon, u...

  • Page 30: Carburetor Idling

    Brake hose bolt master cylinder carburetor idling ● stand the vehicle on the main stand. ● heat the engine to make accurate idling inspection and adjustment. ● verify all engine adjustments satisfy specifications. Make adjustments, if necessary. ● turn the throttle stop screw and make adjustments to...

  • Page 31: Brake Pad/shoe

    Brake pad/shoe brake pad replacement ● check the brake pads for wear. ● if the red mark on the pad reaches the brake disc, replace the pads. Note •replace the brake pads in sets. Brake shoe replacement ● if the arrow mark of the wear limit aligns with the ‘△’ mark when the rear brake lever is fully ...

  • Page 32: Headlight Adjustment

    Rear brake free play adjustment ● turn the adjuster nut to adjust the free play. ● after initial adjustment, check the operation of the rear brake light switch. Make additional adjustments, if necessary. Headlight adjustment ● adjust the headlight beam level by operating the adjusting screw located ...

  • Page 33: Suspension

    Suspension note •do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle’s safety and operation efficiency. Front wheel ● hold the brake lever, and compress the front cushion up and down several times to check the operating ...

  • Page 34: Steering Head Bearing

    ● check the tread depth at the tire center. ● if the tread depth has reached the service limit, replace the tire. Service limit : 4.0mm 7.5mm steering head bearing note •check the cable if it interferes with the handle operation. ● lift the front wheel and check if the handle moves right and left sm...

  • Page 35: 3. External Parts

    3-1 3. External parts service information note ● this section describes external parts removal/installation. ● do not apply unreasonable force when disassembling covers, to prevent possible damage. ● a muffler is hot. Do not service it immediately after the engine is stopped. 3 service information 3...

  • Page 36: Maintenance Procedure

    3-2 external parts 10 11 15 12 5 6 9 7 13 8 1 4 3 2 14 maintenance procedure names of frame covers ● this chart shows arrows connected in the order of disassembling covers. ① luggage box ② plug maintenance cover ③ center cover ④ rear carrier ⑤ body cover ⑥ taillight base ⑦ floor side cover ⑧ floor p...

  • Page 37: Luggage Box

    3-3 external parts washer bolt flange bolt special screw special screw tapping screw special bolt body cover clip special screw luggage box ● release the seat lock using the main key to open the seat. ● loosen 4 washer bolts and 2 flange bolts. ● remove the oil tank cap and the fuel tank cap. Note •...

  • Page 38: Taillight Base

    Body cover clip taillight wiring washer bolt washer screw floor panel cap washer bolt 3-4 external parts taillight base ● remove the luggage box. ( 3-3) ● remove the center cover. ( 3-3) ● remove the rear carrier. ( 3-3) ● remove the body cover. ( 3-3) ● loosen 2 washer bolt securing the frame. ● lo...

  • Page 39: Engine Hanger Side Cover

    3-5 external parts washer screw setting screw special bolt special screw special screw setting screw tapping screw engine hanger side cover ● loosen the 2 washer screw securing the engine hanger side cover. ● install in the reverse order of removal. Front cover ● loosen the upper cover set screws (r...

  • Page 40: Front Under Cover

    Flange bolt flange bolt tapping screw tapping screw tapping screw master cylinder tapping screw tapping screw tapping screw speedometer cable 3-6 external parts front under cover ● remove the front cover. ( 3-5) ● remove the inner box. ( 3-5) ● remove the front fender. ( 3-5) ● remove the front whee...

  • Page 41: Muffler

    3-7 external parts flange bolt flange bolt flange nut flange nut washer bolt washer bolt muffler ● loosen the 3 flange nuts securing the ex pipe comp. ● loosen the 2 flange bolts securing the r. Crankcase. ● loosen the 2 flange bolts securing the rear wheel mud guard. ● remove the ex muffler comp. W...

  • Page 42: Rear Wheel Med Guard

    Rear wheel med guard ● loosen the 2 flange bolts securing the ex muffler. ● loosen the flange bolt securing the air cleaner. ● loosen the flange bolt securing the inlet pipe. ● remove the rear wheel mud guard. ● install in the reverse order of removal. Note •never perform the maintenance of the muff...

  • Page 43: 4. Lubrication System

    4-1 4. Lubrication system service information caution ·remove air from oil tube and oil pump if the oil tube is taken off or if air enters the oil tube. ● if the oil tube is disassembled, remove the air in the oil pass tube. ● maintenanace on the oil pump is done without the engine being removed fro...

  • Page 44: Oil System Drawing

    4-2 lubrication system oil system drawing oil tank oil tube carburetor oil pass tube oil pump oil pump control cable oil pump anchor plate.

  • Page 45

    Oil pump disassembly/assembly ● remove the luggage box. ( 3-3) ● remove the rear wheel mud guard. ( 3-8 ) ● remove the air cleaner. ( 5-4 ) ● remove the carburetor. ( 5-4 ) ● loosen the oil pump cable stay bolt to remove the oil pump anchor plate. ● disconnect the oil control cable from the oil pump...

  • Page 46: Oil Pump Bleeding

    Adjustment caution •perform after inspection and adjustment of throttle cable. ● check to see if the matching mark of the oil pump body and control lever are aligned in a state where the throttle grip is completely rotated. ● adjustment is performed by loosening the oil pump control cable lock nut a...

  • Page 47

    Oil pump/oil tube ● fill the oil tank with engine oil. ● cap around the oil pump and the carburetor with dry cloth. ● locate the end of the oil tube in the level lower than the oil tank and drain the oil to bleed the air. ● install the oil tube in the oil pump. ●incline the oil pump to locate the oi...

  • Page 48: Engine Oil Level Inspection

    ● connect the oil pump and then the carburetor quickly with the both ends of the tube pressed to avoid the air from entering. Note •make sure that the tubes are arranged correctly. ● start the engine. Note •do not start the engine in the poorly-ventilated area. ● open the oil pump control level full...

  • Page 49: Transmission Oil Inspection

    ● remove the oil tank cap and fill the oil tank with oil to the level of the projected portion recommended oil : ultra 2 super oil ● reinstall the oil tank cap and check to see if the pilot lamp turns off when the main swich is turned on. Transmission oil inspection ● check the body and the connecti...

  • Page 50: Oil Tank Disassembly

    Oil tank disassembly ● remove the luggage box. ● remove the oil level switch connector. ● remove the tube in the oil pump. ● install the tube clip or the valve in the oil tube to avoid the oil from leaking. ● remove the flange bolt securing the oil tank and press the left and lower rear fender to re...

  • Page 51: Lubrication Points

    Lubrication points lubricatiaon system throttle grip steering bearing wheel bearing speedometer gear box side stand pivot wheel bearing throttle speedometer brake hose grease grease grease grease grease grease oil 4-9.

  • Page 52

    Fuel system 5-0 carburetor fuel strainer fuel tube auto cock fuel tank.

  • Page 53: Service Information

    Service information general safety warning ● gasoline is extremely flammable. Avoid fire in the work place, also paying particular attention to sparks. Furthermore, the evaporated (gasified) gasoline is highly explosive. Work in a well-ventilated areas. ● exhaust gas contains poisonous substance. Do...

  • Page 54: Troubleshooting

    5-2 fuel system troubleshooting the vehicle does not start. ● no gasoline in fuel tank. ● fuel is not coming out of carburetor. ● too much fuel is flowing into cylinder. ● no spark emitted from spark plug. ● air cleaner is blocked. ● suction system is experiencing secondary intake of air. ● using lo...

  • Page 55: Fuel Tank

    5-3 fuel system fuel tube b auto cock fuel strainer fuel tube a fuel unit seat catch flange bolt flange bolt fuel tank support stay fuel tank removal warning •gasoline is extremely flammable. Avoid fire during work, and pay particular attention to electric sparks. Furthemore, the evaporated (gasifie...

  • Page 56: Air Cleaner Removal

    5-4 fuel system flange bolt washer bolt washer screw air cleaner element connecting bend carburetor carburetor insulator carburetor insulator flange bolt air cleaner removal ● loosen the air cleaner connecting bend screw pin. ● loosen the 2 bottom air cleaner washer bolts. ● loosen the top rear fend...

  • Page 57

    5-5 fuel system washer screw auto by starter set plate air screw throttle stop screw gasket o-ring float pin float float valve float chamber auto by starter cover auto by starter float level gauge main jet throttle stop screw air screw washer o-ring slow jet float valve float carburetor disassembly/...

  • Page 58: Carburetor Inspection

    5-6 fuel system air gun carburetor cleaning ● after removing all parts, blow open air and fuel passages in the carburetor body with compressed air. Caution •cleaning the air and fuel passages with a piece of wire will damage the carburetor body or fuel pump. ● assemble in the reverse order of disass...

  • Page 59: Throttle Valve

    5-7 fuel system ● connect the battery to the auto bystarter terminals and wait for 5 minutes. ● insert a vinyl tube into the fuel enrichening circuit and blow into the tube. ● air should not flow into the circuit. If air flows into the circuit, replace the auto bystarter. ● check the resister if the...

  • Page 60: Fuel Auto Cock

    5-8 fuel system pressure tube fuel auto cock fuel tube fuel auto cock removal/installation ● remove the luggage box. ( ⇨ 3-3) ● remove the plug maintenance cover. ( ⇨ 3-3) ● remove the center cover. ( ⇨ 3-3) ● remove the rear carrier. ( ⇨ 3-3) ● remove the body cover. ( ⇨ 3-3) ● remove the fuel tube...

  • Page 61: Inlet Pipe

    5-9 fuel system rear wheel mud guard flange bolt flange bolt reed valve seat reed stopper reed valve inlet pipe • reed valve removal/installation ● remove the luggage box. ( ⇨ 3-3) ● remove the air cleaner. ( ⇨ 5-4) ● remove the carburetor. ( ⇨ 5-4) ● remove the negative pressure tube connected to t...

  • Page 62

    Engine removal/installation 6-0

  • Page 63: Service Information

    6-1 6. Engine removal/installation service information general safety note •use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •attach tape to the frame to protect it during the engine removal o...

  • Page 64: Engine Removal/installation

    6-2 engine removal/installation cap top negative pressure tube oil tube adjuster nut rear cushion body cover clip engine hanger u nut engine removal/installation ● remove the luggage box. ( ⇨ 3-3 ) ● remove the plug maintenance cover. ( ⇨ 3-3 ) ● remove the center cover. ( ⇨ 3-3 ) ● disconnect the a...

  • Page 65: Engine Hanger Link Removal

    6-3 engine removal/installation u nut engine hanger link ● check the following after the engine is assembled. -electric systems. -adjust of the rear brake free play. -inspection of the throttle cable operation. -inspection of the oil pump cable operation. Engine hanger link removal ● remove the lugg...

  • Page 66

    7-0 kick starter/continuously variable transmission movable driven face guide pin driven face ramp plate weight roller movable drive face drive face boss drive face kick starter spindle kick driven gear kick starter return spring kick spindle bush drive belt movable driven face spring shoe spring cl...

  • Page 67: 7. Kick Starter/continuously

    7-1 7. Kick starter/continuously variable transmission service information general safety ● do not allow oil to contact the drive belt or the pulley face. The transmission rate of driving force is reduced with oil contact. ● do not operate starter motor while the l. Crank case front cover is removed...

  • Page 68: L. Side Cover Removal

    L. Side cover removal ● remove the 13 flange bolts securing l. Side cover. ● remove the rear brake cable clamp. ● remove the l. Side cover gasket. ● remove the dowel pin. ● install in the reverse order of removal. Note ·install the new gasket and dowel pin after removing the gasket of the crankcase ...

  • Page 69

    Kick starter installation ● install the kick spindle bush, spring in the l. Side cover. ● install the kick starter spindle in the l. Side cover. ● install the kick starter spindle washer. ● install the 14mm external circlip in the l. Side cover. ● install the kick starter arm. ● install the kick spi...

  • Page 70: Drive Belt

    Drive belt removal ● remove the l. Side cover. ( 7-2 ) ● hold the clutch outer using the universal holder and remove the nut. ● remove the clutch outer. Tool: universal holder caution ·use the special tool when loosening the lock nut. Holding the rear wheel or rear brake will damage the final reduct...

  • Page 71

    Drive belt inspection ● check the drive belt for cracks, pry separation and wear; replace as necessary. ● measure the width of the drive belt as shown. ● replace the belt if the service limit is exceeded. Service limit : 16.5mm note ·use only a genuine daelim replacement drive belt. ·do not get oil ...

  • Page 72: Drive Pulley

    Drive pulley removal ● remove the l. Side cover. ( )xh @)x?G @v/xg @?V/x?F @@@@@@@@@@@??V/xf @?Hfv/x?E @?Hf?V/xe @? N1e @? J5e @?Hf?W.Ye @@@@@@@@@@@?Ew.Y?E @??W.Yf @?W.Y?F @w.Yg @(y?G (yh 7-2 ) ● hold the drive face using the clutch center holder and remove the nut and washer. Tool : clutch center h...

  • Page 73

    Movable drive face inspection ● the weight rollers push on the movable drive pulley face (by centrifugal force); worn or damaged weight rollers will interfere with this force. ● check the rollers for wear or damage and replace as necessary. ● measure the o.D. Of each roller, replace if the service l...

  • Page 74: Clutch/driven Pulley

    Drive face installation ● squeeze the drive belt into the pulley groove and pull the drive belt over the drive face shaft. ● hold the drive pulley face using the clutch center holder and tighten the nut to the specified torque. Torque value : 5.5kgf · m tool : clutch center holder ● install the driv...

  • Page 75

    28mm special nut disassembly ● the clutch/driven face are assembled toward the clutch spring compressor. Caution ·make sure that the boss portions of the clutch/driven face are matched with the clutch spring compressor hole. Tool : clutch spring compressor ● fix the clutch spring compressor with a v...

  • Page 76

    Clutch shoe inspection ● measure the thickness of each shoe ; replace if the service limit is exceeded. Service limit : 2.0mm movable driven face spring inspection ● measure the free length of the driven pulley spring and replace if the service limit is exceeded. Service limit : 92.8mm driven face i...

  • Page 77

    Clutch shoe replacement ● remove the e-clip and washers, then remove the clutch shoes and shoe springs from the drive plate. Note ·some models use one retainer plate instead of three washers. ● check the shoe springs for damage or loss of tension. ● check the damper rubbers for damage or deformation...

  • Page 78

    ● install the e-clip and washers or retainer plate into the pivot pins. Note ·apply only to the belt type gearless transmission. ·wipe the grease came out from the pivot pin thoroughly. Driven face bearing replacement ● remove the inner bearing note ·if the driven face has an oil seal at inner beari...

  • Page 79

    Clutch/driven pulley assembly ● install new oil seals and o-rings on the movable driven pulley face. ●lubricate the inside of the movable face with the specified amount of grease. Grease application : 5.0~5.5g ● install the movable face on the driven pulley face. ● install the guide pins, or guide p...

  • Page 80

    8-0 cylinder head/cylinder/piston cylinder head bolt cylinder head cylinder head gasket top ring second ring expander stopper pin piston pin needle bearing cylinder gasket piston clip cylinder.

  • Page 81: Service Information

    8-1 8. Cylinder head/cylinder/piston service information general safety ● take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling pin by striking the cylinder too hard. ● take precautions not to damage the inside of the cylinder or the ext...

  • Page 82: Fan Cover, Shroud Removal

    8-2 cylinder head/cylinder/piston engine hanger cover fan cover cover fan cover rubber fan cover comp. Shroud fan cover, shroud removal ● remove the luggage box. ( 3-3 ) ● remove the plug maintenance cover. ( 3-3 ) ● remove the center cover. ( 3-3 ) ● remove the floor side cover. ( 3-4 ) ● remove th...

  • Page 83

    8-3 cylinder head/cylinder/piston flange bolt cylinder head cylinder piston pin piston cylinder head/ cylinder/ piston removal ● remove the luggage box. ( 3-3 ) ● remove the plug maintenance cover. ( 3-3 ) ● remove the center cover. ( 3-3 ) ● remove the floor side cover. ( 3-4 ) ● remove the floor p...

  • Page 84

    8-4 cylinder head/cylinder/piston bearing piston pin clip piston piston pin cylinder head cylinder ● remove the piston. ● remove the piston ring. ● remove the expander. ● remove the needle bearing from the small end of the connecting rod. Note ·do not damage or scratch the piston. ·do not apply side...

  • Page 85

    8-5 cylinder head/cylinder/piston cylinder wear inspection ● inspect the cylinder wall for scratches and wear. Note ·inspect the area near t.D.C (top dend center) carefully. This area is especially subject to wear due to the possibility of borderline lubrication fro heat and top ring compression. ● ...

  • Page 86

    8-6 cylinder head/cylinder/piston piston pin inspection ● measure the piston pin o.D. At three points. ● replace the piston pin if the service limit is exceeded. Service limit : 11.98mm piston pin bore inspection ● measure the piston pin bore i.D. In an x and y axis. Take the maximum reading to dete...

  • Page 87

    8-7 cylinder head/cylinder/piston cylinder head ● coat the needle bearing (2-stroke engine only) and piston pin with the recommended oil. Lubricate the piston pin 2-stroke engine : recommended engine oil. Note ·place a clean shop towel over the crankcase to prevent the clip from falling into the cra...

  • Page 88

    9-0 transmission/crankshaft/crankcase.

  • Page 89: Service Information

    9-1 9. Transmission/crankshaft/crankcase service information general safety ● this section describes how to remove the crank case and to maintain the transmission and the crankshaft. ● always use special tools to change the drive shaft. Fix the bearing inner race, andn install the shaft. ● the follo...

  • Page 90: Transmission

    Transmission disassembly ● remove the l. Side cover. ( 7-2 ) ● remove the continuously variable transmission. ( section 7 ) ● remove the exhaust muffler. ( 3-7 ) ● remove the rear wheel. ( 11-3) ● install the oil sump under the cover of transmission. ● loosen the 6 transmission cover flange bolts. ●...

  • Page 91

    ● inspect the final shaft for wear or damage. ● inspect the countershaft for wear or damage. Bearing inspection ● manually turn the bearing inner race installed inside the transmission cover, and check if the race is turning smoothly. ● verify the outer race is accurately installed in the case. ● re...

  • Page 92

    Transmission assembly ● install the drive shaft on the transmission cover. ● install a new drive shaft oil seal. Tool : crank assembly ● install the thrust washer, final gear and counter gear, side washer on the l. Crankcase. ● install new dowel pins. ● install a new transmission cover seal on the t...

  • Page 93: Crankshaft Removal

    Crankshaft removal ● loosen the 6 r. Crankcase flange bolts. ● secure a crankcase puller on the r. Crankcase and remove the r. Crankcase from the l. Crankcase. Tool : crankcase puller(0751-00003) ● secure a crankcase puller on the l. Crankcase and remove the crankshaft from the l. Crankcase. Note ·b...

  • Page 94: Crankcase Bearing Removal

    ● measure the side gap between the connecting rod big end and the crank weight. Service limit : 0.6mm ● check the vertical shaft play of the connecting rod big end from the x and y direction. Service limit : 0.05mm crankcase bearing removal ● remove the transmission and crankshaft. Inspection ● manu...

  • Page 95: Crankshaft Installation

    ● apply clean engine oil to a new bearing, and assemble it to the crank case. ● install a new final gear oil seal. Crankshaft installation ● apply clean engine oil to the new r. Crankshaft bearing, and press in the bearing into the r. Crank case. Tools : driver handle a outer driver 52x55mm driver p...

  • Page 96

    ● apply a liquid gasket to the l. Crankcase joining face, install the dowel pins. ● install the r. Crankcase. ● install the 6 flange bolts. Note ·make sure that there is no adhesion of gasoline to the r., l. Crankcase liquid gasket face. ·do not apply excessive liquid gasket fluid excessively. Tool ...

  • Page 97: Memo

    Memo.

  • Page 98

    10-0 front wheel/front fork/steering.

  • Page 99: Service Information

    10-1 10. Front wheel/front fork/steering service information general safety caution ● keep oil or brake fluid off the brake disk and pad because the contaminated brake disk and pad reduces the braking performance. If contaminated, replace the pad with a new one, and clean the disk. ● use special tir...

  • Page 100: Troubleshooting

    Troubleshooting hard steering ● steering bearing adjustment nut too tight. ● faulty steering stem bearings. ● damaged steering stem bearings. ● insufficient tire pressure. Steers to one side or does not track straight ● unevenly adjusted right and left shock absorbers. ● bent front forks. ● bent fro...

  • Page 101: Steering Handle

    10-3 front wheel/front fork/steering steering handle removal ● remove the front cover. ( 3-5 ) ● remove the front handle cover. ( 3-6 ) ● remove the rear handle cover. ( 3-6 ) ● removal must be performed with the rear handle cover and the speedometer installed. ● loosen the throttle housing fixing p...

  • Page 102

    10-4 front wheel/front fork/steering ● install the rear brake cable, front brake hose, speedometer cable to the handle cable guide. ● apply daelim bond a to the inside surface of the grip and to the clean surface of the left handle bar. Wait 3~6 minutes and install the grip. (bond a :royal bond 1300...

  • Page 103: Front Wheel

    10-5 front wheel/front fork/steering front wheel removal ● remove screws from the speedometer gear box, and separate the speedometer cable. Note ·loosen axle nuts. Support bottom of engine with a jack until the front wheel is lifted. ● loosen the axle nut. ● remove the front axle. ● remove the front...

  • Page 104

    10-6 front wheel/front fork/steering bearing inspection ● manually turn the bearing inner race, and replace if it makes noise or is worn. Check if the bearing outer race is accurately fitted into the wheel hub, and replace worn ones. Note ·replace bearings in pairs (left and right set). Front wheel ...

  • Page 105

    10-7 front wheel/front fork/steering wheel bearing replacement ● install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance collar. Note ·always replace bearings in pairs, and never use old bearings. Tools : bearing remover head bearing remover ● apply s...

  • Page 106

    10-8 front wheel/front fork/steering front wheel assembly ● apply grease to the right side dust seal rim. ● install the right side dust seal. ● install the brake disk. ● install disk bolts. Torue value : 3.9kgf · m ● install the front brake collar a. ● align the wheel hub tangs with the slots of the...

  • Page 107: Tubeless Tire

    10-9 front wheel/front fork/steering ● apply grease to the dust seal rim. ● install the dust seal, and align the tangs of the speedometer gear retainer with the gear groove to assemble the speedometer gear box. Tubeless tire removal ● remove the wheel. Note ·single brake disk type : to prevent damag...

  • Page 108

    10-10 front wheel/front fork/steering ● be sure that the bead is completely collapsed. ● in case of the tube type tire, insert the tire lever from the opposite side of the valve and raise the bead over the rim. ● on tubeless tires, insert the tire lever from the valve side and raise the bead over th...

  • Page 109

    10-11 front wheel/front fork/steering rim valve replacement ● cut off the rim valve at its base. ● apply mild detergent solution to a replacement rim valve and insert it from inside of the rim. Note ·be sure to use the recommended rim valve. ·do not damage the valve hole. ·replace the rim valve when...

  • Page 110

    10-12 front wheel/front fork/steering ● if the tire has an light mark (yellow paint mark), install the tire with this mark aligned with the valve. ● if the tire has an arrow mark, install the tire with the mark pointing in the direction of rotation. ● stand the tire upright, hold it with one hand an...

  • Page 111

    10-13 front wheel/front fork/steering ● after 3/4 of the bead has been installed, check the bead on the opposite side. Be sure it is still in the center of the rim. Note ·the last portion of the bead is more difficult to install. The rim and bead may be damaged if the bead on the opposite side of th...

  • Page 112: Front Fork

    10-14 front wheel/front fork/steering note ·for tubeless tires, you may hear a loud sound as the bead seats onto the rim. This is normal. ·for tubeless tires, if air leaks out from between the rim and bead, let the wheel stand with the valve at the bottom and put air in while pushing down on the tir...

  • Page 113

    10-15 front wheel/front fork/steering ● loosen the 2 steering stem front fork r., l. Stay bolts. ● remove the front fork. Front fork disassembly ● remove the fork tube cap bolt. Note ·if the screw is completely loosened, the fork tube cap bolt may spring out by the force fo the spring. Take due prec...

  • Page 114

    10-16 front wheel/front fork/steering note ·if the socket bolt turns idle but cannot be removed, temporarily assemble the spring and the fork tube cap bolt first. ·hold the bottom case firmly with a vise, taking precautions not to distort or damage it. ● remove the dust seal. ● remove the oil seal s...

  • Page 115

    10-17 front wheel/front fork/steering ● remove the fork tube from the bottom case. ● remove the piston and rebound spring from the fork tube. Front fork inspection ● place the fork spring on a level place, and measure the free length. ● if the free length deviates from the service limit, replace the...

  • Page 116

    10-18 front wheel/front fork/steering ● wrap the bottom case with a piece of cloth, and fix it to the vise. ● apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. Torque value : 2.0kgf · m note ·when a vise is used to hold the bottom case, do not inse...

  • Page 117

    10-19 front wheel/front fork/steering ● assemble the spring to the fork pipe. Note ·install the spring with the smaller pitch side facing downward. ● assemble the fork bolt to the fork tube. Front fork installation ● install the front fork to the steering stem. ● install the front fork setting bolt....

  • Page 118: Steering Stem

    10-20 front wheel/front fork/steering steering stem removal ● front cover ( 3-5 ) ● front fender ( 3-5 ) ● front handle cover/rear handle cover ( 3-6 ) ● steering handle ( 10-3 ) ● front wheel ( 10-5 ) ● front brake caliper ( 12-7 ) ● front fork ( 10-14 ) ● loosen the steering stem lock nut. ● remov...

  • Page 119

    10-21 front wheel/front fork/steering ● remove the upper ball race/ steering bottom cone race. Tool : ball race driver note ·check all of the races and balls for damage or abnormal wear and replace as necessary. ·if the vehicle has been involved in a collision, the steering stem may be damaged. Stee...

  • Page 120

    10-22 front wheel/front fork/steering ● install the top cone race and the steering head top thread nut on the steering head. ● tighten the top thread nut completely, and loosen by 1/8 turn. Torque value : 1.0 ㎏ f · m ● check the top and bottom free play, and check for smooth left and right movement....

  • Page 121: Service Information

    11-1 11. Rear wheel/brake/suspension service information general safety ● if the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe. ● inhaled asbestos fibers have been found to cause respiratory disea...

  • Page 122: Troubleshooting

    Troubleshooting wobble or vibration in motorcycle ● tire pressure incorrect ● faulty tire ● bent rim ● loose wheel bearing ● swing arm bushing worn ● wheel out of balance soft suspension ● weak springs ● rear damper improperly adjusted, oil leakage hard suspension ● rear damper improperly adjusted ●...

  • Page 123: Rear Wheel

    Rear wheel removal ● support the motor cycle on the main stand. ● loosen the rear brake adjuster, and remove the brake cable. ● remove the brake arm joint b. ● remove the muffler. ( 3-7 ) ● remove the rear wheel mud guard. ● loosen the rear wheel u nut. ● remove the washer. ● remove the rear wheel. ...

  • Page 124: Rear Brake

    ● insert the washer, and tighten with the u nut. Torque value : 6.0~8.0kgf · m ● install the brake arm joint b. ● install the rear brake cable. ● install the rear brake rod adjusting nut. ● install the rear wheel mud guard. ● install the muffler. Rear brake ● remove the rear wheel. ( 11-3 ) inspecti...

  • Page 125: Rear Wheel/brake/suspension

    Rear brake disassembly ● manually open the brake shoe and remove it. ● remove the shoe spring from the brake shoe. ● loosen the rear brake arm fixing bolt. ● remove the rear brake arm, rear brake indicator, brake cam, dust seal. ● remove the rear brake cam. Rear brake assembly/installation ● apply s...

  • Page 126: Rear Cushion

    Rear cushion removal ● remove the plug maintenance cover/ center cover. ( 3-3 ) ● remove the luggage box. ( 3-3 ) ● remove the body cover. ( 3-3 ) ● loosen the top and bottom rear cushion setting bolts. Note ·support the frame firmly prior to working. Disassembly ● install the compressor attachment ...

  • Page 127: Rear Wheel/brake/suspension

    Rear cushion assembly/installation ● assemble the spring, spring guide, and stopper rubber. Note ·install the spring with its narrow pitch side facing upward ● apply thread locking agent to the lock nut, and install the rear cushion compressor attachment on the damper rod. ● fix the upper joint, and...

  • Page 128

    Brake system 12-0

  • Page 129: 12. Brake System

    12-1 12. Brake system hydraulic disk brake braking power unsatisfactory ● air in the brake system. ● moisture in brake fluid ● brake pad and disk contaminated. ● caliper piston seal worn ● master cylinder piston seal worn ● brake pad worn ● caliper inside contaminated ● unsatisfactory caliper slidin...

  • Page 130

    12-2 brake system mechanical drum brake poor brake performance ● improperly adjusted brake ● worn brake linings ● worn brake drum ● worn brake cam ● improperly installed brake linings ● brake cable sticking/needs lubrication ● contaminated brake linings ● contaminated brake drum ● worn brake shoes a...

  • Page 131: Brake Fluid/bleeding

    12-3 brake system master cylinder front caliper brake lever reservoir inside brake fluid/bleeding brake fluid change caution ·a contaminate disk or pad reduces braking power. Do not allow the disk or pad to be contaminated by oil. ·replace contaminated pads, and remove pollutants from the disk compl...

  • Page 132: Brake Pad Replacement

    12-4 brake system master cylinder front caliper ● if the brake bleeder is not used, do the following, ● first, fill the brake fluid up to the upper limit line. ● connect the hose to the bleeder valve to receive brake fluid. ① squeeze the brake lever completely loosen the bleeder valve 1/2 turn, and ...

  • Page 133

    12-5 brake system hanger pin pad pad spring hanger pin ● loosen the 2 front brake caliper fixing bolts from the front fork. ● remove the front caliper. ● to install a new brake pad into the brake, press the piston to return to the original position. ● remove the hanger pin, pad shim, and brake pad. ...

  • Page 134: Brake Disk Inspection

    12-6 brake system hanger pin brake disk dial gauge ● install the brake caliper into the left front fork. Note ·be careful not to damage the brake pad. ● tighten the caliper braket bolt. Torque : 2.7kgf · m ● tighten the hanger pin. Brake disk inspection ● measure the thickness of the disk. Service l...

  • Page 135: Brake Caliper

    12-7 brake system front brake caliper oil bolt oil bolt brake hose air gun caliper piston seal dust seal brake caliper removal ● remove the brake oil bolts and the brake hose from the brake caliper. ● remove the caliper from the l. Front fork and remove the pad spring, hanger pin and brake pad. Caut...

  • Page 136

    12-8 brake system caliper cylinder gauge piston dust seal slide pin pin bush lh. Bracket pad spring piston seal brake caliper inspection caliper cylinder ● check the caliper cylinder bore for scoring, scratches or other damage. ● measure the caliper cylinder i.D. In x and y axis at serveral points. ...

  • Page 137: Master Cylinder

    12-9 brake system master cylinder master cylinder front stop switch master cylinder holder piston boot cir clip master cylinder set ● connect the brake hose to the caliper, and install 2 sealing washers and the brake hose bolt. Torque : 3.5kgf · m ● install the slide pin cap. ● fill the brake fluid,...

  • Page 138

    12-10 brake system master cylinder holder piston boot cir clip master cylinder set ● remove the washer, piston, spring from the master cylinder. ● clean the master cylinder, reserve, master piston with the recommended brake fluid. Master cylinder inspection ● check the piston periphery for kink or s...

  • Page 139

    12-11 brake system master cylinder master cylinder ● install the primary cup with its concaved side toward the inner side of the master cylinder. ● install the snap ring. Tool : snap ring pliers caution ·when installing the cups, do not allow the lips to turn inside out. (refer to the drawing.) ·not...

  • Page 140: Memo

    Memo.

  • Page 141: 13. Battery/charging System

    13-1 13. Battery/charging system service information warning ·do not place flammable materials near battery when charging. This can be a fire hazard as hydrogen gas is created during charging battery. ·do not allow battery acid to come into contact with clothes, skin or eyes. Battery acid contact ca...

  • Page 142: Charging Device Location

    Charging device location 13-2 battery/charging system tubeless tire appl. Korea battery fuse resister regulator/ rectifier a.C.Generator white yellow green green battery lighting switch regulator/ rectifier brown brown green / black resister 5w 6.7 resister 30w 5.9 headlight (12v 35/35w) meterlight ...

  • Page 143: Troubleshooting

    13-3 battery/charging system troubleshooting battery is overcharged ● headlight bulb is out. ● no headlignt beam wire. ● headlight register is damaged (disconnected). ● lighting switch is connected incorrectly. ● regulator/rectifier is not grounded or connected incorrectly. Problems with the chargin...

  • Page 144: Battery Removal/installation

    13-4 battery/charging system battery removal/installation ● loosen the battery cover setting bolt. ● remove the battery cover. ● after removing the negative “⊖” terminal of battery firstly, must remove the positive “⊕” terminal of battery. ● install in the reverse order of removal. Battery inspectio...

  • Page 145

    Note ·check with fully charge the battery which has the voltage between terminal of 13.0~13.2v. ·in case that the engine is started by the starter motor, measurement must be performed after accelating (charging) for 10 seconds. Charging current check ● check the charging current passed through the g...

  • Page 146: Headlight Voltage Inspection

    Headlight voltage inspection ● remove the front cover. ( 3-5) caution ·check voltage with the headlight coupler connected. ● after starting the engine, place the dimmer switch to hi and check the voltage between the blue (+) and green (-) wires of the headlight coupler. Caution ·measurement is perfo...

  • Page 147: A.C. Generator

    A.C. Generator removal ● remove the luggage box. ( 3-3 ) ● remove the plug maintenance cover. ( 3-3 ) ● remove the center cover. ( 3-3 ) ● remove the floor side cover. ( 3-4 ) ● remove the floor panel. ( 3-4 ) ● remove the engine hanger side rh. Cover. ( 3-5 ) ● remove the plug cap. ● loosen the 3 w...

  • Page 148

    Stator installation ● note the direction of stator, and install the stator on the crankcase. ● install the grommet to r. Crankcase cover. ● install ac generator wire coupler to wire harness. ● install the connector to starter motor, then install the ground wire. Flywheel installation ● clean the tap...

  • Page 149: Resister Inspection

    A.C. Generator(charging coil) inspection note ·this test is done with the starter mounted to the engine. ● remove the luggage box. ( 3-3 ) ● disconnect the ac generator coupler. ( 3-3 ) ● measure the resistance of the charging coil (between the white wire and ground) and the lighting coil (between t...

  • Page 150: Memo

    Memo.

  • Page 151: 14. Ignition System

    14-1 14. Ignition system service information general safety ● refer to the malfunction diagnosis when inspecting ignition devices. ● because the ignition devices have installed electrical advancer devices, it is impossible to adjust ignition timing. ● be careful when handling the ignition devices as...

  • Page 152: Ignition Devices Location

    Ignition devices location 14-2 ignition system spark plug ignition main switch ii vv side stand switch blue / yellow pulse generator ac generator main switch side stand switch ignition coil spark plug black / yellow black / white black / red green cdi unit.

  • Page 153: Troubleshooting

    Troubleshooting spark plug does not emit sparks. 14-3 ignition system abnormal state possible causes (start from 1 and go through list in order) 1. Using a tester with a low internal resistance. 2. Cranking speed is low. - battery is low or kick power is weak. 3. Influence of tester sampling time (n...

  • Page 154: Ignition System Inspection

    14-4 ignition system ignition system inspection (peak voltage measurement) note ·when sparks are not emitted from spark plug, after checking for disconnection in wires and looseness, measure peak voltage for each wire. ● connect the peak voltage adaptor to the digital tester. Daelim pva multi tester...

  • Page 155: Ignition Coil

    14-5 ignition system ignition coil fixing screw pulse generator note ·inspect with the spark plug assembled and while there is compression pressure. ● remove the cdi unit. ( 14-7 ) ● remove the coupler from the cdi unit and connect the peak voltage adaptor to the pulse generator wire (blue/ yellow a...

  • Page 156: Excite Coil Inspection

    14-6 ignition system inspection (resistance measurement) ● remove the luggage box. ( 3-3 ) ● measure primary coil resistance between the green and black/yellow terminals. Standard value : 0.1~0.5 Ω (20 ℃ ) ● measure the secondary coil resistance between the plug cap and green wire terminals. Resista...

  • Page 157: Ignition Timing Inspection

    14-7 ignition system timing light cdi unit ignition timing inspection note ·as a cdi device is used in this vehicle, there is no need for adjusting ignition timing. If ignition timing problems occur, inspect the cdi unit and the ac generator and replace if any malfunctions are found in the devices. ...

  • Page 158: Side Stand Ignition

    Ignition system side stand ignition cut-off switch inspection ● remove the plug maintenance cover/ center cover. ( 3-3 ) ● remove the coupler of the side stand switch. ● check for continuity between the terminal as shown below: removal ● remove the floor side cover. ( 3-4 ) ● remove the plug mainten...

  • Page 159: 15. Starting System

    15-1 15. Starting system service information general safety warning ·when performing maintenance on the starter motor and related parts, turn the main switch to off. There is the danger of the starter motor unexpectedly operating if the main switch is not turned to off. ● first check connection with...

  • Page 160: Starting Devices Location

    Starting devices location 15-2 starting system tubeless tire appl. Korea battery starter relay fuse 7a main switch starter switch starter motor red/white yellow/red green/yellow green/yellow battery front stop switch starter relay main switch red green green black fuse rear stop switch starter switc...

  • Page 161: Troubleshooting

    15-3 starting system troubleshooting starter motor does not rotate (no response from starter motor). ● check to see if the fuse is burned out. With the main switch turned to on, squeeze the brake lever. In this state push the starter button and check if a clicking noise then an operating noise is em...

  • Page 162: Starter Motor

    Starter motor removal/installation ● remove the luggage box. ( 3-3 ) ● remove the center cover. ( 3-3 ) ● remove the floor side rh. Cover. ( 3-4 ) ● remove the engine hanger side cover rh. ( 3-5 ) ● disconnect the starter wire connector, remove the wire from the wire fixing clamp. ● loosen the 2 sta...

  • Page 163

    ● check the commutator for : -damage or abnormal wear. → replace with a new one. -discoloration of the commutator bar. → replace with a new one. -metallic debris between commutator bars.→ clean it off. ● check for continuity between pairs of commutator bars. ● make a continuity check between individ...

  • Page 164

    ● insert the brush spring into the brush holder and install the front bracket. Note ·insert the brush spring with care so that it does not lean in the holder. ● apply grease to both ends of the armature shaft. ● install the starter motor cover. Note ·the coil may be damaged if the magnet pulls the a...

  • Page 165: Starter Relay Inspection

    Starter relay inspection ● remove the luggage box. ( 3-3 ) ● when battery voltage is applied between the starter relay green/yellow wire and yellow/red terminals, there should be continuity between the red and red/white terminals. The terminals are distinguished by the corresponding wire color of th...

  • Page 166: Memo

    Memo.

  • Page 167: 16. Lights/meter/switches

    16-1 16. Lights/meter/switches troubleshooting fuel meter indicator malfunctioning ● coupler separated. ● harness disconnected. ● float operation malfuction. ● fuel unit damaged. ● meter damaged. Fuel meter needle unstable ● coupler loose. ● fuel unit damaged. ● meter damaged. Headlight hi-lo not op...

  • Page 168: Fuel Unit

    Fuel unit removal ● remove the luggage box. ( 3-3 ) ● remove the fuel unit wire from the wire harness. ● turn the fuel unit fixing unit set cap comp to the left, and remove it. ● remove the fuel unit from the fuel tank. Note ·be careful of prevention the fuel unit wire from damaging. ·when disassemb...

  • Page 169: Oil Level Switch

    Oil level switch removal/installation ● remove the luggage box. ( 3-3 ) ● remove the oil level switch wire. ● remove the oil level switch from the oil tank. ● install in the reverse order of remeval. Note ·disassemble after adjusting the oil level. Inspection ● move the float to farthest extreme up ...

  • Page 170: Handle Switch Inspection

    Handle switch inspection ● remove the front handle cover. ( 3-6 ) ● remove the handle switch coupler, connector, and inspect continuity of each terminal. ● if abnormal, inspect the switch. Front stop switch inspection ● remove the front handle cover. ( 3-6 ) ● remove the black wire and green/yellow ...

  • Page 171: Bulbs Replacement

    Bulbs replacement headlight bulb ● remove the front cover. ( 3-5 ) ● remove the headlight rubber cover. ● push down on the socket and turn to the left. ● replace with new bulb. Note ·before replacing the bulb, be sure to check the swtiches for loose connection of the connectors. ● install in the rev...

  • Page 172: Meters Replacement

    Rear winker bulb replacement ● press the winker lens groove and open the winker lens using plain screwdriver. ● remove the bulb from the socket, replace with new bulb. ● install in the reverse order of removal. Note ·pay attention not to damage the lens. ·do not apply excessive force when removing t...

  • Page 173: Horn Inspection

    ● roose the 3 tapping screws securing the speedometer and the rear handle cover. ● disconnect the r/l wiring. ● remove the speedometer assembly. ● install in the reverse order of removal. Note ·check the each switch for proper operation. ·the wire and cable must be connected accurately. Horn inspect...

  • Page 174: Memo

    Memo.

  • Page 175

    17-1 17. Wiring diagram 17 y/r push free cord color cord color br/w l e g st hi n lo hl hi w cord color gr sb o lo r n l r l horn lg b/r l/y r/w l/y b/y b/w b/r r/w moter starter 30w 5.9 5w 6.7 m auto acg y g l/y b/r w unit b/s cdi w reg/rec relay g/b start g/y y/r r r/w g/b r r fuse 7a frame earth ...

  • Page 176: 18. Troubleshooting

    18. Troubleshooting engine does not start or is hard to start cause of trouble (1)fuel tank empty. (2)fuel tube up to the fuel tank clogged, or the vacuum tube or fuel tube up to the inlet pipe clogged. (3)float valve clogged. (4)fuel tank cap air hole clogged. (5)fuel supply pipe frozen. (6)fuel st...

  • Page 177: Engine Output Insufficient

    18-2 troubleshooting engine output insufficient cause of trouble (1) air cleaner clogged. (2) insufficient fuel supply. (3) fuel tank cap air hole clogged. (4) muffler clogged. (1) faulty cdi unit. (2) faulty a.C generator. (1) cylinder and piston ring worn. (2) cylinder head gasket damaged. (3) cyl...

  • Page 178

    18-3 troubleshooting poor performance at low speed and idling cause of trouble (1) faulty cdi unit. (1) excessive fuel mixture. (loosen screw to correct adjustment level.) (2) lean fuel mixture. (tighten screw to correct adjustment level.) (1) faulty insulator packing. (2) loose carburetor. (3) faul...

  • Page 179: Unsatisfactory Operation

    18-4 troubleshooting unsatisfactory operation cause of trouble (1) drive belt worn or slips. (2) ramp plate damaged. (3) drive face spring damaged. (4) clutch lining came off. (5) driven pulley shaft spline damaged. (6) faulty transmission. (7) transmission seized. (1) shoe spring damaged. (2) clutc...

  • Page 180

    18-5 troubleshooting cause of trouble (1) brake shoe worn. (2) brake cam worn. (3) shoe and cam contact surface worn. (4) brake drum worn. (1) brake shoe worn. (2) foreign matter in the brake lining. (3) brake drum and shoe contact surface curved. (1) brake wire defective or expanded. (2) only part ...

  • Page 181: Fuel Gauge

    18-6 troubleshooting fuel gauge cause of trouble (1) fuse cut. (2) battery weak or totally discharged. (3) faulty ignition swtich. (4) faulty terminal connection. (5) wire harness damaged. (1) faulty float. (1) balance coil damaged or shorted. (1) terminal loose. (2) faulty terminal connection. (1) ...

  • Page 182: Starter Motor

    18-7 troubleshooting starter motor cause of trouble (1) fuse cut. (2) battery weak or totally discharged. (3) faulty stop switch. (4) faulty terminal connection. (5) ignition swtich damaged or shorted. (1) battery totally discharged. (1) faulty starter switch connection. (2) starter magnetic damaged...

  • Page 183: Memo

    Memo.

  • Page 184

    Service manual 2001. 3. Printed 2001. 3. Publication no copy.

  • Page 185

    Sm40-0103-01e head office (factory) #58, sung san-dong, changwon, kyungnam, korea tel : (82-55) 239-7000 / fax : (82-55) 239-7524 overseas sales office #16-6, pil-dong 2ka, chung-ku, seoul, korea tel : (82-2) 2274-3171 / fax : (82-2) 2269-7997.