Daelim ET-250 SERVICE MANUAL
ET-250
1
Contents
1. INFORMATION..........................................................................................................................................5
1.1 SAFETY ............................................................................................................................................5
1.2 NOTES ..............................................................................................................................................5
1.3 SPECIFICATION ENGINE ..............................................................................................................6
1.4 SERIAL NUMBER ...........................................................................................................................7
1.5 TORQUE VALUES ...........................................................................................................................8
1.6 Special Tools ......................................................................................................................................9
2. MAINTENANCE......................................................................................................................................10
2.1 MAINTENANCE DATA .................................................................................................................10
2.2 MAINTENANCE SCHEDULE......................................................................................................11
2.3 FUEL TUBE....................................................................................................................................11
2.4 THROTTLE OPERATION..............................................................................................................12
2.5 THROTTLE CABLE ADJUSTMENT............................................................................................12
2.6 AIR CLEANER...............................................................................................................................12
2.7 SPARK PLUG .................................................................................................................................12
2.8 IDLE SPEED ...................................................................................................................................13
2.9 DRIVE CHAIN ...............................................................................................................................13
2.10 BRAKE SYSTEM .........................................................................................................................14
2.11 WHEELS AND TIRES ..................................................................................................................16
2.13 TOE-IN ..........................................................................................................................................16
3. ENGINE REMOVE AND INSTALLATION............................................................................................18
3.1 General Information.........................................................................................................................18
3.2 ENGINE REMOVAL......................................................................................................................18
3.3 ENGINE INSTALLATION.............................................................................................................19
4-1 Mechanism Diagram.......................................................................................................................20
4-2 Precautions in Operation.................................................................................................................21
4-3 Troubleshooting...............................................................................................................................21
4-4 Engine Oil........................................................................................................................................22
4-5 Engine Oil Strainer Clean................................................................................................................22
4-6 Oil Pump..........................................................................................................................................23
4-7 Gear Oil ...........................................................................................................................................23
5. FUEL SYSTEM.........................................................................................................................................24
5-1 Mechanism Diagram.......................................................................................................................24
5-2 Precautions in Operation.................................................................................................................25
5-3 Trouble Diagnosis............................................................................................................................26
5-4 Carburetor Remove / Install ............................................................................................................27
5-5 Air Cut-Off Valve ............................................................................................................................28
5-6 Throttle Valve ..................................................................................................................................29
5-7 Float Chamber .................................................................................................................................30
5-8 Adjustment of Idle Speed ................................................................................................................32
5-9 Fuel Tank .........................................................................................................................................33
5-10 Air Cleaner ....................................................................................................................................34
6. CYLINDER HEAD/VALVE.....................................................................................................................35
6-1 Mechanism Diagram.......................................................................................................................35
6-2 Precautions in Operation.................................................................................................................36
2
6-3 Troubleshooting...............................................................................................................................37
6-4 Cylinder Head Removal..................................................................................................................38
6-5 Cylinder Head Inspection................................................................................................................41
6-6 Valve Stem Replacement.................................................................................................................44
6-7 Valve Seat Inspection and Service...................................................................................................45
6-8 Cylinder Head Reassembly .............................................................................................................48
6-9 Cylinder Head Installation...............................................................................................................50
6-10 Valve Clearance Adjustment..........................................................................................................52
7. CYLINDER/PISTON................................................................................................................................54
7-1 Mechanism Diagram.......................................................................................................................54
7-2 Precautions in Operation.................................................................................................................55
7-3 Trouble Diagnosis............................................................................................................................55
7-4 Cylinder and Piston Removal..........................................................................................................56
7-5 Piston Ring Installation ...................................................................................................................59
7-6 Piston Installation ............................................................................................................................60
7-7 Cylinder Installation ........................................................................................................................61
8. V-BELT DRIVING SYSTEM ...................................................................................................................63
8-1 Mechanism Diagram.......................................................................................................................63
8-2 Maintenance Description.................................................................................................................64
8-3 Trouble Diagnosis............................................................................................................................64
8-4 Left Crankcase Cover ......................................................................................................................65
8-5 Drive Belt ........................................................................................................................................67
8-6 Drive Face .......................................................................................................................................69
8-7 Clutch Outer/Driven Pulley.............................................................................................................72
9. FINAL DRIVING MECHANISM ............................................................................................................77
9-1 Mechanism Diagram - transmission cover......................................................................................77
9-2 Precautions in operation ..................................................................................................................78
9-3 Trouble Diagnosis............................................................................................................................78
9-4 Disassembly of Transmission..........................................................................................................79
9-5 Inspection of Mission Mechanism ..................................................................................................82
9-6 Bearing Replacement ......................................................................................................................84
9-7 Re-assembly of Final Driving Mechanism......................................................................................87
10. ALTERNATOR/STARTING CLUTCH..................................................................................................89
10-1 Mechanism Diagram.....................................................................................................................89
10-2 Precautions in Operation...............................................................................................................90
10-3 Right Crankcase Cover Removal..................................................................................................91
10-4 A.C.G. Set Removal.......................................................................................................................91
10-5 Right Cover Bearing ......................................................................................................................91
10-6 Flywheel Removal.........................................................................................................................92
10-7 Starting Clutch...............................................................................................................................93
10-8 Flywheel Installation.....................................................................................................................95
10-9 A.C.G. Set Installation...................................................................................................................96
10-10 Right Crankcase Cover Installation.............................................................................................96
11. CRANKCASE / CRANK........................................................................................................................98
11-1 Mechanism Diagram......................................................................................................................98
11-2 General information.......................................................................................................................99
11-3 Trouble diagnosis...........................................................................................................................99
11-4 Disassembly of crankcase............................................................................................................100
3
11-5 Crankshaft Inspection..................................................................................................................102
11-6 Assembly of crankcase ................................................................................................................103
12. COOLING SYSTEM.............................................................................................................................106
12-1 Mechanism Diagram...................................................................................................................106
12-2 General Information....................................................................................................................107
12-3 Trouble Diagnosis........................................................................................................................107
12-4 Trouble Diagnosis for Cooling System.......................................................................................108
12-5 System Test..................................................................................................................................110
12-6 Radiator .......................................................................................................................................111
12-7 Water Pump .................................................................................................................................113
12-8 Thermostat...................................................................................................................................117
13. STEERING AND SUSPENSION .........................................................................................................118
13.1 PARTS DRAWING......................................................................................................................118
13.2 TROUBLESHOOTING...............................................................................................................119
13.3 HANDLEBAR.............................................................................................................................119
13.4 THROTTLE HOUSING ..............................................................................................................122
13.5 STEERING SYSTEM .................................................................................................................122
14. FRONT WHEEL AND BRAKE SYSTEM ...........................................................................................125
14.1 PARTS DRAWING......................................................................................................................125
14.2 TROUBLESHOOTING...............................................................................................................126
14.3 FRONT WHEELS .......................................................................................................................126
14.4 HYDRAULIC BRAKE...............................................................................................................127
15. REAR WHEEL AND BRAKE SYSTEM .............................................................................................131
15.1 PARTS DRAWING......................................................................................................................131
15.2 TROUBLESHOOTING ...........................................................................................................132
15.2 TROUBLESHOOTING ...........................................................................................................133
15.3 REMOVE REAR WHEEL AND REAR BRAKE ......................................................................133
15.4 SWINGARM & REAR AXLE HOLDER...................................................................................136
15.5 Suspension Adjustment................................................................................................................138
16. FENDERS AND EXHAUST PIPE .......................................................................................................139
16.1 FENDERS DRAWING................................................................................................................139
16.2 REAR FENDERS REMOVAL....................................................................................................140
16.3 FRONT FENDER REMOVAL ...................................................................................................142
16.4EXHAUST PIPE REMOVAL ......................................................................................................143
17. ELECTRICAL SYSTEM ......................................................................................................................144
17.1 TROUBLESHOOTING...............................................................................................................144
17.2 IGNITION COIL.........................................................................................................................145
17.3 IGNITION TIMING....................................................................................................................145
17.4 BATTERY INFORMATION.......................................................................................................145
17.5 ELECTRIC STARTER ................................................................................................................146
17.6 LIGHT BULBS REPLACEMENT.............................................................................................146
18.TROUBLESHOOTING .........................................................................................................................152
18.1 ENGINE CAN NOT WORK.......................................................................................................152
18.2 POOR PERFORMANCE AT LOW AND IDLE SPEEDS .........................................................153
18.3 POOR PERFORMANCE AT HIGH SPEED ..............................................................................153
18.4 LOSS POWER.............................................................................................................................154
18.5 POOR HANDLING.....................................................................................................................155
4
1. INFORMATION
1.1 SAFTY
1.2 NOTES
1.3 SPECIFICATION
1.4 SERIAL NUMBER
1.5 TORQUE VALUE
1.6 SPECIAL TOOLS
1.1 SAFETY
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition.
Do not smoke or allow sparks or flames in your work area.
● CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and lead to death.
● BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect yo ur eyes, skin and
clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte
gets in your eyes.
● HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the
engine is run. Wear insulated gloves before handling these parts.
● USED ENGINE/GEAR OIL
Used engine oil and gear oil may cause skin disease if repeatedly contact with
the skin for long periods.
Keep out of reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base on the latest
product information available at the time of approval for printing.
JI-EE Dynamic Technology Industry Co., Ltd. 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 without written permission.
5
1.3 SPECIFICATION ENGINE
CHASSIS
SUSPENSION
BRAKES
TIRES
Type
Displacement 249c.c.
Bore and Stroke 71 mm x 63 mm
Compression 10.6:1
Maximum Hp 19ps / 5600
Maximum Torque (Nm/rpm) 22.3 Nm / 5500
Carburetor
Ignition DC-CDI
Starting Electric
Lubrication Auto oil injection
Transmission Automatic (C.V.T. V-belt + Reverse)
Overall Length 1815mm
Overall Width 1062mm
Overall Height 1130mm
Wheel base 1193mm
Ground Clearance 150mm
Dry Weight 225Kg
Fuel Tank Capacity 12L
Front Double A-Arm & Adjustable
Rear Swing Arm & Adjustable Shock
4 Stroke，Single Cylinder, Water cooled
Front Front Hydraulic Disc*2
Rear Rear Hydraulic Disc*1
Front 21x7-10
Rear 22x10-10
PRESSURE【 psi ( kgf/cm2) 】
Front 12(0.8)
Rear 12(0.8)
COLORING
Specifications subject to change without notice.
6
1.4 SERIAL NUMBER
The frame serial number is stamped on the front of the frame.
The engine serial number is stamped on the left side of the crankcase.
Frame serial number
7
1.5 TORQUE VALUES
STANDARD
5 mm bolt and nut
● 6 mm bolt and nut
● 8 mm bolt and nut
●10 mm bolt and nut
●12 mm bolt and nut
ENGINE
Cylinder head nut
● Spark plug
● Cylinder head bolt
● Alternator bolt
●
●
FRAME
● Handlebar upper holder bolt
● Throttle housing cover screw
● Steering shaft nut
5 N.m (3.5 lbf.ft)
10 N.m (7.2 lbf.ft)
22 N.m (16 lbf.ft)
35 N.m (25 lbf.ft)
55 N.m (40 lbf.ft)
28 N.m (20.7 lbf.ft)
12 N.m (8.9 lbf.ft)
20 N.m (14.8 lbf.ft)
8 N.m (5.9 lbf.ft)
24 N.m (17.7 lbf.ft)
4 N.m (2.9 lbf.ft)
50 N.m (36.9 lbf.ft)
● Steering shaft holder bolt
● Wheel rim bolt
● Tie rod lock nut
● King pin nut
● Handlebar lower holder nut
● Front wheel bolt
● Front axle castle nut
● Front brake arm nut
● Rear brake arm nut
● Rear axle castle nut
● Rear wheel bolt
● Exhaust muffler mounting bolt
● Engine hanger bolt
● Rear axle holder bolt
● Swing a rm pivot nut
33 N.m (24 lbf.ft)
18 N.m (13.3 lbf.ft)
35 N.m (25.8 lbf.ft)
40 N.m (29 lbf.ft)
40 N.m (29.5 lbf.ft)
24 N.m (17.7 lbf.ft)
40-60 N.m (30-45 lbf.ft)
4 N.m (3.0 lbf.ft)
7 N.m (5.2 lbf.ft)
40-60 N.m (30-45 lbf.ft)
24 N.m (17.7 lbf.ft)
30 N.m (22.1 lbf.ft)
30 N.m ( 22 lbf.ft)
90 N.m (65 lbf.ft)
90 N.m (65 lbf.ft)
● Rear shock absorber mounting nut
45 N.m (33 lbf.ft)
8
1.6 Special Tools
1. Adjustable Hook Spencer
(E1105-LRA0-FT1)
Purpose: Adjusting of suspension
2. Ball Joint Puller(E0205-LRA0-FT1)
Purpose: Taking out the ball joint from front knuckle as repairing.
9
2. MAINTENANCE
rpm
2.1 MAINTENANCE DATA 2.8 IDLE SPEED
2.2 MAINTENANCE SCHEDULE 2.9 DRIVE CHAIN
2.3 FUEL TUBLE 2.10 BRAKE SYSTEM
2.4 THROTTLE OPERATION 2.11 WHEELS AND TIRES
2.5 THROTTLE CABLE AJUSTMENT 2.12 STEERING SYSTEM
2.6 AIR CLEANER 2.13 TOE -IN
2.7 SPARK PLUG
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG
SPARK PLUG GAP 0.8 mm
RECOMMENDED SPARK PLUGS NGK CR8E
THROTTLE LEVER FREE PLAY 5-10 mm
IDLE SPEED 1700±100
BRAKE LEVER FREE PLAY 15-25 mm
DRIVE CHAIN SLACK 10-25 mm
TOE-IN 5±10 mm
TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL 1.4 Liter (1.2Liter for change)
GEAR LUBRICATION OIL 750cc (650cc for change)
10
2.2 MAINTENANCE SCHEDULE
The internal maintenance in the following table is based on average riding, normal conditions.
Riding in unusually dusty areas, require more frequent servicing.
300KM
1 Month 3 Months 6 Months 1 Year 2 Years
Fuel Lines I I R
Throttle Operation I I
Air Filter I C R
Fuel Filter R
Spark Plug I I R
Drive Chain I, L Lubricate for every 1 month
Brake Shoes I
Brake System I I
Brake Fluid I R
Nuts, Bolts & Fasteners I
WHEEL/TIRES I I
Wheels I I
Steering System I I
Suspension System I I
C.V.T Drive belt I R
Transmission Oil R Replace for every 3,000km or 6 Months
Engine Oil R Replace for every 3,000km or 6 Months
Battery I I,C I,C
Oil Filter (Screen) C C
Valve Clearance I I
Coolant I I R
Cooling Fan I I
Carburetor (Idle Speed) I I
Choke I
Note – I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary
C: Clean L: Lubricate R: Replace
Every Every Every Every Notes
2.3 FUEL TUBE
Inspect the fuel lines for deterioration, damaging or
leakage and replace if necessary.
11
2.4 THROTTLE OPERATION
Inspect for smooth throttle lever full opening and automatic
full closing in all steering positions.
Inspect if there is no deterioration, damage or kink in the
throttle cable, replace it if necessary.
Check the throttle lever, free play is 5-10 mm at the tip of the
throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to prevent
premature wear.
2.5 THROTTLE CABLE ADJUSTMENT
Slide the rubber cap of the adjuster off the throttle
Housing, loosen the lock nut and adjust the free play
of the throttle lever by turning the adjuster on the throttle housing.
Inspect the free play of the throttle lever.
Throttle
2.6 AIR CLEANER
Please remove the four hooks, and then disassemble
two screws inside the air cleaner case.
Pull out the air filter element from the air cleaner case.
Washing the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the every component into air cleaner in the reverse order of
removal.
Note: for more detail please check chapter 5-10
2.7 SPARK PLUG
This spark plug is located at the front of the engine.
Disconnect the spark plug cap and unscrew the spark plug.
Check the condition of spark plug electrodes wear.
12
Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned.
Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped.
The spark plug gap shall keep in 0.6-0.7mm
With the sealing washer attached, thread the spark plug in by hand to prevent crosses threading.
Tighten the spark plug with 12-19 N.m
2.8 IDLE SPEED
Connect an engine speed meter.
Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. “Turn in” (clockwise) will
get higher speed. “Turn out” (counter clockwise) will get lower speed.
IDLE SPEED: 1700±100 rpm
2.9 DRIVE CHAIN
Stopping the ATV and shift the transmission into neutral(N) .
Measure the drive chain slack midway between the
sprockets.
Chain slack =15~25mm (5/8~1 inch)
Adjust the chain slack.
Loosen the lock nuts and turn drive chain adjusting nuts
until get the correct slack.
Tighten the axle holder bolts.
Torque = 90N.m (65 lbf.ft)
When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator.
Please use special chain oil to lubricate the drive chain.
Clean the drive chain with kerosene and wipe it dry.
Inspect the drive chain for any possible wearing or damaging.
Replace the ch ain, if it is worn excessively or damaged.
Inspect the sprocket teeth, if it is excessive wearing or damaging,
please replace it.
13
2.10 BRAKE SYSTEM
Inspect the front brake lever and cable for excessive play or other
damage.
Replace or repair if necessary.
Measure the brake lever free play at the end of the brake lever trip.
Front Brake lever free play is 15 -25 mm.
Turn the parking brake to the left side is “parking off”, while
turn to right side is “parking on”.
Inspect the rear brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the rear brake lever free play at the
end of the lever trip .
Rear Brake lever free play is 15-25 mm.
14
Brake le ver
Adjustable nut
Parking Brake
Parking Off
Parking On
Adjustment
Brake level
Rear Brake
NOTE:
Ÿ The second method to adjust brake level is under the driver
seat and rear brake component.
Ÿ In order to avoid a pre-load occurred between brake disk and
lining. After all adjusting of brake system are completed,
please check the small clearance between brake disk and
lining.
Adjustable nut
Parking Brake Adjustable nut
15
2.11 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails or other sharp ob jects.
Check the each tire surface at cold tire condition.
*The standard of tire pressure is 12(0.8) psi ( kgf/cm2)
STEERING SHAFT HOLDER BUSHING
Remove the front fender first.
Remove the steering shaft holder and check the steering shaft bushing
for wears or damage.
If the bushing is worn or damaged, please change a new one.
Grease the steering shaft bushing and install the parts
in the reverse order of removal.
Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)
2.13 TOE-IN
Keep the vehicle on level ground and the front wheels facing straight
ahead.
Mark the centers of the tires to indicate the axle center height.
Measure the distance between the marks.
Carefully to move the vehicle back, let the wheels turn 180 degree,
so the marks on the tires are aligned with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear measurements.
Toe-in: 5±10mm
16
Lock Nuts
If the toe-in is out of standard, adjust it by changing
the length of the tie-rods equally by turning the tie -rod
while holding the ball joint.
Tighten the lock nuts.
Torque: 35-43 N.m
17
3. ENGINE REMOVE AND INSTALLATION
3.1 REPAIR CONDITION 3.3 ENGINE INSTALLATION
3.2 ENGINE REMOVAL
3.1 General Information
ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRMENT OR
ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY
3.2 ENGINE REMOVAL
Before removing engine, you need to remove all of components such as seat, front and back fender,
fuel tube, exhaust pipe, carburetor cable and drive chain…etc. You can then see three hanger bolts which have
screwed on engine.
Loosen these three hanger bolts. You have succeeded to remove this engine.
There are some pictures to describe main step of removing engine.
Disconnect the wire connectors. There are three connectors for
carburetor auto-choke, starter motor and generator respectively.
Remove the drive chain cover.
Remove the drive chain retaining clip and master link,
and remove the drive chain.
Hanger bolt
18
3.3 ENGINE INSTALLATION
The Engine installation is essentially in the reverse order of removal.
The torque of engine hanger bolt is 30 N.m
Route the wires and cable in reverse order properly.
19
4. LUBRICATION SYSTEM
4-1 Mechanism Diagram
4-2 Precautions in Operation
4-3 Troubleshooting
4-4 Engine Oil
4-5 Engine Oil Strainer Clean
4-6 Oil Pump
20
4-1 Mechanism Diagram
Press-In Lubrication
Oil Route
Con-Rod
Spray Lu brication
Press-In Lubrication
Valve Rocker Arm
Cam Shaft
Spray Lubrication
Oil Route
Rotate Direction
Oil Pump
Oil Strainer
21
4-2 Precautions in Operation
General Information:
l This chapter contains maintenance operation
for the engine oil pump and gear oil
replacement.
Specifications
Engine oil quantity Disassembly: 1400 c.c.
Change: 1200c.c.
Oil viscosity SAE 10W-30 (Recommended
King serial oils)
Gear oil Disassembly: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 140
(Recommended SYM Hypoid gear oils)
Items Standard (mm) Limit (mm)
Inner rotor clearance 0.15 0.20
Clearance between outer rotor and body 0.15~0.20 0.25 Oil pump
Clearance between rotor side and body 0.04~0.09 0.12
Torque value
Torque value oil strainer cap 1.5~3.0kgf -m
Engine oil drain bolt 1.9~2.5kgf -m
Gear oil drain bolt 1.0~1.5kgf -m
Gear oil join bolt 1.0~1.5kgf -m
Oil pump connection bolt 0.8~1.2kgf -m
??:mm
4-3 Troubleshooting
Low engine oil level
Ÿ Oil leaking
Ÿ Valve guide or seat worn out
Ÿ Piston ring worn out
Low oil pressure
Ÿ Low engine oil level
Ÿ Clogged in oil strainer, circuits or pipes
Ÿ Oil pump damage
Dirty oil
Ÿ No oil change in periodical
Ÿ Cylinder head gasket damage
Ÿ Piston ring worn out
22
4-4 Engine Oil
Turn off engine, and park the ATV in flat surface
with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that makes sure
oil can be drained smoothly and completely.
Place an oil pan under the ATV, and remove oil
drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Drain bolt
Torque value? 1.9~2.5kgf-m
4-5 Engine Oil Strainer Clean
Drain engine oil out .
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Torque value? 1.5~3.0kgf-m
Add oil to crankcase (oil viscosity SAE 10W-30)
Recommended using King serial oil.
Engine oil capacity: 1200c.c. when replacing
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks.
Oil strainer cap
O-ring
23
Oil strainer
4-6 Oil Pump
Oil Pump Removal
Remove generator and starting gear. (Refer to
chapter 10) ?
Remove cir clip and take out oil pump driving
chain and sprocket.
Make sure that pump shaft can be rotated freely.
Remove 2 screws on the oil pump, and then
remove oil pump.
Oil Pump Disassembly
Remove the screws on oil pump co ver and
remove the cover.
Remove oil pump shaft roller and shaft.
Clip
2 screws
1 screw
Roller
24
Oil Pump Inspection
P
ins
Check the clearance between oil pump body and
outer rotor.
Limit: 0.25 mm
Check clearance between inner and outer rotors.
Limit: 0.20 mm
Check clearance between rotor side face and
pump body
Limit: 0.12 mm
Oil Pump Re-assembly
Install inner and outer rotors into the pump body.
Align the indent on driving shaft with that of
inner rotor.
Install the oil pump shaft and roller.
Install the oil pump cover and fixing pins
properly.
25
Tighten the oil pump screw.
Oil Pump Installation
Install the oil pump, and then tighten screws.
Torque value? 0.8~1.2kgf-m
Make sure that oil pump shaft can be rotated
freely.
Install oil pump drive chain and sprocket, and
then install cir clip onto oil pump shaft.
Install starting gear and generator.
(Refer to chapter 10)
1 screw
Roller
2 screws
Clip
26
4-7 Gear Oil
Gear Oil Change
Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.
Torque value: 1.0~1.5kgf-m
Make sure that the drain bolt washer can be re-used.
Add oil to specified quantity from the join hole .
Gear Oil Quantity: 650c.c. when replacing
Make sure that the join bolt washer can be re-used,
and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is in
correct level.
Make sure that no oil leaking.
Gear oil join bolt
Gear oil drain bolt
5. FUEL SYSTEM
Carburetor
Fuel
tank cap
Fuel
strainer
5-1 Mechanism Diagram
5-6 Throttle Valve
5-2 Precautions in Operation
5-3 Trouble Diagnosis
5-4 Carburetor Remove / Install
5-5 Air Cut-Off Valve
5-1 Mechanism Diagram
5-7 Float Chamber
5-8 Adjustment of Idle Speed
5-9 Fuel Tank
5-10 Air Cleaner
Fuel unit
Fuel tank
Inlet pipe
Auto fuel cock
5-2 Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in a well-ventilated place and
strictly prohibit flame when working with gasoline.
Cautions
Ÿ Do not bend off throttle cable. Damaged throttle cable will make unstable drive-ability.
Ÿ When disassembling fuel s ystem parts, pay attention to O-ring position, replace with new one as
re-assembly
Ÿ There is a drain screw in the float chamber for draining residual gasoline.
Ÿ Do not disassemble air cut valve arbitrarily.
Tool
Special service tools
¢ Vacuum/air pressure pump
¢ Fuel level gauge
Specification of CARBURETOR
ITEM UA25A
Carburetor diameter Ø 22mm
I.D. number PTG 050
Fuel level 14.8mm
Main injector # 110
Idle injector # 35
Idle speed 1700 ± 100rpm
Throttle lever clearance 1~3 mm
Air screw 2 turns
5-3 Trouble Diagnosis
Poor engine start
Ÿ No fuel in fuel tank
Ÿ Clogged fuel tube
Ÿ Too much fuel in cylinder
Ÿ No spark from spark plug(malfunction of
ignition system )
Ÿ Clogged air cleaner
Ÿ Malfunction of carburetor chock
Ÿ Malfunction of throttle operation
Stall after started
Ÿ Malfunction of carburetor chock
Ÿ Incorrect ignition timing
Ÿ Malfunction of carburetor
Ÿ Dirty engine oil
Ÿ Air existing in intake system
Ÿ Incorrect idle speed
Rough idle
Ÿ Malfunction of ignition system
Ÿ Incorrect idle speed
Ÿ Malfunction of carburetor
Ÿ Dirty fuel
Intermittently misfire as acceleration
Ÿ Malfunction of ignition system
Late ignition timing
Ÿ Malfunction of ignition system
Ÿ Malfunction of carburetor
Power insufficiency and fuel consuming
Ÿ Fuel system clogged
Ÿ Malfunction of ignition system
Mixture too lean
Ÿ Clogged fuel injector
Ÿ Vacuum piston stick and closed
Ÿ Malfunction of float valve
Ÿ Fuel level too low in float chamber
Ÿ Clogged fuel tank cap vent
Ÿ Clogged fuel filter
Ÿ Obstructed fuel pipe
Ÿ Clogged air vent hose
Ÿ Air existing in intake system
Mixture too rich
Ÿ Clogged air injector
Ÿ Malfunction of float valve
Ÿ Fuel level too high in float chamber
Ÿ Malfunction of carburetor chock
Ÿ Dirty air cleaner
Loading...