DAELIM DAYSTAR, DAYSTAR VL125E Service Manual

SER VICE MANUAL

How to use this manual

This manual explains how to maintain the Daystar of the DAELIM MOTOR CO., LTD.

Follow the maintenance schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition.

Section 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, grouped according to location.

Most sections start with an assembly or system illustration, service information and trouble shooting for the section. The subsequent pages give detailed procedures.

If you don’t know the source of the trouble, go to section 20, trouble shooting.

All information, illustrations, directions and specificiations included in this publication are based on the latest product information avaliable at the time of approval for printing. DAELIM reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced wihtout written permission. Some drawings of this manual can be slightly different from actual specification of model.

General Information

1

2

3

4

5

6

7

8

9

10

13

14

15

16

17

18

19

20

21

Lubrication

Maintenance

Fuel System

Engine Removal / Installation

Clutch / Gearshift

A.C. Generator / Starter Clutch

Cylinder Head / Valve

Cylinder / Piston

Crankcase / Transmission Crankshaft / Kick-Starter

11

Cooling System

Front Wheel / Front Fork / Steering

Rear Wheel / Rear Brake / Suspension

Hydraulic Brake

Charging System / Battery

Ignition System

Electric Starter

Lights / Switches / Horn

Wiring diagram

Troubleshooting

Contents

Engine

Frame

Electrical

General

12

Seat / Exhaust Muffler

1. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

2. The battery contains sulfuric acid(electrolyte) Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water. If electrolyte gets on your eyes, flush with water and call physician. Electrolyte is poisonous. Keep out of reach of children.

3. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in your working area.

4. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged period. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil.

Service Rules

1. Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents.

2. Use the special tools designed for this product.

3. Install new gaskets, o-ring, piston pins, clips, cotter pins, etc. When reassembling.

4. When tightening a series of bolt or nuts, begin with the larger-diameter of inner bolts first, and tighten to the specified torque diagonally, in incremental steps unless a particular sequence is specified.

5. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners.

6. Clean parts in cleaning solvent upon disassembly. Remove the cleanser with compressed air.

7. Lubricate any sliding surface before reassembly with recommended grease.

8. After reassembly, check all parts for proper installation and operation.

General Information

General Safety ………………………1-1

Service Rules ………………………1-1 Model Identification…………………1-2 Specification …………………………1-3

Torque Values ………………………1-5 Safety Notice …………………………1-7 Tools / T ester gauge / V alve Seat Cut …1-8 Cable & Harness Routing …………1-10

1. General Information

1

1-1

General Safety

!

WARNING

△

1-2

General Information

Model Identification

Frame No

Engine No

1-3

General Information

Item Specifications

Overall Length 2,240mm Overall Width 860mm Overall Height 1,140mm

Dimensions

Wheel Base 1,505mm Seat Height 720mm Ground clearance 135mm Dry Weight 147.5kgf Curb Weight 341kgf

Type Double Cradle Front Suspension Stroke Telescopic fork 140mm Rear Suspension Stroke Swingarm 35mm Front Tire Size 90/90 - 18 (Tubeless) Rear Tire Size 130/90 - 15 (Tubeless) Tire Pressure 1 Person Front 2.00kgf/cm

2

(200kPa)

Rear 2.00kgf/cm

2

(200kPa)

Frame

2 Person Front 2.00kgf/cm2(200kPa)

Rear 2.00kgf/cm

2

(200kPa) Front Brake Hydraulic Disk Rear Brake Drum Brake Fuel Capacity 17.3 Fuel Reserve Capacity 2.9 Caster Angle 32 Trail Length 147mm Front Fork Oil Capacity 280cm

3

Type Oil / Air Cooled 4-stroke

SOHC Engine

Cylinder Number, arrangement 1 Cylinder, 15 Bore and Stroke 56.5 X 49.5mm Displacement 124.1cm

3

Comparison Ratio 11.5:1 Valve Train SOHC Chain Drive Oil Capacity 1.2 After Disassembly

1.15After Draining and Oil Filter Change

Engine

1.1 After Draining Lubrication System Forced Pressure Splash Type Air Cleaner Viscose Oil Wet Filter Cylinder compression 14kgf/cm

2

(550rpm)

Intake Value Opens 6BTDC

Closes 22ABDC at 1.12mm Lift

Exhaust Value Opens 24BBDC

Closes 4BTDC at 1.12mm Life Valve Clearance Intake 0.120.02mm(0.0050.001 in) (a cooling-off period)

Exhaust 0.120.02mm(0.0050.001 in)

Engine Dry Weight 32.3kg

Specifications

1-4

General Information

Item Specifications

Carburetor Type Piston Valve/24mm(0.94 in) Setting Mark VL125 B Main Jet #102

Carburetor

Slow Jet #38 Pilot Screw Initial Setting 2 1/4 Float level 19mm Idle Speed 1,400100(rpm)

Clutch Hydraulic, Multi-plate Transmission Type Constant Mesh Transmission Primary Reduction 3.650(73/20) Secondary Reduction 3,000(42/14) Gear Ratio 1st 3.083(37/12)

Drive Train

Gear Ratio 2nd 1.882(32/17) Gear Ratio 3rd 1.380(29/21) Gear Ratio 4th 1.095(23/21) Gear Ratio 5th 0.923(24/26)

Gearshift Pattern Left foot operated return system

1-N-2-3-4-5

Ignition CDI Ignition Ignition Timing “F” Mark 8BTDC / 1,400(rpm)

Full Advance 28BTDC / 3,900(rpm)

AC Generator 90W / 5,000(rpm)

Battery Capacity 12V 9AH Spark Plug CR8EH-9 Spark Plug Gap 0.8 -0.9mm Fuse Capacity 15A Starting System Kick/Starter Motor

Electrical

Headlight (High/Low Beam) 12V 60W/55W Winker 12V 10W4 Tail/Stop Lights 12V 5W/21W Meter Light 12V 3W/3.4W(1.7W2) Neutral Indicator Lamp 12V 1.7W High Beam Pilot Lamp 12V 1.7W

1-5

General Information

Item Q’ty

Thread dia Torque

Remark

Oil Filter Screen Cap 1 36 1.5(15) Oil Filter Relief Valve Oval Screw 1 10 1.2(12) Oil Filter Cover Socket Bolt 3 6 1.1(11) Oil Pump Mounting Bolt 2 6 1.1(11) Valve Adjusting Screw Lock Nut 4 5 1.1(11) Drive Sprocket 2 6 1.2(12) Engine Hanger Bolt(Front) 2 8 2.7(27) Engine Hanger Bolt(Front 1, Rear 2) 3 10 4.9(49) Clutch Lock Nut 1 16 6.5(65) Apply Engine Oil Drum Stopper Arm Bolt 1 6 1.2(12) Primary Drive Gear Bolt 1 16 6.5(65) Apply Engine Oil R Crank Case Cover Bolt 11 6 1.1(11) Kick Starter Pedal Bolt 1 8 2.2(22) Gear Change Arm Bolt 1 6 1.2(12) Flywheel Bolt 1 10 5.5(55) Apply Engine Oil Starter Clutch Socket Bolt 3 8 3.2(32)

Apply a locking nut agent Cam Chain Tensioner Pivot Bolt 1 8 1.1(11) Spark Plug 1 10 1.1(11) Cam Shift Holder 8mm nut 4 8 2.0(20) Apply Engine Oil Cam Chain Tensioner Mounting Bolt 2

6 1.2(12)

Cam Chain Tensioner Sealing Screw

16 0.4(4) Cylinder Head Cover Bolt 2 6 1.0(10) Crank Shaft Hole Cap 1 30 0.8(8) Timing Hole Cap 1 14 0.6(6) L Crank Case Cover Bolt 7 6 1.1(11) Main Shaft Bearing Setting Plate 2 6 1.2(12)

Apply a locking nut agent Crank Case Bolt 11 6 1.1(11) Starter Motor Terminal Nut 1 6 1.2(12) Cylinder(Oil Through Bolt) 2 12 3.2(32) Radiator(Oil Through Bolt) 2 12 3.2(32)

Torque Values

Engine

Item Q’ty

Thread dia Torque

Remark

Handle Holder Bolt 2 10 2.6(26) Steering Stem Nut 1 22 7.4(74) Steering top Thread Nut 1 22 1.8(18)

With a Starting torque

0.3(3)

With a Finishing torque

Front Fork Top Bridge Bolt 2 7 1.1(11, 8)

Front Fork Bottom Bridge Bolt 2 8 3.3(33) Front Fork Socket Bolt 2 8 2.0(20)

Apply a locking nut agent Front Fork Tube Cap 2 26 2.3(23) Front Axle Nut 1 14 5.9(59)

Front Wheel Stud Bolt 5 6 0.6(6, 4.3)

Apply a locking nut agent

Ignition Switch Bolt 2 8 3.3(33) Front Brake Disk Nut 6 8 4.2(42) Self lock nut

Frame

(mm)

kgf.m,(N.m)

(mm)

kgf.m,(N.m)

1-6

General Information

Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.

SH(Small Head): 6mm Bolt of 8mm Flange Head.

Type

Torque

Type

Torque

kgf-m N.m kgf-m N.m

15mm Bolt, nut 0.45~6 4.5~6 5mm Screw 0.35~0.5 3.5~5 16mm Bolt, nut 0.8~1.2 8~12 6mm Screw&Flange 0.7~1.1 7~11

bolt (SH TYPE)

18mm Bolt, nut 1.8~2.5 18~25 6mm flange bolt, nut 1.0~1.4 10~14

10mm Bolt, nut 3.0~4.0 30~40 8mm flange bolt, nut 2.4~3.0 24~30 12mm Bolt, nut 5.0~6.0 50~60 10mm flange bolt, nut 3.5~4.5 35~45

Item Q’ty

Thread dia Torque

Remark

Brake Caliper Bracket Bolt 2 8 3.0(30) Brake Caliper Bleed Valve 1 8 0.6(6) Brake Pad pin Bolt 2 8 (1.8, 13) Master Cylinder Reservoir Cap Screw

240.13(1.3) Brake Hose Bolt 2 10 3.4(34) Brake Lever Pivot Bolt 1 6 1.0(10, 7) Brake Lever Pivot Lock Nut 1 6 1.0(10, 7) Rear Axle Nut 1 14 8.8(88) Final Driven Sprocket Nut 4 10 5.9(59) Rear Brake Arm Bolt 1 6 1.0(10) Rear Shock Absorber Upper Bolt 1 10 3.4(34) Rear Shock Absorber Lower Bolt 1 10 3.4(34) Rear Fork Pivot Bolt 1 12 4.5(45) Self lock nut Rear Brake Pedal Bolt 1 8 2.2(22) Chain Tensioner Flange Nut 1 8 3.6(36)

(mm)

kgf.m,(N,m)

1-7

General Information

!

WARNING

△

Safety Notices

Following marks indicate some warnings and caution against some specific service methods.

The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance

Special greases, etc. that do not correspond to the above are indicated without using symbols.

Symbol Caution Symbol Caution

Mark Meaning Mark Meaning

Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed

Use recommended engine oil, unless otherwise specified

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)

Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent)

Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent)

Use silicone grease

Apply a locking agent. Use the agent of the middle strength, unless otherwise specified

Apply sealant

Replace the parts with new ones before assembly

Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified.

Use Forkor Suspension Fluid

Use special tool

Use optional tool. These tools are obtained as you order parts

Indicates reference page. (Example: Refer to page 3-1)

(⇨ 3-1)

Indicates a possibility of personal injury or equipment damage if instructions are not followed.

Gives helpful information

NOTE

!

CAUTION

△

O.P. TOOL

S TOOL

CUSHION OIL

1-8

General Information

Tools

Special Common

Description

Reference section

Description

Reference section

Clutch Center Holder 6 Wrench, 8 9mm 3 Flywheel Puller 7 Adjusting Wrench, B 3 Lock Pin Puller Set 8 Float Level Gauge 4 Sliding shaft 8

Lock Nut Wrench, 20 24mm

6 Sliding Weight 8 Extension Bar 6, 13 Valve Guide Reamer 8 Fly Wheel Holder 6, 7 Universal Bearing Puller 10 Valve Spring Compressor 8 Bearing Remover Set, 15mm

10 Driver 10, 13, 14 Remover Assy, 15mm 10 Attachment, 32 35mm 10, 14 Remover Shaft, 15mm 10 Attachment, 42 47mm 10, 13, 14 Remover Head 10 Attachment, 62 68mm 10 Sliding Weight 10 Attachment, 72 78mm 10 Thread Adopter 10 Pilot, 15mm 10, 14 Assembly Shaft 10 Pilot, 20mm 10 Crank Case Assembly Color

10 Pilot, 35mm 10 Ball Race Driver 13 Pilot, 28mm 10 Steering Stem Driver 13

Lock Nut Wrench, 30 32mm

13 Fork Seal Driver 13 Attachment, 37 40mm 13 Steering Stem Socket 13 Pilot, 12mm 13 Snap Ring Pliers 15 Fork Seal Driver Body 13

Remover Head, 12mm 13 Bearing Remover Shaft 13, 14 Remover Head, 15mm 14 Rear Cushion Compressor 14 Attachment 14

1-9

General Information

Tester, Gauge

Compression Gauge Digital Circuit Tester Circuit Tester Inspecion Adapter Spark Adapter

3 16, 17 16, 17

17 17

RemarkDescription Reference section

Valve Seat Cut

Valve Seat Cutter 45 Valve Seat Cutter 35 Valve Seat Cutter 35 Valve Seat Cutter 60 Cutter Holder 5mm

8

24.5mm IN, EX 23mm IN 20mm EX 22mm IN, EX Use with Valve Seat

RemarkDescription Reference section

1-10

General Information

Cable & Harness Routing

Note the following when routing cables and wire harnesses:  A loose wire, harness or cable can be safety

hazard. After clamping, check each wire to be sure it is secure.

 Do not squeeze wires against the weld or its

clamp.

 Secure wires and wire harnesses to the frame

with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses.

 Route harnesses so they are neither pulled

tight nor have excessive slack.

 Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape.

 Do not use a wire or harnesse with a broken

insulator. Repair by wrapping then with protective tape or replace them.

 Route wire harnesses to avoid sharp edges or

corners.

 Avoid the projected ends of bolts and screws.  Keep wire harnesses away from the exhaust

pipes and other hot parts.

 Be sure grommets are seated in their grooves

properly.

 After clamping, check each harness to be

certain that it is not interfering with any moving or sliding parts.

 After routing, check that the wire harnesses

are not twisted or kinked.

 Wire harnesses routed along the handlebars

should not be pulled taut, have excessive slack, be pinched by or interfere with adjacent or surrounding parts in all steering positions.

 Do not bend or twist the control cables.

 Damaged control cables will not operate

smoothly and may stick or bind.

 : CORRECT  : INCORRECT

1-11

General Information

R. Front Winker Cord

Engine Stop Switch Cord (Starter Kill Switch Cord)

R. Horn Cord

Horn(Low)

R. Front Winker Cord

Front Brake Hose

R. Rear Winker Cord

Winker Relay

Regulator / Rectifier

Starter Magnetic Cable

Starter Motor Cable

Fuel Meter Code

Horn Sub Harness

Clutch Cable

L. Front Winker Cord

Winker Switch Cord

L. Horn Cord

Horn(High)

Head Light Cord

L. Front Winker Cord

Position Light Cord

Speedometer Cable

Starter Magnetic Switch Cord

Starter Magnetic Switch

Starter Magnetic Cable

L. Rear Winker Cord

Tail Light Sub Cord

C.D.I Cord

C. D. I

1-12

General Information

Wire Harness

Fuel Tube

Fuel Unit cord

Drain Tube

Tacho Meter Cord Combination Cord

Speedometer Cord

Wire Clamp

Brake Hose

Speedometer Cable

Brake Clamp

Speedometer Cable Guide

Cable Grommet

A.C.G Cord

Fuel Tube

Choke Cable

High Tension Cord

Ignition Coil

Choke Cable

Clutch Cable

Engine breather tube

Battery Earth Cable

Clutch Cable

Noise Supperssor

High Tension Cord

Clutch Cable

Front Brake Hose

Cable Guide

Throttle Cable Starter Kill Switch Cord Front Brake Hose

Starter Kill Switch Cord

Throttle Cable

Battery Breather Tube

Cable Guide

Clutch Cable Choke Cable Winker Switch Cord

2-1

Lubrication

Service Information

If the engine must be running to do some work, make sure the area is well ventilated. Never run the

engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area.

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged.

Although it is unlikely to happen unless you handle used oil on a daily basis, it is still advisable to wash your hands thoroughly with soap and water as soon as possible after handling used oil.

The oil pump can be serviced with the engine installed in the frame.

2. Lubrication

Service Information …………………2-1 Specifications ………………………2-1 Troubleshooting ……………………2-2 Engine Oil Level Check ……………2-3

Engine Oil Change …………………2-3 Engine Oil Filter Element Change

…2-4 Oil Pump………………………………2-4 Lubrication Points …………………2-7

Engine oil

1.2

(all capacity)

Oil Capacity

1.15(after oil filter change)

1.1(after oil change)

API Service Classification:SE or SH

Oil

Viscosity:SAE10W-30

Recommendation

10W

20·20W

30

40 20W 50 20W 40 10W 40

10W - 30

10 0 10 20 30 40℃

Pump Body clearance 0.15~0.20(0.006~0.008) 0.25(0.010) Rotor end clearance 0.15(0.006) 0.20(0.008) Pump side clearance 0.05~0.09(0.002~0.004) 0.12(0.005)

Oil Filter Screen Cap 1.5kgf-m(15N.m) Oil Filter Relief Valve Oval Screw 1.2kgf-m( 9N.m) Oil Filter Cover Socket Bolt 1.1kgf-m(11N.m) Oil Pump Mounting Bolt 1.1kgf-m(11N.m)

Item Standard Value Service Limit

Oil Pump

Torque Valves

Unit : mm(in)

2

!

WARNING

△

Specifications

(Other viscosities shown in the chart may be

used when the average temperature in your riding area is within the indicated range.)

2-2

Lubrication

Troubleshooting

Low oil pressure

 Oil level low  Pressure relief valve stuck open  Plugged oil pick-up screen  Oil pump worm  External oil leaks

High oil pressure

 Pressure relief valve stuck closed  Plugged oil filter, gallery, or metering orifice  In correct oil being used

No oil pressure

 Oil level low  Oil pump drive gear broken  Oil pump faulty  Internal oil leakage

2-3

Lubrication

Engine Oil Level Check

 Run the engine and allow it to idle for few

minutes. Stop the engine and place the motorcycle on its center stand.

 After 2-3 minutes, check the oil level with the

filler cap/dipstick.

 Do not screw it in when making this check.  If the oil level is below or near the lower level

mark on the dipstick, add the recommended oil up to the upper level line.

Engine Oil Change

Change engine oil with engine warm and the motorcycle on its side stand to assure complete and rapid draining.

 Remove the oil filter cap.  Remove the oil filter cap, spring, and screen.  Start quick starter arm several times and drain

the oil from the engine.

 Clean the filter screen with clean wash. check

that the oil filter screen and O-ring of the screen cap are in good condition. Assemble filter screen, spring and cap.

Torque : 1.5kgf-m(15N.m)

Fill the crankcase with recommended engine oil. Oil Capacity :

1.2 (After disassembly)

1.15 (After Oil filter change)

1.1 (After oil change)

Oil Recommendation :

DAELIM genuine oil API service classification : SE or SH Viscosity : SAE 10W-30

 Install the oil level gauge.  Start the engine and let it idle for a few minutes.  Stop the engine and check that the oil level is at

the upper level mark. If the oil level is below or near the lower level mark, add the recommended oil up to the upper level mark,

 Make sure if there is no oil leak.

Oil Level Gauge

Oil Filter Cap

Filter Screen

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

Gear Change

Pedal Bolt

!

CAUTION

△

2-4

Lubrication

Engine Oil Filter Element Change



Remove the drain plug and drain the oil. (2-3)

 Remove the oil filter cover bolt, filter cover,

filter element and spring.

 Replace the oil filter element with a new oil

filter.

 Check the operation of the relief valve.  If the relief valve is fully opened when released,

it is in good condition.

 Check if the oil filter seal is in good condition.  Install the filter element spring and filter cover,

and tighten the socket bolt.

Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw : 1.2kgf-m(12N.m)

Oil Pump

Removal

 Remove the right crank case cover. (6-3)  Remove the oil pump mounting bolts, oil

pump, pump plate, and lock pin.

 Clean the oil pump body, inner and outer

rotors with cleaning solvent.

Inspection

 Install the inner and outer rotor into the oil

pump body.

 Measure the pump body clearance.

Service Limit : 0.25mm(0.010 in)

Oil Filter Cover

Filter Element

Oil Pump

Inner Rotor

Outer Rotor

Mount Bolt

2-5

Lubrication

 Measure the rotor end clearance.

Service Limit : 0.20mm(0.008 in)

Disassembly / Assembly

 Remove the inner and outer rotor from pump

body.

 Remove the setting ring, spacer, oil seal and

pump shaft. Clean each parts with cleaning solvent.

 Measure the pump side clearance.

Service Limit : 0.12mm(0.005 in)

 Connect the pump shaft, oil seal, and spacer,

then install into the setting ring.

 Install the inner and outer rotors.

Setting Ring

Outer Rotor

Inner Rotor

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Setting

Ring

Spacer

Pump Body

Pump Shaft

Oil Seal

2-6

Lubrication

 Remove the oval screw, sealing washer, spring

and relief valve from oil filter cover.

 Remove the oil filter element from R. crank

case cover.

 Blow the oil path way of crank case cover with

compressed air, and clean.

Torque Oil filter cover : 1.1kgf-m(11N.m) Oval screw: 1.2kgf-m(12N.m)

 Install the dowel pins and oil pump plate into

the pump body.

 Install the oil pump into the right crank case

cover and tighten the bolt.

Torque : 1.1kgf-m(11N.m, 8ft-lb)

 Install the right crank case cover

Oil Pump Plate

Dowel Pin

Oil Pump

Mount Bolt

2-7

Lubrication

Lubrication points

if there is no specific indication of oil, use general grease to lubricate the lubrication parts. Lubricate the other operation parts which are not shown below with oil or grease.

Control Cable Lubrication

Periodically, disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. Check the cable for loose, replace them if necessary.

Clutch Lever Pivot

Brake Lever Pivot

Throttle Grip

Wheel Bearing

Drive Chain

Brake Caliper

Brake Pedal Pivot

Wheel Bearing Speedometer Gear

Steering Head Bearing

Front Fork Dust Seal

Speedometer Cable, Clutch Cable

Throttle Cable, Choke Cable

Main Stand Pivot

Side Stand Pivot

MEMO

3-1

Maintenance

Service Information

 If the engine must be running to do some work, make sure the area is well ventilated. Never run the

engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area.

 Engine oil and oil filter see page 2-3, 2-4  Before working, stand the main stand.

3. Maintenance

 Throttle grip free play: 26mm(0.078~0.236 in)  Spark plug: CR8EH9  Spark plug gap: 0.80.9mm(0.031-0.035in)  Valve clearance: IN) 0.12 0.02mm(0.005-0.001in)

EX) 0.120.02mm(0.005-0.001in)  Carburetor idle speed: 1,400100(rpm)  Cylinder compression: 14f/(550rpm)  Drive chain free play: 50~60mm(1.968~2.362 in)  Rear brake pedal free play: 20~30mm(0.787~1.181 in)  Clutch lever free play: 10~20mm(0.393~0.787 in)

Specifications

Tires

Driver only

Front 200kPa (2.00kgf/)

Cold tire pressure

Rear 200kPa (2.00kgf/)

Driver and a passenger

Front 200kPa (2.00kgf/)

Rear 200kPa (2.00kgf/)

Tire size

Front 90/90 -18

Rear 130/90 -15

Tire  part minimum-depth

Front 4mm (0.16 in)

Rear 8.5mm (0.3 in)

3

Service Information

…………………3-1 Maintenance Schedule ………………3-3 Fuel Line ………………………………3-4 Throttle Grip Operation………………3-4 Carburetor Choke ……………………3-5 Air Cleaner ……………………………3-5 Spark Plug ……………………………3-6 Valve Clearance ………………………3-6 Cylinder Compression Pressure …3-7 Carburetor Idle Speed ………………3-8 Drive Chain ……………………………3-8 Battery …………………………………3-10

Brake Fluid ……………………………3-10 Brake Pad / Shoe………………………3-10 Brake System …………………………3-11 Brake Stop Switch ……………………3-12 Headlight Adjustment ………………3-12 Clutch……………………………………3-12 Side Stand………………………………3-13 Suspension ……………………………3-13 Bolts, Nuts Fasteners ………………3-14 Wheels / Tires …………………………3-14 Steering Head Bearings ……………3-15

NOTE

3-2

Maintenance

Torque Values

Spark Plug 1.1 kgf-m( 11N.m) Cylinder Head Cover Bolt 1.0 kgf-m( 10N.m) Valve Adjusting Nut 1.1 kgf-m( 11N.m) Timing Hole Cap 0.6 kgf-m( 6N.m) Crankshaft Hole Cap 0.8 kgf-m( 8N.m) Rear Axle Nut 8.8kgf-m(88N.m)

Tools

Common Tool

Wrench, 89 mm Adjuster Wrench Compression Gauge

3-3

Maintenance

＊ Fuel Line I I I I 3-4 ＊ Fuel Filter R R R 3-4 ＊ Throttle Grip Operation I I I 3-4 ＊ Carburetor Choke I I I 3-5

Air Cleaner R R R 3-5 NOTE 2 Spark Plug I R I 3-6

＊ Valve Clearance I I I I 3-6  Engine Oil R R R R 2-3

Engine Oil filter Element R R R R 2-4

＊ Carburetor Idles speed I I I I 3-8

Drive Chain 1,000km : I,L 3-8 Battery Fluid I I I 3-10 Brake Fluid I I I 3-10 NOTE 3 Brake Shoe/Pad I I I 3-10 Brake System I I I I 3-11

＊ Brake Stop Switch I I I 3-12 ＊ Head Light Aim I I I 3-12

Clutch System I I I I 3-12 Side Stand I I I 3-13

＊ Suspension I I I 3-13 ＊ Bolt, Nut Fastener I I 3-14  Wheels/Tires I I I 3-14  Steering Head Bearing I I 3-15

Maintenance Schedule

Perform the Pre-ride inspection in the Owner’s manual at each scheduled maintenance period. I : Inspect and clean, adjust, lubricate or replace if necessary R : Replace L : Lubricate C : Clean

＊Should serviced by an authorized DAELIM dealer, unless the owner has proper tools and service date

and is mechanically qualified.

 In the interest of safety, we recommended these items be serviced only by an authorized DAELIM

dealer.

NOTES:

1. After high odometer reading 12,000km(7,500mi), repeat at the frequency interval established here.

2. Service more frequently when riding in unusual wet or dustry areas

3. Replace every 2 years. In case of replacing, proper skills are needed.

Item

Frequency

Remark

Refer to

Page

Odometer Reading (NOTE 1)

1,000km 4,000km 8,000km

12,000km

61218

3-4

Maintenance

Fuel Line

 Check the fuel lines for deterioration, damage,

or leakage. Replace the fuel lines.

Throttle Grip Operation

 Check the throttle grip for smooth operation.  Complete opening and automatic closing in

all steering positions.

 Lubricate the throttle cables if throttle

operation is not smooth (2-7)

 Make sure if there is no deterioration,

damage, or kinking in the throttle cables.

 Measure the throttle grip free play at the

throttle grip flange.

Free Play : 2~6mm(0.078~0.236in)

 Adjust the free play by loosening the lock nut

and turning the adjuster. Tighten the lock nut.

 Recheck the throttle free play.

Fuel Cock

Fuel Tube

Choke Cable

Lock Nut

Adjuster

3-5

Maintenance

Carburetor Choke



Make sure if there is no deterioration, damage or kinking in the choke cable. Check for smooth chock lever operation at any adjusting position.

 Pull the choke lever forward all the way up to

fully closed. Make sure that the choke valve is

fully closed by moving the choke arm If

necessary, adjust the choke valve up to the fully

opened position by loosening the choke cable

clamp and moving the choke cable cover.

 Depress the choke lever forward up to the fully

opened position. Make sure that the choke

valve is fully opened by checking the operation

between the choke arm and cable cover.

 Recheck the carburetor choke free play.

Air Cleaner



Loosen the four screw, and remove the air cleaner case cover.



Loosen the three screw, and remove the air cleaner element.

Choke Lever

Fuel Cock

Choke Cable

Fuel Tube

3-6

Maintenance



Make sure if there is no deterioration and damage in the air cleaner element. Replace damaged parts.



The element is a viscous type which contains oil. Therefore do not use compressed air to clean the air cleaner element.



Assemble the Air cleaner element in the reverse order of removal

Spark Plug



Remove the spark plug cap and spark plug.



Check any dirt, damage from around the spark plug bases. If necessary, clean away the dirt from around the spark plugs with a plug cleaner or a wire brush.



Measure the new spark plug using a wire-type feeler gauge. Adjust the gap by bending the side electrode carefully.

Pure Plug : CR8EH-9 Spark Plug Gap : 0.8~0.9mm



Install the plug by turning with finger.

Tighten it with plug wrench.

Torque: 1.1kgf.m(11N.m)

Install the spark plug caps

Valve Clearnance



Perform valve inspection/adjustment with the engine at normal operating temperature (Below 35 / 95)

Remove the cylinder head cover. Align the “T” mark on the flywheel with the index mark on the left crank case cover, turning the flywheel to the left. At this time, the piston should be placed on the groove of the compression stroke.

Element

ElementElement

Element

Check the Washer For damage

Check the Plug for Cracks

Check the Plug for Clearance, Contamination Deposit

0.8~0.9mm

A.C Generator Cap

A.C Generator CapA.C Generator Cap

A.C Generator Cap

NOTE

3-7

Maintenance



Measure the valve clearance with filler gauge.

Valve Clearance: Intake: 0.120.02mm(0.050.001in) Exhaust: 0.120.02mm(0.050.001in)



Loosen the lock nut with a valve wrench, and adjust the adjuster screw to the standard clearance using a valve adjusting wrench. When the standard clearance is done, hold the adjuster screw with a valve adjusting wrench. And then tighten the lock nut.

Torque : 1.1kgf-m(11N.m) Tools : Wrench 89mm

Adjusting wrench



Measure the valve clearance again.



After connecting the cylinder head cover, tighten the bolt.

Torque : 1.0kgf-m(10N.m)



Install the timing hole cap and crank case hole cap.

Timing Hole Cap : 0.6kgf-m(6N.m) Crank Case Hole Cap : 0.8kgf-m(8N.m)

Cylinder Compression Pressure

 Warm up the engine to normal operating

temperature.

 Stop the engine, disconnect the spark plug

caps and spark plug. Install the compression gauge.

 Open the throttle all the way and crank the

engine with the starter motor until the gauge reading stops rising.

Tool: Compression gauge

 The maximum reading is usually reached

within 4~7 seconds.

Compression Pressure : 14.0f/(550rpm)

If compression is low, check the following:

 Incorrect valve clearance adjustment  Valve for leakage  Exposed cylinder head from the gasket  Worn piston/cylinder

If compression is high, check the following:

 Carbon deposits on the piston head, cylinder

head

Filler Gauge

Filler GaugeFiller Gauge

Filler Gauge

Adjusting Wrench

Adjusting WrenchAdjusting Wrench

Adjusting Wrench

Cylinder Head Cover Bolt

Cylinder Head Cover BoltCylinder Head Cover Bolt

Cylinder Head Cover Bolt

Compression Gauge

Compression GaugeCompression Gauge

Compression Gauge

NOTE

3-8

Maintenance

Carburetor Idle Speed

Inspect all other engine adjustments are within

specifications and adjust idle speed.

The engine must be warm for accurate

adjustment. Support the motorcycle on a level surface and shift the transmission into neutral. Check the idle speed and adjust by truning the throttle stop screw if necessary.

Drive Chain

Stop the engine to inspect the drive chain,

otherwise fingers can be caught in the drive chain while the drive chain is operating.

Chain Free Play Adjustment

 Stop the engine and shaft the gear into neutral,

support the motorcycle on a level surfase.

 Remove the chain tensioner.  Move the position of chain tensioner roller up

and down with hands to check if the chain free play is within recommended range.

Free Play: 50~60mm

 If necessary, adjust the drive chain free play.

 Adjust by loosening the axle nut and lock nuts

in the right/left chain adjusters and turning the adjusting nut.

Adjust the chain adjuster reading scale into the

same place in the right and left sides. Tighten the axle nut

Torque: 88kgf-m(88N.m)

Throttle Stop Screw

Throttle Stop ScrewThrottle Stop Screw

Throttle Stop Screw

Retainer Clip

Retainer ClipRetainer Clip

Retainer Clip

NOTE

Removal/Inspection

 Inspect the drive chain for contamination.

50~60mm

3-9

Maintenance

Installation

 After assembling the chain tensioner, keep the

upper part of bracket which is holding chain tensioner-roller to the underline of rear swing arm under pipe.

 Install the drive chain with the closed area of

the clip facing to the proceeding direction. While driving, master link will be removed suddenly when facing to the opposite direction.

Check for the master link-to-retainer clip clearance.

 Inspect the drive chain for adherence and

damaging.

 Remove the contamination with a cleaner.

After drying completely, coat the chain with #80-90 gear oil. Wipe any excessive oil off the chain, check the drive chain for wear and damage, replace it if necessary.

 Check the drive sproket for wear and damage.  Replace it if necessary.

New motocycle adapts endless-type drive chain

(end-type for after-sales service purpose)

After once disassembling chain, chain clip can

be accidentally removed, so even change new one after disassembling chain once.

 If the chain or sprocket requires replacement,

the chain and sproket must be replaced as a set.

 Inspect the rollar for wear and damage, and

remove the chain tensioner

Service limit: 30.5mm

RR. Brake Pedal Return Spring

RR. Brake Pedal Return SpringRR. Brake Pedal Return Spring

RR. Brake Pedal Return Spring

Chain Tensioner Rollar

Chain Tensioner RollarChain Tensioner Rollar

Chain Tensioner Rollar

Chain Tensioner Braket

Chain Tensioner BraketChain Tensioner Braket

Chain Tensioner Braket

Flange Bolt

Flange BoltFlange Bolt

Flange Bolt

Dry

Gear Oil(#80-90)

NOTE

Chain tensioner

3-10

Maintenance

Brake Pad/Shoe

Brake Pad Replacement

 Check the brake pads for wear. Replace the

brake. If the red marks in the pads reach to the brake.(15-4)

 Always replace the brake pads as a set to

assure even disc pressure.

Brake Fluid

 Check the fluid level of the front brake

reservoir. If the level nears the lower level, remove the cover set plate and diaphram. Fill the reservoir to the upper level with DOT 3 or DOT 4 fluid from a sealed container. Check the system for leaks.

 Do not allow dust or water to enter the system

when filling the reservoir.

 Do not remove the reservoir cover until the

reservoir is level.

 Avoid spilling the fluid on painted, plastic, or

rubber parts.

Battery

 Remove the right side cover.  Inspect the battery electrolyte level. When the

level nears the lower level, add distilled water to the upper level.

 Add only distilled water.  Avoid spilling the fluid of battery on other parts.

 The battery contains sulfuric acid(electrolyte).

Contact with skin or eyes may cause severe burns. If electrolyte gets on your eyes, flush with water for at least 15 minutes and call a physician.

 Replace the battery when there is white electro

deposits inside battery or residuals in the bottom of the cell from the electrodetype.

Master Cylinder

Master CylinderMaster Cylinder

Master Cylinder

Brake Hose Bolt

Brake Hose BoltBrake Hose Bolt

Brake Hose Bolt

“UP” Mark

“UP” Mark“UP” Mark

“UP” Mark

Pad Mark

NOTE

!

CAUTION

△

!

CAUTION

△

!

CAUTION

△

3-11

Maintenance

Brake Shoe Replacement

 Replace the brake shoes if the arrow on the

brake arm aligns with the reference mark  on full application of the rear brake pedal.

Brake System

 Inspect the front brake hoses for deterioration,

cracks. If there are signs of leakage, replace them as soon as possible. Replace hoses as required.

 Inspect the rear brake pedal and brake rod for

looseness or damage. Tighten any loose fittings. Replace them if necessary.

Brake Pedal Height

 Perform brake pedal clearance adjustment

after adjusting brake pedal height.

Free play: 20~30mm(0.787~1.181in)

 If adjustment is necessary, use the rear brake

adjusting nut.

 after adjusting the brake pedal free play, check

the rear brake light switch operation and adjust it if necessary.

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

▵

Mark

Arrow

ArrowArrow

Arrow

Brake Hose

Brake HoseBrake Hose

Brake Hose

Brake Caliper

Brake CaliperBrake Caliper

Brake Caliper

Brake Hose Bolt

Brake Hose BoltBrake Hose Bolt

Brake Hose Bolt

Adjusting Nut

Adjusting NutAdjusting Nut

Adjusting Nut

3-12

Maintenance

Headlight Adjustment

 Adjust the headlight beam by turning the case

adjustment screw.

 Adjust the headlight beam as specified by local

laws and regulations.

 An improperly adjusted headlight may blind on

coming drivers, or it may fail to light a road for a safe distance.

Height Adjustment

 Adjust the brake pedal height to 10-20mm.

 The adjustment faulty of height may caused

that the brake runs in state of operation. Loosen the lock nut, and then adjust the height by turning the brake pedal stoper bolt. After adjusting, tighten the lock nut securely.

 After adjusting the brake pedal height, inspect

the operation of rear brake light switch and brake pedal, and adjust them if necessary.

Brake Stop Switch

 Adjust the brake light switch so that the brake

light may come on, when the brake pedal is depressed, and brake engagement begin. Hold the switch body and turn the adjusting nut.

Clutch

 Measure the clutch system free play at the end

of clutch lever.

Free Play: 10~20mm(0.393~0787 in)

Stoper Bolt

Stoper BoltStoper Bolt

Stoper Bolt

Stop Switch

Stop SwitchStop Switch

Stop Switch

Adjust Nut

Adjust NutAdjust Nut

Adjust Nut

Bolt

BoltBolt

Bolt

!

CAUTION

△

!

CAUTION

△

NOTE

3-13

Maintenance

Suspension

 Do not ride a vehicle with a faulty suspension.

Loose, worn or damaged suspension parts impair vehicle stability and control.

Front

 Check the action of the fork by compressing

the front suspension several times.

 Check the entire fork assembly for leaks,

damage, or looseness.

 Perform the light adjustment by loosening the

lock nut from the handle and turning the adjuster.

 Perform the main adjustment by loosening the

lock nut from the engine and turning the adjusting nut.

 Tighten the lock nut.  Inspect the clutch operation.

Side Stand

 Set up the main stand.  Check of smooth operation, when pulling the

low end part of the side stand.

 If the side stand is hard, coat the pivot with

grease.

 If the side stand moves too freely, inspect the

side stand spring. Make sure that the side stand is not bent.

Lock Nut

Lock NutLock Nut

Lock Nut

Adjuster

AdjusterAdjuster

Adjuster

Lock Nut

Lock NutLock Nut

Lock Nut

Adjust Nut

Adjust NutAdjust Nut

Adjust Nut

!

CAUTION

△

3-14

Maintenance

Rear

 Check the action of the rear cushion by

compressing them several times. Check the rear cushion for leaks, damage, or looseness.

 Support the motorcycle with a main stand.  Check for worn rear fork bush by attempting

to move the wheel side to side. Replace the bearings if any looseness is noted. Tighten all nuts and bolts of the rear suspension.

Bolts, Nuts Fasteners

 Check that all nuts and bolts are tightened to

correct torque values.

 Check that all cotter pins, safety clips, hose

clamps and cable stays are in place. (3-3)

Wheels/Tires

 Tire pressure should be checked when the tires

are cold.

 Check the tires for cuts, embedded nails, or

other damage. Replace them if necessary.

Recommended Tire Pressure

: kgf/cm2(kPa)

Front Rear

1 Person 2.00(200) 2.00(200) 2 Person 2.00(200) 2.00(200)

NOTE

3-15

Maintenance

 Measure the tread depth at the center of the

tire.

 Replace the tire when the tread depth reaches

the following limits:

Minimum Tread Depth: 4mm (0.16 in)

8.5mm (0.3 in)

Steering Head Bearings

 Check that the control cables do not interfere

with handle bar rotation.

 Raise the front wheel off the ground. Check

that the handle bar moves freely from side to side. If the handle bar moves unevenly, bends, or has vertical movement, inspect the cables and electric code wires. If the handle bar moves too freely, adjust the steering head bearings.

NOTE

Fuel System

4-0

4-1

Fuel System

Item Specifications

Setting Mark VL125 B Main Jet #102 Slow Jet #38 Jet Needle Clip Second Float Level 19mm Pilot Screw Initial Opening 2 Idle Speed 1,400100(rpm) Throttle Grip Free Play 2~6mm

Service Information

General

 Gasoline is extremely flammable and is explosive under certain conditions.

Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refuelled.

 If the engine must be running to do some work, make sure the area is well ventilated.

Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhausted evacuation system in an enclosed area.

 Bending or twisting the control cables will impair smooth operation and may cause the cables stick or

blind to result in loss of vehicle control.

 When disassembling fuel system parts, note the locations of the O-rings.  Replace them with new ones on assembly.  The float bowls have drain screws that can be loosened to drain residual gasoline.

Specifications

Fuel Tank Capacity 17.3 Reserve Fuel Capacity 2.9

If the vehicle is to be stored for more than one month, drain the float chambers. Fuel left in the float chambers may cause clogged jet to result in hard starting or poor drive ability

4. Fuel System

Service Information

…………………4-1 Troubleshooting ………………………4-2 Fuel Tank ………………………………4-3 Air Cleaner Case………………………4-4

Throttle Valve …………………………4-5 Carburetor………………………………4-6 Accelerator Adjustment ……………4-11

Carburetor Specifications

4

!

WARNING

△

NOTE

!

CAUTION

△

4-2

Fuel System

Troubleshooting

Engine cranks but wont start

 No fuel in tank  No fuel to carburetor  Engine flooded with fuel  Clogged air cleaner  No spark at plug(Ignition system faulty)

Rough idle, hard starting or stalling starting

 Incorrect idle ring adjustment  Lean mixture, rich mixture  Clogged air cleaner  Faulty air cut off valve  Clogged fuel system

Lean mixture

 Clogged carburetor jets  Clogged fuel tank breather  Clogged fuel strainer screen  Restricted fuel tube  Faulty float valve  Low float level

Rich mixture

 Choke valve closed  Faulty float valve  Float level too high  Clogged air jets

Misfiring during acceleration

 Faulty accelerator pump

Torque

Air cleaner case cover screw 0.43kg-m (4.3N.m, 3.1ft-lb)

Tools

Float level gauge

4-3

Fuel System

Fuel Tank

Removal

 Gasoline is extremely flammable and is

explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refueled.

 Loosen the speedometer cable screw.  Remove the L. front side cover.  Remove the seat.( 12-2)  Turn the fuel cock OFF and remove the fuel

tube.

 Remove a fuel tank mounting bolt.  Remove fuel unit wire coupler.  Remove the fuel tank.

 If there is not enough fuel supply from the fuel

cock, drain the gasoline from the tank and clean the strainer screen after removing the fuel cock.

Installation

 Install the fuel tank in the reverse order of

removal.

 Check for the oil leakage.

 When the fuel is needed, the fuel alarm lamp is

lighted.

 Fill the fuel at gas station.

Fuel Tube

Fuel TubeFuel Tube

Fuel Tube

Fuel Cock

Fuel CockFuel Cock

Fuel Cock

Choke Cable

Choke CableChoke Cable

Choke Cable

Fuel Tank

Fuel TankFuel Tank

Fuel Tank

Bolt

BoltBolt

Bolt

!

WARNING

△

!

CAUTION

△

Fuel Meter

Fuel Cock

Fuel Tank

4-4

Fuel System

Air Cleaner Case

Removal

 Remove the L. side cover.  Remove the air cleaner connecting tube band

out of the air cleaner side. Remove the battery.

 Remove the air cleaner mounting bolt.  Remove the air cleaner case.

Installation

 Installation is essentially the reverse order of

removal. Install the air cleaner case cover screw.

Air Cleaner Case Cover

Air Cleaner Inlet Duct

Air Cleaner

Connecting Tube

Air Cleaner Case

Element

Air Cleaner Inlet Cover

4-5

Fuel System

Throttle Valve

Removal

 Remove the R. side cover.  Remove the seat and the fuel tank. Loosen the

carburetor top slowly and remove the throttle valve.

 Remove the throttle cable connection out of

the throttle valve, then remove the throttle valve.

 Remove the throttle valve spring, carburetor

top out of the throttle cable.

 Remove the retainer clip and jet needle. Inspect

the jet needle, throttle valve for damage and wear.

Carburetor Top

Carburetor TopCarburetor Top

Carburetor Top

Spring

SpringSpring

Spring

Throttle Valve

Throttle ValveThrottle Valve

Throttle Valve

Carburetor Top

Carburetor TopCarburetor Top

Carburetor Top

Spring

SpringSpring

Spring

Throttle Valve

Throttle ValveThrottle Valve

Throttle Valve

Retainer Clip

Retainer ClipRetainer Clip

Retainer Clip

Jet Needle

Jet NeedleJet Needle

Jet Needle

4-6

Fuel System

Carburetor

Removal

 Remove the fuel tank and seat( 4-3)  Remove the carburetor top( 4-5)  Remove the carburetor drain screw and drain

gasoline from the carburetor.

 Gasoline is extremely flammable and is

explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the area where gasoline is drained or stored and where the fuel tank is refuelled.

 Remove the choke cable.  Loosen the air cleaner connecting tube band.

Installation

 Install the jet needle, retainer clip into the

throttle valve.

 Needle clip standard position: 2nd Level  Install the carburetor top, spring into the

throttle cable.

 Install the throttle cable into throttle valve.

 Install the carburetor aligning the throttle valve

groove with the throttle stop screw.

 Inspect the following items.

- Throttle grip free play:2~6mm

- Idling speed:1,400100 rpm

Spring

SpringSpring

Spring

Carburetor Top

Carburetor TopCarburetor Top

Carburetor Top

Lean Mixture

First Level

Standard

2nd Level

3rd Level

Rich Mixture

Throttle Valve

Throttle ValveThrottle Valve

Throttle Valve

Throttle ValveThrottle Valve

Throttle Valve

Choke Cable

Choke CableChoke Cable

Choke Cable

Drain Screw

Drain ScrewDrain Screw

Drain Screw

Throttle Stop Screw

Throttle Stop ScrewThrottle Stop Screw

Throttle Stop Screw

!

CAUTION

△

4-7

Fuel System

 Remove the throttle cable.  Loosen the carburetor mounting nut, and

remove the carburetor.

Disassembly

 Remove the fuel and drain tube.

Accelerator Pump

 Take of the 3 screws, and remove the pump

cover.

 Remove the spring.  Inspect the damage of Accelerator pump rod

and diaphragm. Blow the fuel pathway of diaphragm with air lightly and clean the clogged place.

Drain Tube

Drain TubeDrain Tube

Drain Tube

Diaphragm

DiaphragmDiaphragm

Diaphragm

Spring

SpringSpring

Spring

Screw

ScrewScrew

Screw

Pump Cover

Pump CoverPump Cover

Pump Cover

Fuel Tube

Fuel TubeFuel Tube

Fuel Tube

4-8

Fuel System

 Align the diaphragm projecting part with float

chamber groove. Install the spring to diaphragm cover, and install the cover to the float chamber preventing the diaphragm form damaging.

 Adjust the accelerator pump.

Float, Float Valve

 Take off the 3 screws and remove the float

chamber.

 Take off the float arm pin, and remove the float

and float valve.

 Inspect the wear and tear of the part facing

valve seat.

 Inspect transformation of float, and whether

the gasoline is inhaled to the inside of float.

Groove

GrooveGroove

Groove

Projecting Part

Projecting PartProjecting Part

Projecting Part

Screws

ScrewsScrews

Screws

Float Chamber

Float ChamberFloat Chamber

Float Chamber

Float Valve

Float ValveFloat Valve

Float Valve

Float

Float Float

Float

Float Arm Pin

Float Arm PinFloat Arm Pin

Float Arm Pin

Float Valve

Float ValveFloat Valve

Float Valve

Valve Set

Valve SetValve Set

Valve Set

4-9

Fuel System

Jet

 Remove the main jet, needle jet holder, and

needle jet. Remove the slow jet, Remove the pilot screw after recording the number of turns until the pilot screw is tightened to clockwise completely.

 Do not tighten up the Pilot screws by force.

It can cause the damaging of the seat part.

 Remove the throttle stop screws.  Clean the jet with cleaning solvent.  Inspect the pilot screws and jets and change the

wear and tear parts with new ones.

Installation

!

CAUTION

△

Main Jet

Main JetMain Jet

Main Jet

Needle Jet Holder

Needle Jet HolderNeedle Jet Holder

Needle Jet Holder

Slow Jet

Slow JetSlow Jet

Slow Jet

Throttle Stop Screws

Throttle Stop ScrewsThrottle Stop Screws

Throttle Stop Screws

Needle Jet

Needle JetNeedle Jet

Needle Jet

Pilot Screws

Pilot ScrewsPilot Screws

Pilot Screws

4-10

Fuel System

 Blow each jet and body pathway with compressed

air, and clean the clogged place.

 Install the needle jet, needle jet holder, main jet

and slow jet. Install the throttle stop screw and pilot screw.

 After tighten the pilot screw completely, back

it out according to the recorded turns when removing.

 If installing the new pilot screw, adjust the

pilot screw.

 Install the float valve, float, and float arm pin.

Oil Level Adjustment

 Measure the oil level height in the state of

contacting with float valve and float arm by inclining the carburetor.

Standard Level:19mm Tool : Float level gauge

 Check the smooth operation of float.

!

CAUTION

△

Throttle Stop Screw

Throttle Stop ScrewThrottle Stop Screw

Throttle Stop Screw

Main Jet

Main JetMain Jet

Main Jet

Float Arm Pin

Float Arm PinFloat Arm Pin

Float Arm Pin

Float Valve

Float ValveFloat Valve

Float Valve

Float

FloatFloat

Float

Float Level Gauge

Float Level GaugeFloat Level Gauge

Float Level Gauge

4-11

Fuel System

Accelerator Adjustment

 Do not adjust unless replacing the adjuster

screws.

 Adjust the idling.( 3-8)  Adjust the operation of throttle grip.( 3-4)  Loosen the lock nut, turn the adjuster screws to

contact with accelerator pump cap, and then adjust the accelerator pump rod clearance.

 Tighten the lock nut.

Clearance : 0mm (0in)

 Install the new o-ring to the float chamber

groove.

 Install the float chamber and screws.

Assembly

Install the fuel tube and drain tube.

 Install the new o-ring into carburetor intake

flange.

 Assemble the carburetor between carburetor

insulator and connecting tube. Install the carburetor assembly nut and tighten the connecting tube bend screw.

 Connect the choke cable and throttle cable.  Adjust the chock cable.( 3-5)  Install the throttle valve.( 4-5)  Adjust the throttle grip clearance.( 3-4)

Fuel Tube

Fuel TubeFuel Tube

Fuel Tube

Drain Tube

Drain TubeDrain Tube

Drain Tube

Connecting Tube

Connecting TubeConnecting Tube

Connecting Tube

Throttle Stop Screw

Throttle Stop ScrewThrottle Stop Screw

Throttle Stop Screw

Carburetor

Carburetor Carburetor

Carburetor

!

CAUTION

△

Float Level Chamber

Float Level ChamberFloat Level Chamber

Float Level Chamber

O-Ring

O-RingO-Ring

O-Ring

4-12

Fuel System

Pilot Screw Adjustment

1. Turn each pilot screw clockwise until it seats lightly and back it out to the specification given.

Initial Opening : 2

 Damages to the pilot screw seat will occur if

the pilot screw is tightened against the seat.

2. Warm up the engine to operating temperature.

Adjust the number of turns to the 1,400 100rpm with the throttle stop screw.

3. Turn the pilot screws out by

turn each until

engine speed does not increase.

4. Perform steps 2 and 3.

5. Adjust the idle speed with the throttle stop screw.

6. Pull the throttle grip lightly. If the idle speed changes, perform steps from 2 to 5.

Pilot Screw

Pilot ScrewPilot Screw

Pilot Screw

!

CAUTION

△

5-1

Engine Removal/Installation

5. Engine Removal/Installation

Service Information

…………………5-2

Engine Removal ………………………5-3

Engine Installation………………………5-4

5

5-2

Engine Removal / Installation

Service Information

General

● A floor jack or other adjustable support is required to support and maneuver the engine.

Be careful not to damage the frame, engine body, cables, wire system.

● The following parts or components can not be served with the engine installed in the frame.

● Cylinder head, valve(⇨ Chapter 8)

● Cylinder, piston(⇨ Chapter 9)

● Transmission, kick starter(⇨ Chapter 10)

● Crank shaft(Chapter 10)

Specification

● Engine oil capacity 1.2ℓ

Torque Values

● Engine hanger bolt(Front 1) 2.7kgf-m(27N.m)

(Front 1, Rear 2) 4.9kgf-m(49N.m)

● Gear change arm bolt 1.2kgf-m(12N.m)

● Drive sprocket bolt 1.2kgf-m(12N.m)

5-3

Engine Removal / Installation

Engine Removal

● Drain the engine oil.(⇨2-3)

● Remove the following

- Side cover(⇨ 12-2)

- Seat(⇨ 12-2)

- Fuel tank(⇨ 4-3)

- Mufflers(⇨ 12-3)

● Disconnect the connector of the starter motor

cable, AC generator wire, gear change switch wire.

● Remove the battery negative cable, clutch cable,

high tension code. Remove the carburetor.

● Remove the gear change pedal, L. rear cover

drive sprocket cover.

● Remove the rear axle nut, drive chain adjuster.

● Remove the drive sprocket after pushing the

rear wheel forward.

● Remove the front engine hanger bolt, engine

hanger bracket.

● Remove the rear engine hanger bolt.

Screw

ScrewScrew

Screw

Drive Sprocket

Drive SprocketDrive Sprocket

Drive Sprocket

Drive Chain Guide

Drive Chain GuideDrive Chain Guide

Drive Chain Guide

Clutch Cable

Clutch CableClutch Cable

Clutch Cable

High Tension Code

High Tension CodeHigh Tension Code

High Tension Code

5-4

Engine Removal / Installation

Engine Installation

Engine installation is essentially the reverse order of removal.

• Carefully align mounting points with the jack to prevent damage from mounting bolt threads and wire harness and cables.

• Be careful not to damage any part of the frame and bolt nuts.

• Be sure to install the cables, tubes, and wires to their correct positions(⇨ 1-11~13).

Torque Engine hanger bolts:

(Front 1) 2.7kgf-m(27N.m)

(Front 1, Rear 2) 4.9kgf-m(49N.m) Gear change arm bolt 1.2kgf-m(12N.m) Drive sprocket bolt 1.2kgf-m(12N.m)

● Inspect the following after installing the engine.

- Engine oil

- Throttle glip operation

- Clutch lever operation

- Drive chain

NOTE

MEMO

6-0

Clutch, Gearshift

6-1

Clutch, Gearshift

6. Clutch / Gearshift

Service Information …………………6-1

Troubleshooting ……………………6-2 R. Crankcase Cover Dissembly …6-3 Clutch Disassembly…………………6-4

Gearshift Linkage……………………6- 7 Clutch Installation …………………6- 9 Primary Drive Gear …………………6-10 R. Crank Case Cover ………………6-11

Service Information

● The clutch, gearshift linkage can be serviced with the engine in the frame.

● If the shift fork, drum and transmission require service, remove the engine and separate the crank case.

● The quality and level of fluid affect clutch operation. If the clutch slips, check the fluid level before

servicing the clutch system.

Specifications

Item Standard Service Limit

Spring Free 35.5(1.40) 34.2(1.35) Disk Thickness 2.9~3.0(0.114~0.118) 2.6(0.10)

Clutch Plate Warpage 0.2(0.01)

Clutch Outer O.D 28.000~28.013(1.1024~1.1029) 28.030(1.1035) Clutch Outer Guide(O.D.) 27.967~27.980(1.1011~1.1016) 27.950(1.1004)

Torque Values

Clutch lock nut 6.5kgf-m(65N.m)-Apply engine oil Drum stopper arm bolt 1.2kgf-m(12N.m) Primary drive gear bolt 6.5kgf-m(65N.m)-Apply engine oil Right crank case cover bolt 1.1kgf-m(11N.m) Kick starter pedal bolt 2.2kgf-m(22N.m)

Tools

Special

Clutch center holder

Common

Lock nut wrench Extension bar Flywheel holder

Unit:mm(in)

6

6-2

Clutch, Gearshift

Troubleshooting

Clutch operation problem can be corrected by adjusting a cable free play.

Clutch lever pull too hard

● Damaged, clogged or sticking clutch cable

● Damaged lifter mechanism

● Damaged clutch lifter plate bearing

● Incorrect wiring of clutch cable

Clutch slips

● Too big clutch lever free play

● Clutch plate warpage

● Clutch lock nut loose

● High fluid level or high fluid weight

Clutch disengages

● Sticking lifter hydraulic system

● Worn disks

● Weak spring

● Too small clutch lever free play

Difficult to thrust the gear level

● Incorrect clutch adjustment(too big free play)

● Bent shift fork

● Bent shift fork shaft

● Damaged gear shift spindle

● Damaged shift drum guide groove

● Damaged shift drum guide pin

Gear jumps out

● Worn gear dog

● Bent shift fork shaft

● Damaged shift drum stopper

● Worn shift drum guide groove

● Worn gear shift fork groove

6-2

6-3

Clutch, Gearshift

R. Crankcase Cover

Disassembly

● Drain the engine oil(⇨ 2-3)

● Remove the kick starter pedal.

● Remove the clutch adjusting lock nut and

adjusting nut. Separate the clutch cable from the clutch arm.

● Remove the cable out of the cable holder.

● Remove the right crank case cover bolt and

remove the cover.

● Remove the dowel pins and gasket.

Clutch Arm/Lift Shaft Removal

● Remove the lifter rod, and separate the clutch arm/lift Shaft and clutch arm spring from the R. crank case cover.

Kick Starter Pedal

Kick Starter PedalKick Starter Pedal

Kick Starter Pedal

Right Crank Case Cover

Right Crank Case CoverRight Crank Case Cover

Right Crank Case Cover

Dowel Pin

Dowel PinDowel Pin

Dowel Pin

Clutch Arm

Clutch ArmClutch Arm

Clutch Arm

Lift Rod

Lift RodLift Rod

Lift Rod

Lifter Rod

Clutch Cable Holder

Clutch Cable HolderClutch Cable Holder

Clutch Cable Holder

6-4

Clutch, Gearshift

● Separate the clutch arm spring and o-ring from the clutch arm/lift shaft.

● Inspect the wear and damage of the lifter rod and clutch arm/lift shaft.

● Inspect the wear and damage of the clutch arm spring.

Clutch Arm/Lifter Shaft Assembly

● Coat the new o-ring with grease, and assemble the clutch arm/lifter shaft. Install the clutch arm spring to the clutch arm/lifter shaft.

● Install the spring ends into the hole of the lifter shaft.

● After installing the clutch arm/lifter shaft into the R. crankcase cover, turn the clutch arm to the right and install the lifter rod aligning the shaft with cover hole.

Clutch Disassembly

● Remove the following

● Clutch spring bolts

● Clutch lifter plate

● Clutch spring

• Loosen the clutch spring bolt in a crisscross

pattern in two or three steps and remove the bolts.

NOTE

Clutch Spring Bolt

Clutch Spring BoltClutch Spring Bolt

Clutch Spring Bolt

Lifter Plate

Lifter PlateLifter Plate

Lifter Plate

Clutch Arm Spring

Clutch Arm SpringClutch Arm Spring

Clutch Arm Spring

O-ring

O-ringO-ring

O-ring

Clutch Arm Spring

Clutch Arm SpringClutch Arm Spring

Clutch Arm Spring

Hole

HoleHole

Hole

O-ring

O-ringO-ring

O-ring

Spring Ends

Spring EndsSpring Ends

Spring Ends

Lift Rod

Lift RodLift Rod

Lift Rod

Lifter Rod

6-5

Clutch, Gearshift

● Press the clutch center using the clutch center holder and remove the clutch lock nut.

Tools:

Clutch Center Holder Lock Nut Wrench, 20×24mm Extension Bar

● Remove the lock washer.

● Remove the clutch center, disk, plate, and

pressure plate.

● Remove the spline washer and clutch outer.

● Remove the clutch outer guide and thrust

washer.

Lock Nut Wrench

Lock Nut WrenchLock Nut Wrench

Lock Nut Wrench

Extension Bar

Extension BarExtension Bar

Extension Bar

Disks and Plates

Disks and PlatesDisks and Plates

Disks and Plates

Clutch Center

Clutch CenterClutch Center

Clutch Center

Pressure Plate

Pressure PlatePressure Plate

Pressure Plate

Lock Wesher

Lock WesherLock Wesher

Lock Wesher

Spline Washer

Spline WasherSpline Washer

Spline Washer

Clutch Outer

Clutch OuterClutch Outer

Clutch Outer

Outer Guide

Thrust Washer

Thrust WasherThrust Washer

Thrust Washer

6-6

Clutch, Gearshift

Inspection

● Inspect the lifter plate bearing for scoring and other damage.

● Inspect the lifter plate for damage.

● If necessary, replace them.

● Measure the clutch spring free height.

● Service Limit:34.2mm(1.35in)

● Check the clutch disk. If necessary, replace it.

● Measure the disk amplitude.

Service Limit: 2.6mm(0.10 in)

● Check the plate for warpage on a surface plate, using a feeler gauge.

Service Limit: 0.2mm(0.01 in)

•

If any of the disk and plate requires replacement, it must be replaced as a set.

NOTE

Lifter Plate

Lifter PlateLifter Plate

Lifter Plate

Bearing

BearingBearing

Bearing

6-7

Clutch, Gearshift

● Check the slots  in the clutch outer for nicks or indentations made by the clutch discs. If necessary replace them.

● Measure the clutch outer inside diameter.

Service Limit:28.030mm(1.1035in)

● Measure the clutch outer guide outsider diameter.

Service Limit:27.950mm(1.1004in)

Installation

● Installation is essentially the reverse order of removal.

Gear Shift Linkager

Removal

● Remove the following:

- Gear change pedal from the gear shift spindle

- Right crank case cover

- Clutch ass’y

● Remove the gear shift spindle and thrust washer.

● Remove the gear shift cam bolt, cam, and dowel pins.

● Remove the drum stopper arm bolt, stopper arm, collar, and spring.

Gear Change Pedal

Gear Change PedalGear Change Pedal

Gear Change Pedal

Thrust Washer

Gear Shift Spindle

Gear Shift Cam

Gear Shift CamGear Shift Cam

Gear Shift Cam

Bolt

BoltBolt

Bolt

Drum Stopper Arm

Drum Stopper ArmDrum Stopper Arm

Drum Stopper Arm

Gear Shift Cam

Gear Shift CamGear Shift Cam

Gear Shift Cam

Bolt

BoltBolt

Bolt

Spring

SpringSpring

Spring

Drum Stopper Arm

Drum Stopper ArmDrum Stopper Arm

Drum Stopper Arm

6-8

Clutch, Gearshift

Installation

● Install the drum stopper arm collar, spring, stopper arm, and bolt. Tighten the bolts.

Torque:1.2kgf-m(12N.m)

Inspection

● Check the gear shift spindle for wear or damage.

● Inspect the gear shift plate for deformation, wear, or other damage.

● Check the return spring and gear shift plate spring for wear or damage.

● Press the stopper arm, and install the cam, aligning the dowel pin with the gear shift hole.

● Install the thrust washer into the gear shift spindle.

● Install the gear shift spindle into the crank case, aligning the teeth of the return spring with the tappet of the right crank case as shown.

զ

Part

Collar

Stopper Arm

Thrust Washer

Gear Shift Spindle

Return Spring Teeth

Return Spring TeethReturn Spring Teeth

Return Spring Teeth

Spring

Return Spring

Return SpringReturn Spring

Return Spring

Gear Shift Plant

Gear Shift PlantGear Shift Plant

Gear Shift Plant

Gear Shift Plate

Gear Shift PlateGear Shift Plate

Gear Shift Plate

6-9

Clutch, Gearshift

Clutch Assembly

● Coat the clutch outer guide with clean engine oil.

● Install the trust washer and outer guide into the main shaft.

● Install the following:

- Clutch assy.

- R. crank case cover

● Install the gear shift arm into the gear shift spindle

● Install the clutch outer and spline washer.

● Coat the clutch and plate disk. With clean

engine oil.

● Install the 6 disk. and 5 plates to the clutch center by turns.

Clutch Center

Disk

Plate

Pressure Plate

Clutch Outer Guide

Clutch Outer GuideClutch Outer Guide

Clutch Outer Guide

Thrust Washer

Thrust WasherThrust Washer

Thrust Washer

Spline Washer

Spline WasherSpline Washer

Spline Washer

Clutch Outer

Clutch OuterClutch Outer

Clutch Outer

6-10

Clutch, Gearshift

● Install the lock nut by pressing clutch center into the clutch center holder.

Torque : 6.5kgf-m (65N.m) Tools:

Clutch center holder Lock nut wrench, 20×24mm Extension bar

● Install the clutch spring, lifter plate and clutch spring bolt diagonally several times.

• Check if the pressure plate press the disc, and plate exactly.

Primary Drive Gear

Removal

● Remove the crank case.

● Hold the flywheel using a flywheel holder.

● Remove the primary drive gear lock nut.

Tools:

Flywheel holder Lock nut wrench, 20×24mm Extension bar

● Remove the lock nut, primary drive gear, and woodruff key.

● Install the pressure plate, disk, plate and clutch center into the clutch outer.

● Coat the nut parts with clean engine oil, and tighten the lock nut.

NOTE

Clutch Spring Bolt

Clutch Spring BoltClutch Spring Bolt

Clutch Spring Bolt

Lifter Plate

Lifter PlateLifter Plate

Lifter Plate

Extension Bar

Extension BarExtension Bar

Extension Bar

Lock Nut

Lock NutLock Nut

Lock Nut

Lock Nut Wrinch 20X24mm

Lock Nut Wrinch 20X24mmLock Nut Wrinch 20X24mm

Lock Nut Wrinch 20X24mm

Lock Nut Wrench

Lock Nut WrenchLock Nut Wrench

Lock Nut Wrench

Extension Bar

Extension BarExtension Bar

Extension Bar

6-11

Clutch, Gearshift

● When replacing the primary drive gear, select the gear which the paint mark, same colar of R.crank case paint mark, is indicated.

Paint mark of crank case Paint mark of primary drive gear

White White(Primary drive gear A) Blue Blue(Primary drive gear B) Yellow Yellow(Primary drive gear C)

• Select the correct gear. If not install the correct gear, the back-lash between the drive gear and driven gear is out of regulation and the noise of gear occur.

Installation

● Install the woodruff key into the key groove of the crankshaft.

● Align the primary drive gear key groove with the crankshaft key and install the gear.

● Install the washer.

● Coat the nut with clean engine oil, and tighten

the lock nut.

● Hold the flywheel with a flywheel holder.

● Tighten the primary drive gear lock nut.

Torque : 6.5kgf-m(65N.m) Tools:

Flywheel holder Lock nut wrench, 20×24mm Extension bar

!

CAUTION

△

Crankshaft

CrankshaftCrankshaft

Crankshaft

Woodruff Key

Woodruff KeyWoodruff Key

Woodruff Key

Key Groove

Key GrooveKey Groove

Key Groove

Lock Nut

Lock NutLock Nut

Lock Nut

Lock Nut Wrench 20X24mm

Lock Nut Wrench 20X24mmLock Nut Wrench 20X24mm

Lock Nut Wrench 20X24mm

Extension Bar

Extension BarExtension Bar

Extension Bar

6-12

Clutch, Gearshift

R. Crankcase Cover

Installation

● Remove the gasket from the crank case surface.

● Install the dowel pins and a new gasket.

● Install the right crank case cover, aligning the

spline of the crank shaft and with the oil pump shaft spline.

• If any difficulty is encountered in joining the crank shaft spline to the oil pump shaft spline, remove the crankshaft hole cap, then install the right crank case cover while turning the crankshaft to the right slowly.

● Install the clutch cable holder and crank case cover bolt.

Torque: 1.1kgf-m(11N.m)

● Install the clutch cable into the clutch cable holder.

● Align the end of the cable with the clutch arm.

● Check the clutch cable free play(⇨ 3-12)

● Install the kick starter pedal and tighten the

bolt.

Torque: 2.2kgf-m(22N.m)

● Fill the crankcase with the recommended

oil (⇨ 2-3)

Dowel Pin

Dowel PinDowel Pin

Dowel Pin

Clutch Cable Holder

Clutch Cable HolderClutch Cable Holder

Clutch Cable Holder

R. Crank Case Cover

R. Crank Case CoverR. Crank Case Cover

R. Crank Case Cover

Kick Starter Pedal

Kick Starter PedalKick Starter Pedal

Kick Starter Pedal

NOTE

7-0

A.C Generator / Starter Clutch

7-1

A.C Generator / Starter Clutch

7. A.C Generator / Starter Clutch

Service Information …………………7-1 A.C Generator ………………………7-2

Starter Clutch ………………………7-7

Service Information

General

● This section covers removal and installation of the A.C. generator.

● Refer to section 16 for inspection of the A.C. generator.

● The A.C. generator/starter clutch service may be done with the engine in the frame.

Specification

Item Standards Service Unit

O.D. 42.195-42.208(1.6612-1.6617) 42.180(1.658)

Starter Driven Gear

I.D 22.022-22.010(0.8670-0.8665) 22.100(0.870) Starter Idle Gear I.D 10.045-10.028(0.3942-0.3948) 10.100(0.393) Starter Idle Gear Shaft O.D 9.991 -10.100(0.3933-0.3937) 9.97(0.393) Reduction Gear I.D 10.013-10.045(0.3942-0.3955) 10.100(0.393) Reduction Gear Shaft I.D 9.991-10.100(0.3933-0.3937) 9.97(0.393)

Torque Values

Flywheel Bolt 5.5kgf-m(55N.m) Starter Clutch Socket Bolts 3.2kgf-m(32N.m) Left Crank Case Cover Bolt 1.1kgf-m(11N.m)

Tools

Common

Flywheel Puller Flywheel Holder

Unit:mm(in)

7

7-2

A.C Generator / Starter Clutch

● Loosen the one bolt attaching A.C. generator and remove the A.C. generator wire clamp.

A.C Generator

Removal

● Remove the gear change pedal.

● Remove the L. lower cover.

● Disconnect the coupler of the A.C. generator

wire, gear change switch wire coupler.

● Loosen the 3 bolts and remove the starter reduction gear cover.

L. Rear Cover

L. Rear CoverL. Rear Cover

L. Rear Cover

Drive Chain Guide

Drive Chain GuideDrive Chain Guide

Drive Chain Guide

Reduction Gear Cover

Reduction Gear CoverReduction Gear Cover

Reduction Gear Cover

7-3

A.C Generator / Starter Clutch

● Remove the starter reduction gear shaft and starter reduction gear.

● Loosen the left crank case cover adjusting bolt and remove the left crank cover. Remove the gasket and the dowel pins.

● Remove the starter idle gear shaft and starter idle gear.

● Hold the flywheel rotor with a holder and remove the rotor bolt.

Tool: Flywheel holder

Starter Reduction Gear

Starter Reduction GearStarter Reduction Gear

Starter Reduction Gear

Shaft

ShaftShaft

Shaft

L. Clank Case Cover

L. Clank Case CoverL. Clank Case Cover

L. Clank Case Cover

Starter Idle Gear

Starter Idle GearStarter Idle Gear

Starter Idle Gear

Flywheel Rotor

Flywheel RotorFlywheel Rotor

Flywheel Rotor

7-4

A.C Generator / Starter Clutch

● Remove the woodruff key from the crank shaft.

● Remove the starter driven gear collar.

● After installing the flywheel puller on the

rotor, remove the rotor.

Tool: Flywheel puller

Stator Removal/Installation

● Loosen the pulse generator mounting screw and remove the pulse generator.

● Loosen the screw and remove the wire guide.

● Remove the stator mounting screw and remove

the stator. Assemble and install in the reverse order of disassembly removal.

• Make sure that the grommet is correctly placed on the slot.

NOTE

Flywheel Puller

Woodruff Key

Woodruff KeyWoodruff Key

Woodruff Key

Starter Driven Gear Collar

Starter Driven Gear CollarStarter Driven Gear Collar

Starter Driven Gear Collar

Pulse Generator

Pulse GeneratorPulse Generator

Pulse Generator

Wire Guide

Wire GuideWire Guide

Wire Guide

Grommet

GrommetGrommet

Grommet

Stator

StatorStator

Stator

7-5

A.C Generator / Starter Clutch

Starter Idle Gear Inspection

● Inspect the wear and damage of starter ldle gear.

● Measure the gear inside diameter.

Service Limit : 10.100mm(0.393in)

● Measure the gear shaft inside diameter.

Service Limit : 9.97mm(0.393in)

Reduction Gear Inspection

● Inspect the wear and damage of reduction gear.

● Measure the gear inside diameter.

Service Limit : 10.100mm(0.393in)

● Measure the gear shaft outside diameter.

Service Limit : 9.97mm(0.393in)

Assembly

● Install the starter driven gear collar.

● Clean the taper part of crank shaft and remove

the dust. If installing the rotor with dust in taper part, the key will be damaged. Because the contacted area of taper will be small and it will occur the stress in the woodruff key.

● Install the woodruff key into the crank shaft key groove.

● Install the rotor into the crank shaft aligning the key.

● After checking whether inside magnet of rotor is attached by the bolts and nuts, install them.

If installing the rotor with the foreign material, the starter coil is damaged.

● Install the rotor bolt temporally. After fixing the flywheel with a holder, tighten the rotor bolt.

Torque : 5.5kgf-m(55N.m) Tool: Flywheel Holder

NOTE

Flywheel Rotor

Flywheel RotorFlywheel Rotor

Flywheel Rotor

Starter Idle Gear

Gear Shaft

Reduction Gear

Gear Shaft

Woodruff Key

Woodruff KeyWoodruff Key

Woodruff Key

Starter Driven Gear Collar

Starter Driven Gear CollarStarter Driven Gear Collar

Starter Driven Gear Collar

7-6

A.C Generator / Starter Clutch

● Install the starter idle gear and shaft.

● Install the new gasket and dowel pin.

● Install the l. crankcase cover and tighten the

bolt.

Torque : 1.1kgf-m(11N.m)

● Install the starter gear and shaft.

● Install the new o-ring.

Starter Idle Gear

Starter Idle GearStarter Idle Gear

Starter Idle Gear

Shaft

ShaftShaft

Shaft

L. Crank Case Cover

L. Crank Case CoverL. Crank Case Cover

L. Crank Case Cover

Starter Reduction Gear

Starter Reduction GearStarter Reduction Gear

Starter Reduction Gear

O-ring

O-ringO-ring

O-ring

7-7

A.C Generator / Starter Clutch

● Connect the AC generator wire and gear position light switch wire coupler, and install the wire clamp.

● Install the L. Lower cover and gear change pedal bolt.

● Tighten the gear change pedal bolt.

Starter Clutch

● Remove the flywheel(⇨ 7-4)

● If the starter driven gear turns to the right when

pressing the flywheel as shown, it is in good condition.

Disassembly

● Remove the three socket bolts, and remove the one way clutch from the flywheel.

Gear Change Pedal

Gear Change PedalGear Change Pedal

Gear Change Pedal

7-8

A.C Generator / Starter Clutch

● Check the starter driven gear for damage and wear.

● Measure the driven gear I.D. and O.D.

Service Limit: O.D. : 42.180mm(1.658in) I.D. : 22.100mm(0.870in)

Assembly

● Inspect the one way clutch for wear and damage.

● Install the way clutch fringe onto the clutch outer.

● After coating the socket bolt with the nut locking bond, install it.

Torque : 3.2kgf-m(32N.m)

Clutch Outer

Flange Part

MEMO

8-0

Cylinder Head / Valve

8-1

Cylinder Head / Valve

Service Information

General

 Rocker arm and cam shaft can be serviced with the engine installed in the frame. To service the

cylinder heads. the engine must be removed from the frame.

 Cam shaft lubrication oil is fed through an oil pipe. Be sure that the oil pipes and orifice are not

clogged before installing the cylinder head.

Specifications

8. Cylinder Head / Valve

Service Information

…………………8-1 Troubleshooting ………………………8-2 Camshaft Removal ……………………8-3 Cylinder head Removal………………8-5 Cylinder Head Disassembly…………8-6

Valve Guide Replacement……………8-8 Valve Seat Inspection ………………8-9 Cylinder Head Assembly ……………8-11 Cylinder Head Assembly ……………8-13 Cylinder Heand Installation …………8-13

Item Standard Service Limit

Rocker Arm

Rocker Arm I.D 12.016~12.034(0.4731~0.4738) 12.060(0.4748) Rocker Arm O.D 11.982~12.000(0.4717~0.4724) 11.950(0.4505)

Cam Shaft Cam Height

IN. 37.640~37.800(1.4819~1.4881) 37.420(1.4732)

EX. 37.520~37.680(1.4772~1.4835) 37.300(1.4685)

Valve Spring Free Length

IN., EX. 41.65(1.640) 40.0(1.57)

Valve Stem O.D

IN. 4.975~4.990(0.1959~0.1965) 4.925(0.1939)

EX. 4.995~4.970(0.1951~0.1957) 4.905(0.1931)

Valves Valve Guide I.D IN., EX. 5.000~5.012(0.1969~0.1973) 5.03(0.198)

Stem to Guide IN. 0.010~0.037(0.0004~0.0015) 0.08(0.003) Clearance EX. 0.030~0.057(0.0012~0.0022) 0.10(0.004) Valve Seat Width 0.7~0.9(0.028~0.035) 1.3(0.051)

Unit:mm(in)

8

8-2

Cylinder Head / Valve

Torque Values

Cam Chain Tensioner Pivot Bolt 1.1kgf-m(11N.m) Spark Plug 1.1kgf-m(11N.m)-Apply engine oil Camshaft Holder 8mm nut 2.0kgf-m(20N.m)-Apply engine oil Cam Chain Tensioner Mounting Bolt 1.2kgf-m(12N.m) Cam Chain Tensioner Sealing Screw 0.4kgf-m(4N.m) Cylinder Head Cover Bolt 1.0kgf-m(10N.m) Crank Shaft Hole Cap 0.8kgf-m(8N.m) Timing Hole Cap 0.6kgf-m(6N.m)

Tools

Special

Dowel Pin Puller Set Sliding Shaft Sliding Weight Valve Guide Reamer Valve Guide Driver

Common

Valve Spring Compressor Valve Seat Cutter Seat Cutter IN 35(23mm) EX 35(20mm) IN 45(24.5mm) EX 45(24.5mm) IN 60(22mm) EX 60(22mm) Cutter Holder 5mm

Iow compression

 Valves

- Improper valve clearance adjustment

- Broken or damaged valve spring

- Incorrect valve timing

- Faulty valve seat adherence

 Cylinder head

- Leaking or damaged head gasket

- Warped or cracked cylinder head

 Cylinder and piston (Refer to section 9)

Excessice smoke from muffler

 Worn valve guide or valve stem  Damaged valve stem seal  Worn and damaged piston ring

Incorrect idle speed

 Compression is too low

Compression is too high

 Excessive carbon build-up on piston or

combustion chamber

Excessive noise

 Incorrect valve clearance adjustment  Sticking valve or broken valve spring  Worn or damaged camshaft  Worn or damaged rocker arm and rocker arm

shaft

 Worn or damaged cam chain  Worn or damaged cam chain tensioner  Damaged cylinder head gasket  Improper spark plug installation

Troubleshooting

 Cylinder head operation problem can be diagnosed by a compression test, or by tracing noises to the

topend with a sounding rod or stethoscope.

8-3

Cylinder Head / Valve

Camshaft Removal

 Remove the fuel tank( 4-3)  Remove the cylinder head cover bolts and

cover.

 Remove the timing hole cap and crank shaft

hole cap out of the left crankcase cover.

 Rotate the crankshaft clockwise, place the

flywheel Tmark on the left crankcase cover index mark.

 Make surethat the piston is placed on the

compression groove. (All the cam lobes of the camshaft should face down.)

 Rotate the crankshaft clockwise on turn(360)

and place the Tmark on the index mark.

 Loosen the sealing screw of the cam chain

tensioner. Remove the tensioner mounting bolt and tensioner.

 Remove the camshaft holder 8mm nuts.  Remove the camshaft holder from the cylinder.

Timing Hole Cap

Timing Hole CapTiming Hole Cap

Timing Hole Cap

Crank Shaft Hole Cap

Crank Shaft Hole CapCrank Shaft Hole Cap

Crank Shaft Hole Cap

Sealing Screw

Sealing ScrewSealing Screw

Sealing Screw

Tensioner Mounting Bolt

Tensioner Mounting BoltTensioner Mounting Bolt

Tensioner Mounting Bolt

8-4

Cylinder Head / Valve

 Remove the cam chain from camshaft.  In order to separate the cam chain from the

crank case, bind it with the thread or a string.

 Remove the camshaft.

Camshaft Holder Disassembly

 Remove the end of the rocker arm spring from

the dowel pins.

 Remove the dowel pins from the Camshaft

holder using the following

Tools:

- Dowel pin puller set

- Sliding shaft

- Sliding weight

 Put the 6mm bolt into the rocker arm shaft,

remove the rocker arm shaft, pulling the bolt.

 Remove the rocker arm and rocker arm spring  Remove the other rocker arm shaft, rocker

arm, and rocker arm spring following the same order.

Cam Chain

Cam ChainCam Chain

Cam Chain

Cam Shaft

Cam ShaftCam Shaft

Cam Shaft

Rocker Arm Spring

Rocker Arm SpringRocker Arm Spring

Rocker Arm Spring

Dowel Pins

Dowel PinsDowel Pins

Dowel Pins

Dowel PinsDowel Pins

Dowel Pins

Dowel PinsDowel Pins

Dowel Pins

Rocker Arm Spring

Rocker Arm SpringRocker Arm Spring

Rocker Arm Spring

8-5

Cylinder Head / Valve

Inspection

 Inspect the rocker arm and rocker arm shaft for

wear and damage.

 Measure the rocker arm I.D.

Service Limit : 12.060mm(0.4748in)

 Measure the rocker arm O.D.

Service Limit : 11.950mm(0.4505in)

 Inspect the cam lobe of the camshaft for wear

and damage.

 Measure the height of the cam lobe.

Service Limit:IN) 37.420mm(1.4732in)

EX) 37.300mm(1.4685in)

 Turn the outer race of each bearing with your

finger. The bearing should turn smoothly and quietly.

 Check the bearing for damage.

Cylinder Head Removal

 Remove the engine from the frame ( 5)  Remove the camshaft.  Remove cylinder head from the cylinder.

8-6

Cylinder Head / Valve

 Remove the valve spring, valve cotter, retainer,

spring, and valve.

Tool: Valve spring compressor

 To prevent the loss of tension, do not compress

the valve springs more than necessary to remove the cotters.

 Mark all parts during disassembly so they can

be placed back in their original locations.

 Remove the valve stem seals and valve spring

seals, remove the carbon deposits from the combustion chamber.

Cylinder Head

 Clean off the head gasket surface.

 Avoid damaging the gasket surfaces.

 Remove the gasket, dowel pins, and cam chain

guide from the cylinder.

Cylinder Head Disassembly

 Loosen the pivot bolt and remove the cam

chain tensioner.

 Remove the carburetor insulator.  Remove the spark plug from the cylinder head.  Remove the spark plug cover from the cylinder

head.



NOTE

!

CAUTION

△

!

CAUTION

△

Cam Chain Guide

Cam Chain GuideCam Chain Guide

Cam Chain Guide

Pivot Bolt

Pivot BoltPivot Bolt

Pivot Bolt

Cam Chain Tensioner

Cam Chain TensionerCam Chain Tensioner

Cam Chain Tensioner

8-7

Cylinder Head / Valve

 Inspect the spark plug assembly hole and the

crack of near valve seat. Check for the warp of the cylinder head with a square and filler gauge.

Service Limit : 0.1mm(0.004in)

Valve Spring

 Measure the free field of valve spring.

Service Limit : 40.0mm(1.57in)

 If any valve spring is shorter than the service

limit, it must be replaced as a set.

Valve Step-To-Guide Clearance

 Inspect the bent, clogging, damaging, and step

wear of valve.

 Check the valve step with valve guide.  Measure the valve step outside diameter and

record it.

Service Limit : IN) 4.925mm(0.1939in)

EX) 4.905mm(0.1931in)

 After inserting the valve guide reamer to the

combustion chamber, remove the carbon deposits.

 The incoming and outgoing of reamer should

be performed by turning the reamer to the right. If the entrance of reamer without turning or turing to the left, the guide inside will be damaged.

Tool: Valve guide reamer

 Measure the valve guide inside diameter and

record it.

Service Limit : 5.03mm(0.198 in)

 Calculate the valve step and guide clearance.

Service Limit : IN) 0.08mm (0.003 in)

EX) 0.10mm (0.004 in)

 Measure the inside diameter of new valve

guide, and must be replaced with the new valve if the clearance is not in service limit.

!

CAUTION

△

!

CAUTION

△

8-8

Cylinder Head / Valve

Valve Guide Replacement

 When replacing the valve guide, valve seat

must be amended.

 Heat the cylinder head equally to 130-140.  Avoid heating over 150

 Avoid performing the unskilled work. It is

caused a burn.

 When heating the cylinder Head, do not heat it

sectionally using a gas burner. It is caused the twist of cylinder Head.

 Hold the cylinder head, and remove the valve

guide from the combustion chamber using valve guide driver.

Tool : Valve guide driver

 Avoid the cylinder head from damaging.

 Install the new o-ring into the new valve guide.

 Insert the valve guide in the top of the cylinder

head.

Tool: Valve guide driver.

 After inserting the valve guide, install the

valve guide reamer in the combustion chamber of the cylinder head and trim the valve guide.

!

CAUTION

△

!

CAUTION

△

!

CAUTION

△

Valve Guide Driver

Valve Guide DriverValve Guide Driver

Valve Guide Driver

Valve Guide DriverValve Guide Driver

Valve Guide Driver

8-9

Cylinder Head / Valve

 Trim the reamer not to lean. If cutting the

reamer by leaning, the valve hole is inclined, the step seal is leaked, and the around of valve seat is enlarged. So the around of seat is not amended.

 The entrance of reamer is always performed by

turning the reamer to the right. If not, the guide inside is damaged.

Tool: Valve guide reamer

 Clean the cylinder head and remove the

foreign substances.

 Check the around of valve seat and amend

them.

Valve Seat Inspection

 Remove the carbon deposits of valve.  Coat the valve of cylinder head with the ink

thinly.

 Trim valve guide reamer using a valve guide

dreamer without turning the valve, and align the position exactly.

 Tale off the valve, inspect the opposite side of

the seat with the ink attachment of valve pace side.



If the valve seat is damaged, amend the valve seat.

 If the valve is inclined, inspect the valve guide-

to-step gap and replace valve guide if necessary.

 It is impossible to amend the valve. If the valve

pace clogging, wear and connection are bad, the valve must be replaced.

 Measure the valve seat width.

Standard Value : 0.7~0.9(0.028~0.035) Service Limit : 1.3mm(0.05in)

Valve Seat Cutter

 Amend the worn valve seat using a valve seat

cutter and a grinder.

 Perform them according to the instruction

manual.

60

。

35

。

45。

IN : 22mm Ex : 22mm

IN : 23mm EX : 20mm

IN : 24.5mm

Ex : 24.5mm

!

CAUTION

△

!

CAUTION

△

!

CAUTION

△

Valve

8-10

Cylinder Head / Valve

Valve Seat Amendment

 If the Seat part is damaged or rough, cut them

using 45cutter.

 After replacing the valve guide, cut the seat

part.

 Amend the flat using a 35cutter side by side.

 Amend the inside using a 60cutter side by

side.

 Amend the seat part with a standard width

using a 45cutter.

절삭전 시트폭

35

。

60

。

45

。

0.7~0.9mm (0.028~0.035 in)

!

CAUTION

△

Cut The Seat Part

Seat Width Before Cutting

Damaged or Rough

Valve

Seat

45

。

8-11

Cylinder Head / Valve

 Coat the valve seat with the compound.  Use the valve guide reamer without turning the

Valve, check the attached state by hitting against lightly.

 If the position of contacting side is high, cut it

using a 35cutter, and then cut it using a 45 cutter according to the standard width.

 If the position of contacting side is low, cut it

using a 60cutter, and then cuts by 45cutter according to the standard width.

 After amending, coat the valve seat with a

compound and align the valve using a valve guide reamer.

 If it is turned by pressing the valve to seat

strongly when aligning the valve, it is damaged. Therefore, align it by trimming lightly .

 If aligning the valve in same position, it is

caused that seat is worn partly. Therefore align valve by turning.

 Avoid putting compound in the gap of step and

guide while aligning the Valve.

Cylinder Head Assembly

 Install the valve spring seat and a new stem

seal.

 Lubricate each valve stem with molybdenum

disulfide grease and insert the valve into the valve guide. To avoid damage to the stem seal, turn the valve slowly when inserting.

 Check the valve for freedom of up-down

movement.

35

。

60

。

!

CAUTION

△

Contact Part is Hight

Contact Part is Low

Seat Width Before

Cutting

Seat Width Before

Cutting

Cotter

CotterCotter

Cotter

Spring

SpringSpring

Spring

Retainer

RetainerRetainer

Retainer

Valve

ValveValve

Valve

Stem Seal

Stem SealStem Seal

Stem Seal

Spring Seat

Spring SeatSpring Seat

Spring Seat

8-12

Cylinder Head / Valve

 Install the valve springs. The springs tightly

would coils should face toward the cylinder head.

 Install the springs retainer.  Compress the valve spring and install the valve

cotters.

 To prevent the loss of tension, do not compress

the valve springs more than necessary to install the valve cotters.

Tool: Valve spring compressor

 Tap the valve stems gently two or three times

with a soft hammer to firmly seat the cotters.

 Be careful not to damage the valve.

 Coat a new O-ring with engine oil and install it

into the carburetor insulator groove.

 Install the carburetor insulator with the

mounting bolt tightly.

 Install the cam chain tensioner and tighten the

pivot bolt.

Torque : 1.1kgf-m(11N.m)

 Install the spark plug.

Torque : 1.1kgf-m(11N.m)



NOTE



NOTE

For Cylinder Head

For Cylinder HeadFor Cylinder Head

For Cylinder Head

Valve Spring Compressor

Valve Spring CompressorValve Spring Compressor

Valve Spring Compressor

Pivot Bolt

Pivot BoltPivot Bolt

Pivot Bolt

Cam Chain Tensioner

Cam Chain TensionerCam Chain Tensioner

Cam Chain Tensioner

8-13

Cylinder Head / Valve

Cylinder Head Installation

 Clean the cylinder head surface of any gasket

materials.

 Install the cam chain guide into the cylinder.  Install the dowel pins and a new gasket.

 Install the cylinder head.  Install the cam shaft.  Install the engine into the frame( 5)

Camshaft Installation

 Install the rocker arm ring and rocker arm on

the camshaft holder.

 Coat the rocker arm shaft with engine oil and

installl it into the camshaft holder.

 Rotate the rocker arm shaft with a driver, align

the dowel pin hole and bolt hole of the cam shaft holder and rocker arm shaft.

Cam Chain Guede

Cam Chain GuedeCam Chain Guede

Cam Chain Guede

Dowel Pin

Dowel PinDowel Pin

Dowel Pin

Rock Arms

Rock ArmsRock Arms

Rock Arms

Shaft

ShaftShaft

Shaft

Bolt

Holes

Dowel Pin

Holes

Cam Shaft Holder

Cam Shaft HolderCam Shaft Holder

Cam Shaft Holder

8-14

Cylinder Head / Valve

 Insert the dowel pins into the camshaft holder

thoroughly. Align the teeth of the rocker arm spring with the dowel pins as shown.

 Check the camshaft assy for wear or damage,

and Install the Cylinder head

 Install the cam chain on the cam sprocket.

 Rotate the crankshaft to the left slowly, aligh

Tmark on the flywheel with the index mark

on the left crankcase cover.

 When turning the crankshaft, make sure that

the cam chain does not come off from the crankshaft timing gear.

 Coat the camshaft with engine oil, and install

the cam lobe on the cylinder head with the cam lobe facing down. With the timing marks on the cam sprocket parallel to the top of the cylinder head, Install the chain and sprocket.

 Install the dowel pins on the cylinder head.  Install the dowel pin into the cylinder Head.



NOTE

Cam Shaft

Cam ShaftCam Shaft

Cam Shaft

Cam Chain

Cam ChainCam Chain

Cam Chain

8-15

Cylinder Head / Valve

 Install the dowel pin into the cylinder Head.

 Install the camshaft holder.  Apply engine oil to the nut part, install and

tighten the cam shaft holder nut and bolt in two or three steps as shown

Torque : 2.0kgf-m(29N.m)

 Remove the sealing screw and washer from the

cam chain tensioner lifter. Remove the shaft from the body by turning the tensioner shaft to the right with a small driver.

 When dropping the cam chain tensioner lifter,

the shaft is proceeded by the spring power.

!

CAUTION

△

Sealing Screw

Sealing ScrewSealing Screw

Sealing Screw

Mount Bolt

Mount BoltMount Bolt

Mount Bolt

8-16

Cylinder Head / Valve

 Hold the tensioner shaft with the light clip as

shown Install a new gasket into the tensioner lifter, then install the tensioner lifter into the cylinder.

 Install the tensioner mounting bolt.

Torque:1.2kgf-m(12N.m)

 From the tensioner lifter, remove the clip

which holds the tensioner shaft.

 Install the sealing washer and screw on the

tensioner lifter

Torque:0.4kgf-m(4N.m)

 Apply clean engine oil to all the operation

parts of the cylinder head.

 Adjust the valve clearance( 3-6)  Install the crankshaft hole cap and timing hole

cap.

Torque: Crank shaft hole cap: 0.8kgf-m(8N.m) Timing hole cap: 0.6kgf-m(6N.m)

 Clean oil in the slot part  of the cylinder

head cover.

 Place the gasket on the correct position in the

cover.

 Install the cylinder head cover.  Tighten the cylinder cover bolt.

Torque:1.0kgf-m(10N.m)

 Install the fuel tank( 4-3)

Tensioner Lifter

Mounting Bolt

Mounting BoltMounting Bolt

Mounting Bolt

Sealing Screw

Sealing ScrewSealing Screw

Sealing Screw

Gasket

GasketGasket

Gasket

MEMO

9-0

Cylinder / Piston

9-1

Cylinder / Piston

9. Cylinder / Piston

Service Information …………………9-1 Troubleshootint ……………………9-1 Cylinder ………………………………9-2

Piston …………………………………9-3 Piston/Cylinder Installation ………9-5

Service Information

Geaneral

When removing the cylinder, avoid damaging the cylinder joint part with a driver or cooling pin by

hitting the cylinder strongly.

Avoid damaging the inside of the cylinder and piston surface.

Lower or uneven compression

 Worn piston  Worn, damaged piston rings.  Worn cylinder.

Excessive smoke from muffler

 Worn cylinder, piston, and piston rings.  Improperly installed piston rings.  Damaged piston, cylinder.

Overheating

 Excessive carbon deposits on piston head.

Piston noise

 Worn cylinder and piston.  Worn piston pin, connecting rod small end.  Damaged piston rings.  Excessive carbon deposits on piston head.

Troubleshooting

Item Standard Service Unit

I.D 56.500-56.510(2.2244-2.2248) 56.60(2.228)

Cylinder Outer of round  0.1(0.004)

Taper  0.05(0.002) Warpage  0.1(0.004) Piston O.D. 56.470-56.490(2.2232-2.2240) 56.37(2.219)

Piston pin hole I.D 15.002-15.008(0.5906-0.5909) 15.04(0.592) Piston Piston Pin O.D 14.994-15.000(0.5903-0.5906) 14.96(0.589) Piston Pin Piston pin-to-piston clearance 0.002-0.14(0.0001-0.0006) 0.02(0.001) and

Piston ring-to-groove

top 0.015-0.045(0.0006-0.0018) 0.09(0.004)

Piston Ring clearance second 0.015-0.045(0.0006-0.0018) 0.09(0.004)

Piston ring top/second 0.10-0.25(0.004-0.010) 0.5(0.02)

end gap oil(side rail) 0.2-0.7(0.01-0.03) 1.1(0.04)

Piston-to-cylinder clearance 0.010-0.040(0.0004-0.0016) 0.15(0.006) Connecting rod small end I.D. 15.010-15.028(0.5909-0.5917) 15.06(0.593) Connecting rod small end-piston pin clearance 0.010-0.034(0.0004-0.0013) 0.04(0.002)

Specifications

Unit: mm(in)

9

9-2

Cylinder / Piston

Cylinder

Removal

 Remove the cylinder head(Section 8).  Remove the cam chain guide from the

cylinder.

 Loosen the cylinder mounting bolt, and

remove the cylinder.

 Remove the gasket and dowel pins. Remove

the gasket from the cylinder.

 Avoid damaging the gasket surface.

Inspection

 Measure the cylinder inside diameter in 6

places of top, middle, bottom with the piston pin direction and right-angled direction(X-Y direction), and record them. The cylinder inside diameter sets the maximum value.

Service Limit:56.60mm(2.228in)

 Measure the piston outside diameter.( 9-4)  Subtract the piston outside diameter from the

cylinder inside diameter, and then get the cylinder-to-piston clearance.

Service Limit : 0.15mm(0.006in)



Figure out the taper(balance between the X direction and Y direction) and out of round(inside diameter balance of the top, middle, bottom parts by X or Y direction). Choose the maximum value regardless of any one, and settle the taper and out of round.

Service Limit:Taper) 0.05mm(0.002in)

Out of round) 0.1mm(0.004in)

 The boring assembly of cylinder measure the

outside diameter of the over size piston. And then perform the boring assembly so that the cylinder-to-Piston clearance become the standard value.

Over Size: 0.25mm(0.010in), 0.50mm(0.020in)

0.75mm(0.030in), 1.00mm(0.039in)



NOTE

Cam Chain Guide

Cam Chain GuideCam Chain Guide

Cam Chain Guide

Gasket

GasketGasket

Gasket

Dowel Pins

Dowel PinsDowel Pins

Dowel Pins

9-3

Cylinder / Piston

nspect the twist of cylinder.

Service Limit:0.1mm(0.004in)

Piston

Removal

 Remove the piston pin clips.

 Do not let the clips fall into the crankcase.  Push the piston pin out and remove the piston.

 Check the piston ring for damage or

deterioration.

 Remove the piston rings.

 Be careful when removing the rings.

 Measure the piston ring-to-groove clearance.

Service Limit:

Top/Second:0.09mm(0.004in) Oil:0.09mm(0.004in)

 Inspect the piston for damage and wear.



NOTE



NOTE

Ruller

Filter Gauge

Piston

Piston Pin Clip

Piston Pin

Piston Ring

Ring

Cylinder

DAELIM DAYSTAR, DAYSTAR VL125E Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual