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- DAELIM
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- S4 four
- Service Manual
DAELIM S4 four Service Manual
Summary of S4 four
Page 1
Sm62-1003-01e.
Page 3: Contents
Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of daelim motor co., ltd., contents service information inspections / adjustments external parts lubricat...
Page 5: Service Information
1. Service information engine serial number location frame serial number location serial number location · ·· ·· · 1-1 specifications · ·· ·· ·· ·· ·· ·· ·· ·· · 1-2 twist torque · ·· ·· ·· ·· ·· ·· ·· ·· ·· · 1-4 symbols / abbreviations · ·· ·· ·· · 1-5 lubrication oil · ·· ·· ·· ·· ·· ·· ·· ·· ·· ...
Page 6
Specification i t e m d i m e n s i o n s f r a m e e n g i n e overall length overall width overall height wheel base seat height ground clearance dry weight gross weight type front suspension rear suspension front tire size/type rear tire size/type tire pressure 1 person front rear 2 persons front...
Page 7
I t e m c a r b u r e t o r e l e c t r i c a l s y s t e m d r i v e t r a i n type/ ventury bore model mark choke type main jet pilot screw reverse revolution speed float level idle spped ignition system ignition timing f mark battery capacity spark plug spark plug gap fuse capacity starting syste...
Page 8: Torque Values
Service information item reference torque value thread dia (mm) q’ty 1.5 kgf · m 2.5 kgf · m 1.1 kgf · m 1.1 kgf · m 5.5 kgf · m 5.5 kgf · m 4.0 kgf · m 1.2 kgf · m 5.5 kgf · m 2.0 kgf · m 1.0 kgf · m 0.4 kgf · m 1.1 kgf · m 1.2 kgf · m 1.0 kgf · m 0.9 kgf · m 1.0 kgf · m 0.9 kgf · m 30 12 5 6 12 12...
Page 9: Symbols / Abbreviations
Service information symbol caution note symbols / abbreviations the following symbols are used in this manual to represent job-related warnings or cautions. Meaning indicates dangerous area. Serious accident may result if instructions are not followed. The following symbols indicate oil adding, oil ...
Page 10: Lubrication Oil
Lubrication oil a p p l i c a t i o n a r e a r e m a r k s valve guide / valve stem working area contact area of cam shaft contact area of valve rocker arm cam shaft drive chain piston & piston ring grove inside cylinder connecting rod piston pin hole connecting rod crank shaft oil pump drive chain...
Page 11: Wiring Diagram
Wiring diagram service information winker relay sai pipe fuel cock cdi unit fuel tank side stand speedometer cable rear brake cable magnetic switch regulator rectifier fuel hose.
Page 12
Service information regulator rectifier magnetic switch ignition coil acg coupler fuel tank sai pipe cdi unit front brake caliper muffler horn winker relay.
Page 13
Service information speedometer winker relay horn key set master cylinder brake hose.
Page 14
Service information fuel tank battery cable acg coupler cdi unit magnetic switch regurator rectifier sai pipe carburator.
Page 15: General Safety
Service information general safety warning 1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous...
Page 16
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. Align...
Page 17
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 rota...
Page 18
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 equ...
Page 19: Caution When Wiring
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 . • w...
Page 20
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 21
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 22
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 23: 2. Inspections/adjustments
Epair standards throttle grip diffe spark plug spark plug gap valve gap carburetor idle speed cylinder compres sion pressure 2-6mm cr6hsa 0.6~0.7mm 0.1mm 0.1mm 1,700 ± 100rpm 10kg/cm 2 (600rpm) in ex 2.00 kgf/cm 2 (28psi) 2.00 kgf ・ cm 2 (28psi) 2.00 kgf ・ cm 2 (28psi) 2.25 kgf ・ cm 2 (33psi) 3.50 -...
Page 24
Spark plug 1.2 ㎏ f ・ m cylinder head cover bolt 0.9 ㎏ f ・ m valve adjusting nut 1.1 ㎏ f ・ m torque wrench 8 × 9mm adjust wrench compression gauge tool inspections / adjustments.
Page 25: 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 appropriate type of tools and maintenance data availa...
Page 26: Fuel Line(Fuel Tube)
Carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor fuel tube fuel tube fuel tube fuel tube fuel tube fuel tub...
Page 27: Air Cleaner
0.6 ~ 0.7mm check the damage of sealing washer. Check the crack. Check the cap, contamination. Air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air cleaner element air c...
Page 28: Cylinder Compression
Valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut valve rocker arm, lock nut val...
Page 29: Carburetor Idl Speed
Throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw ...
Page 30: Brake Fluid
Brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window brake fluid check window ...
Page 31: Side Stand
Side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand side stand front cushion front cushion front cushion front cushion fr...
Page 32: Wheels / Tires
Tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge tire pressure gauge ...
Page 33: Lubrication Points
4 front brake lever pivot trottle grip steering bearing wheel bearing / speedometer gear side / main stand pivot wheel bearing inspections / adjustments lubrication points unless specifically designated, use generd grease to lubricate the lubrication points. For stiding parts not shown here, add oil...
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Page 35: 3. External Parts
3. External parts service information caution ● this section describes external parts removal / installation ● do not apply unreasonable force when disassembling or assembling covers to prevent their possible damage. ● because the muffler is hot, do not service it immediately after the engine is sto...
Page 36: Maintenance Procedure
① seat ② luggage box ③ rear carrier ④ battery cover ⑤ center cover ⑥ body cover ⑦ rear fender ⑧ floor side cover ⑨ floor panel ⑩ under cover ⑪ front cover ⑫ inner box ⑬ front fender ⑭ front wheel ⑮ front under cover ⑯ front handle cover ⑰ rear handle cover ⑱ rear wheel mud guard ⑲ rear splash cover ...
Page 37: Seat Removal /
Center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover washer bolt wa...
Page 38: Body Cover Removal /
Center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover center cover tapping screws...
Page 39: Floor Side Cover
Floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side cover floor side ...
Page 40: Under Cover Removal /
Front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover front cover under cover under cover under cover ...
Page 41: Inner Box Removal /
Special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s crews special s cr...
Page 42: Front Under Cover
Washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt washer bolt front under cover front under cover ...
Page 43: Speedometer Removal /
Washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts washer bolts speedometer sp...
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Page 45: 4. Lubrication System
Engine oil oil capacity recommended oil 0.85l( at disassembling ) 0.70l( at changing ) daelim geguine oil api service classification sl grade viscocity : 10w-40 ( use appropriate type of oil with viscocity satisfying the atmospheric temperature. In your riding area based on the table shown on the ri...
Page 46: Trouble Shooting
Lubrication system trouble shooting oil level low ● natural oil consumption ● external oil leaking ● worn piston ring or incorrect piston ring installation ● worn valve guide or valve stem seal oil contamination ● oil or filter not changed often enough ● faulty cylinder head gasket ● piston ring wor...
Page 47: Engine Oil Level Check
Oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level gauge oil level ga...
Page 48: Oil Pump
Ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator ac generator frange bolt fr...
Page 49
Pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump plate pump shaft pump shaft pump shaft pump shaft pump shaft pum...
Page 50
Oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings oil rings fan screws fan screws fan screws fan screws fan screws fan screws fan screws fan...
Page 51: Transmission Oil
Oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole oil check hole ...
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Page 53: Service Information
Carburetor specifications i t e m type/ venturi diameter model mark main jet no. Pilot screw reverse-rolling float level idling speed throttle grip tollerance cv type(vacuum)/ Ø 16 pd 19j #80 2 ± 1/2 11mm 1,700 ± 100rpm 2-6mm s t a n d a r d s float level gauge tool service information general safet...
Page 54: Troubleshooting
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. Idle is unstable and engine turns off after starting. ● idle is adjusted...
Page 55: Fuel Tank
Fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel tank fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit ...
Page 56
Carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor carburetor fan screws fan screws fan screws fan screws fan screws fan...
Page 57
Float float float float float float float float float float float float float float float float float float float float float float float valve float valve float valve float valve float valve float valve float valve float valve float valve float valve float valve float valve float valve float valve ...
Page 58
Main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet main jet clean compressed air clean compressed air clean compressed air clean compressed air clean compressed a...
Page 59
Diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp diaphragm comp ...
Page 60
Compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spring compression spr...
Page 61: Carburetor Insulator
Inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inlet pipe inl...
Page 62
Throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw ...
Page 63: Fuel Cock
Throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw throttle stop screw ...
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Page 65: 6. Engine Removal/inspection
6. Engine removal/inspection service information ····· 6-1 engine removal/assembly ·· 6-2 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 ta...
Page 66: Engine Removal/inspection
Rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion carburetor car...
Page 67: Engine Removal/inspection
Rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion under bolt rear cushion...
Page 68
Belt type continuously variable transmission / kick starter.
Page 69: Transmission / Kick Starter
7. Belt type continuously variable transmission / kick starter 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 due to oil contact. ● do not operate starter motor while the lh. Crank case front cover...
Page 70: Lh. Crank Case Cover
Kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spring kick return spr...
Page 71: Check
Kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b kick spindle bush b ...
Page 72: Drive Belt
Drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face drive face driven pulley ass ’ y driven pulley ass ’ y driven pulley ...
Page 73
Driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley sub ass ’ y driven pulley ...
Page 74: Driven Pulley Ass’Y
Drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate drive plate clutch spring compressor clutch spri...
Page 75
Seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar seal collar oil seal oil seal oil seal oil seal ...
Page 76
Inspection ● check each part ● check driven face needling bearing(inside) for damage or excessive play and replace necessary. Turn the inner race of the outer bearing with your finger. Check that the bearing turns smoothly and quietly, and that the bearing outer race fits securely. ● measure the fre...
Page 77
Replace driven face bearing ● replace inner bearing. ● remove snap ring, disassemble outer bearing to the side of inner bearing. ● assemble new replacement outer bearing. ● assemble snap ring. ● apply grease to the designated position of right side picture. Applying grease capacity : 9.0~9.5g ● asse...
Page 78
Lock nut wrench movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face movable driven face mova...
Page 79: Movable Drive Face
Driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulley sub driven pulle...
Page 80
Cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling ...
Page 81
Cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling fan cvt cooling ...
Page 82
7-14 flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut flange nut belt type continuously variable transmission / kick s...
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Page 84
A.C. Generator /rh. Crank case cover.
Page 85: Service Information
8. A.C. Generator /rh. Crank case cover service information general safety ● this section describes the removal and assembling of the a.C. Generator. ● for the information of a.C. Generator inspection, refer to the section 15. ● the charging systme can be maintained without removing the engine. Serv...
Page 86: Cooling Fan Cover
Cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cover cooling fan cover ...
Page 87
Acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor puller acg rotor p...
Page 88: Rh. Crank Case Cover
Cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan cooling fan rh.Crank case cover rh.Crank case co...
Page 89
Oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal dowel pin dowel pin dowel pin dowel pin dowel pin dowel pin dowel pin dowel pin dowel pin dowel pin do...
Page 90
Cylinder head / valves.
Page 91: Service Information
Unit : mm item standard value service limit rocker arm rocker arm inner diameter rocker arm outer diameter cam height in ex in in ex in, ex in ex cam shaft valve valve guide cylinder head warfage 34.1 ~ 30.5 4.975-4.990 4.965-4.980 5.000-5.012 0.010-0.040 0.020-0.050 0.8 10.000-10.015 9.972-9.987 25...
Page 92: Troubleshooting
Cylinder head / valves ● engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down test or by tracing noises to the top-end with a sounding rod or stethoscope. Low compression ● valves - incorrect valve adjustment - burned or bent valve - incorre...
Page 93: Camshaft
Flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts flange nuts cam shaft holder cam shaft holder ca...
Page 94
Cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft cam shaft rocker arm shaft rocker arm shaft rocker arm shaft rocker arm shaft rocker arm s...
Page 95: Cylinder Head
Bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing bearing cylinder head gasket cylinder head gasket cylinder head gasket cylinder head gasket cylinder head gasket cylinder head gaske...
Page 96: Valve Spring
B a inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve spring inner valve...
Page 97: Valve Guide
Valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide reamer valve guide rea...
Page 98: Valve Seat
In valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve in valve ex valve ex valve ex valve ex valve ex valve ex valve ex valve ex valve ex valve ex valve ex valve ex ...
Page 99
Spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug spark plug valve stem valve stem valve stem valve stem valve stem val...
Page 100: Cylinder Head Assembly
Cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylinder head cylind...
Page 101
“ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark “ t ” mark washer washer washer washer washer washer washer washer wa...
Page 102
Tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift tensioner lift ...
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Page 104
Cylinder / piston.
Page 105: 10. Cylinder / Piston
Item standard value service limit inner diameter taper out-of-round head contact warpage piston skirt outer diameter piston pin hole inner diameter piston pinouter diameter piston to piston pin clearance cylinder to piston clearance connecting rod small end inner diameter gap between connecting rod ...
Page 106: Cylinder
Cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge cylinder gauge ...
Page 107: Piston
Piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring piston ring ...
Page 108
Feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge 90 ° 90 ° 90 °...
Page 109: Piston / Cylinder
Mark r top ring second ring side rail side rail piston in 20mm spacer crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft crank shaft cr...
Page 110
Cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cam chain cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder...
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Page 112
Transmission/crankshaft/crankcase.
Page 113: Service Information
Specifications 단위 : mm transmission oil oil capacity recommended oil 0.12l( full capacity ) 0.10l( after oil change ) daelim genuine mission oil or sae 80w/90 11. Transmission/crankshaft/crankcase service information general safety ● this section describes how to remove the crank case and to maintai...
Page 114: Troubleshooting
Transmission/crankshaft/crankcase engine noise ● connecting rod big and small ends loose. ● crank pin bearing loose. Engine started but unable to move out ● transmission damage. ● transmission seized. Noise during operation ● gear worn, overheated, cracked. ● bearing worn. Oil leaks ● excessive oil ...
Page 115: Transmission
Final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft gear final shaft...
Page 116: Transmission Bearing
Final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft final shaft drive shaft drive shaft drive shaft ...
Page 117
Transmission/crankshaft/crankcase ● replace the bearings if necessary. ● press the bearing to the case with special tool. Tool: bearing remover set assembly ● install the drive shaft on the transmission cover. ● install a new drive shaft oil seal. Tool: crank assembly shaft crank assembly collar ● c...
Page 118
Transmission/crankshaft/crankcase ● apply clean engine oil to the new bearing and insert by pressure to crank case. Tool : driver handle, driver outer ● assemble the new final shaft oil seal. ● assemble drive shaft to lh. Crank case. ● assemble the new drive shaft oil seal. Tool : driver handle ● as...
Page 119: Crank Case Removal
Flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt rh. Crank case rh. Crank case rh. Cr...
Page 120: Crank Shaft Removal
Dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge dial gauge crank crank crank crank crank crank crank crank crank cran...
Page 121: Crank Shaft Installation
Feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge feeler gauge dial gauge dia...
Page 122: Crank Case Installation
Flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt transmission/crankshaft/crankcase cr...
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Page 124
Front wheel / front brake / front fork / steering stem.
Page 125: Service Information
12. Fr. Wheel / fr. Brake / fr. Fork / steering stem 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 ...
Page 126: Troubleshooting
Front wheel / front brake / front fork / steering stem troubleshooting hard steering ● steering bearing adjustment nut too tight. ● faulty steering stem bearings. ● damaged steering stem bearings. ● insufficient tire pressure. Steer to one side or does not track straight ● bent fork. ● bent front ax...
Page 127: Steering Handle
Washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw washer screw tapping screw ...
Page 128: Front Wheel
Front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel front wheel handle bar handle bar handle bar han...
Page 129: Front Wheel Bearing
Front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle front axle bearing remover head bearing remover head bearing remover ...
Page 130: Speedometer Gear Box
Speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedo...
Page 131: Front Wheel
Speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedometer gear box speedo...
Page 132: Front Brake
Master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylinder master cylin...
Page 133
Oil cup cap diaphragm plate diaphragm spring cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder cylinder primary cup primary cup primary cup primary cup ...
Page 134: Brake Fluid Replacement
Diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm plate diaphragm pl...
Page 135
Brake bleeder front wheel / front brake / front fork / steering stem note • do not release the brake lever until the bleeder valve has been closed. ● remove the master cylinder cup cap. ● remove the master cylinder cup cap, diaphragm plate, and diaphragm from the master cylinder. Connect the bleeder...
Page 136: Brake Caliper
Flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt front caliper front caliper front ca...
Page 137
Air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun air gun piston seal piston seal piston seal piston seal piston seal piston seal piston seal piston seal piston seal piston seal pist...
Page 138
Front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper front brake caliper ...
Page 139: Front Fork
Socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt socket bolt front fork front fork front fork fro...
Page 140
Oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal stop ring oil seal stop ring oil seal stop ring oil seal stop ring oil seal stop ring oil sea...
Page 141
Front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork spring front fork s...
Page 142
Front wheel / front brake / front fork / steering stem ● assemble the fork pipe to the bottom case. ● assemble the springs to the fork pipe. Note • install the spring with the smaller pitch side facing downward. ● accurately assemble the stop ring to the bottom case. ● install the dust seal. ● fix b...
Page 143
Front wheel / front brake / front fork / steering stem ● fill a prescribed amount of automatic transmission fluid in to the fork pipe. Capacity: 90 ㎤ ㎤ ● slowly press the fork tube 2-3 times to discharge air. ● check the oil level the fork tube is completely compressed condition. ● install the fork ...
Page 144: Steering Stem
Steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y steering stem under ball ass ’ y ste...
Page 145
Bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top cone race bearing top co...
Page 146
Handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar handle bar front wheel / front brake / front fork / steering stem ● a...
Page 147
M e m o.
Page 148
Rear wheel / rear brake / rear cushion.
Page 149: Service Information
13. Rear wheel / rear brake / rear cushion 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...
Page 150: Trouble Shooting
Rear wheel / rear brake / rear cushion trouble shooting rear wheel wobbling or vibration ● deformed wheel, rim ● bad tire ● axle bad fastening ● bad tire air pressure ● improper wheel balancing soft rear suspension ● bad spring ● bad rear damper, oil leakage hard suspension ● twisted damper rod ● ba...
Page 151: Rear Wheel
Muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler muffler lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nu...
Page 152: Rear Brake
Lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut lock nut brake lining brake lining brake lining brake lining brake lining brake lining brake lining brake linin...
Page 153
Brake shoe shoe spring brake cam brake shoe shoe spring brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake arm brake cam brake cam brak...
Page 154: Rear Cushion
Rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion rear cushion r...
Page 155
Rear wheel / rear brake / rear cushion inspection ● measure the rear cushion spring free length. ● check the damper rod for deflection or damage. Service limit: 185 mm installation ● install the spring, stop rubber. ● apply thread locking agent to the lock nut, and install the rear cushion compresso...
Page 156
C h a r g i n g d i a g r a m fuel tank fuel cocke fuel hose m a g n e t i c switch regulater rectifier sai pipe cdi unit winker relay rear brake cable speedometer cable side stand ac. Generator w g g r r fuse(7a) battery (12v 3ah) regurator rectifier auto by starter register 5w 6.7 y y y y y headli...
Page 157: 14. Charging System
Digital tester pva multi-tester rpm tester battery tester specifications item capacity terminal to terminal voltage charging coil resistance value (20° c) rpm at charging start regulator voltage battery ac. Generator standard value 12v 6ah 12.6~13.0v 0.5~1.5Ω 2,000rpm 14.5v /5.000rpm tool regulator ...
Page 158: Trouble Shooting
Charging system measure battery current leakage. Inspect the body of the register/rectifier. Faulty battery. Wire harness is short-circuited. Coupeler is connected incorrectly. · short-circuited harness. · damaged main switch. · register/rectifier is switch. Check the a.C generator charging coil. Da...
Page 159: Battery
Battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover battery cover batter...
Page 160: A.C Generator
Battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ terminal battery ⊖ termi...
Page 161: Regulator Rectifier
R y w g w g r y unit : mΩ (20°c) 2,751 4.95 ∞ 1,248 1,248 13.94 regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectifier regurator rectif...
Page 162
I g n i t i o n s y s t e m g g g g g kill s/w side stand s/w b/w b/r l/y pulse generator ac. Generator cdi unit ignition coil b/y spark plug ignition system fuel tank cdi unit magnetic switch ignition coil regulator rectifier acg coupler sai pipe front brake caliper winker relay horn muffler.
Page 163: 15. Ignition System
Multi tester pva multi-tester general safety tool item ignition coil resistance value 20℃ primary coil secondary coil pulse generator coil resistance value 20℃ spark plug spark plug gap standard value with plug cap without plug cap 0.1~0.5Ω 6.5~9.8㏀ 2.7~3.5㏀ 50~200Ω cr6hsa 0.6~0.7mm 15. Ignition sys...
Page 164: Trouble Shooting
Trouble shooting spark plug does not emit sparks. Unusual condition possible causes (start from 1 and go through list in order) 1. Cranking speed is low. - battery is low or kick power is weak. 2. Poorly connected connectors or an open circuit in ignition system 3. Faulty ignition coil 4. Faulty cdi...
Page 165: Cdi Unit Inspection
Item excite input voltage ground wire pulse gernerator ignition (primary)coil check that there is battery voltage between main switch wire(black/red)and ground wire when the ignition is on pva 225 ± 25v over 1.5v 225 ± 25v continuoty check that the resistance of coil (between white/red and green)is ...
Page 166: Ignition Coil Inspection
Ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil ignition coil igniti...
Page 167
Memo.
Page 168
S t a r t e r s y s t e m c i r c u i t r/w r r y/r g/y b starter motor starter s/w starter relay fuse main s/w rear stop s/w front stop s/w battery (12v 3ah) g g g m starting system fuel tank fuel cock fuel hose m a g n e t i c switch regulater rectifier sai pipe cdi unit winker relay rear brake ca...
Page 169: 16. Starting System
Multi-tester vernier caliper item standard value service limit starter motor brush length tool specification 11.0~11.05 6.5mm 16. Starting system service information general safety ● the starter motor can be maintained without removing the engine from the vehicle. ● always turn the ignition switch o...
Page 170: Trouble Shooting
Starting system trouble shooting starter motor does not rotate (no response from starter motor). ● check to see if the fuse is burned out. ● check to turn on the lamp of stop switch. With the main switch turned to on, squeeze the brake lever. In this state push the starter button and check if a clic...
Page 171: Starter Motor
Flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt flange bolt starter motor starter motor starter ...
Page 172
Oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal oil seal brush brush brush brush brush brush brush brush brush brush brush brush brush brush brush brush brush ...
Page 173
Front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front bracket front ...
Page 174: Starter Magnetic Switch
Starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magnetic switch starter magn...
Page 175: 17. Lights// Switches / Horn
17. Lights// switches / horn trouble shooting light not turned on when the main switch is on ● faulty light bulb ● faulty switch ● faulty or disconnected wiring ● fuse cut ● battery discharged dim headlight ● battery discharged ● wiring and switch resistance high headlight hi-low beam can not be cha...
Page 176: Headlight Bulb
Headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb headlight bulb ...
Page 177: Rear Combination Light
Rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker bulb rear winker...
Page 178: Main Switch
R n l color winker switch w gray sky blue orange r l main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main switch main sw...
Page 179: Horn
Free push color horn switch ho light green black bat2 hi (n) lo color dimmer switch bat3 dg/y blue purple hi lo front stop switch front stop switch front stop switch front stop switch front stop switch front stop switch front stop switch front stop switch front stop switch front stop switch front st...
Page 180: Fuel Unit
Measure the resistance between the terminal ✽ resistance value = resistance between y/w & green resistance between l/w & green wire terminal green & y/w green & b/w b/w & b/w float upper line 30~40 Ω 500~600 Ω 550~650 Ω fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit fuel unit ...
Page 181: 18. Troubleshooting
18. Troubleshooting engine won’t start or hard to start cause of trouble · no fuel to fuel tank. · disconnected or damaged fuel pump negative pressure tube. · clogged fuel tube. · clogged float valve. · clogged fuel strainer. · clogged fuel tank cap. · fuel pump malfunction. · faulty spark plug. · c...
Page 182
Engine stalls, hard to start, rough idling cause of trouble · no fuel to fuel tank. · clogged fuel tube. · clogged float valve. · clogged fuel tank cap. · clogged fuel strainer. · disconnected or damaged fuel pump negative pressure tube. · contaminated spark plug. · using spark plug with an incorrec...
Page 183
Engine speed does not increase sufficiently. Abnormal low clogged contaminated or discolored. Overheated engine knocking poor performance at low speed and idling cause of trouble · clogged air cleaner. · insufficient fuel supply. · clogged fuel tank cap air hole · clogged muffler. · faulty cdi unit....
Page 184: Poor Operation
Poor operation cause of trouble · worn or damaged drive belt. · damaged ramp plate. · faulty weight roller. · faulty movable drive face. · damaged driven pulley weight shoe spring. · faulty transmission. · seized transmission. · broken driven pulley weight spring. · seized clutch outer and weight. ·...
Page 185
Cause of trouble · weak cushion spring · overloaded · oil leakage from damper unit · bent fork pipe or cushion rod · worn slider · damaged cushion stopper rubber soft suspension. Hard suspension. Suspension noisy. Poor front/rear suspension performance.
Page 186
Memo.
Page 187
2010. 03 printed 2010. 03 publication c co op py y p pr ro oh hiib biit t service manual.
Page 188
Sm62-1003-01e.