Daelim S1 SERVICE MANUAL

How to use this manual

This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO., LTD.

To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule(Section 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service information, and troubleshooting guide.

Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co.,Ltd.,

Service Information

1

2

3

4

6

7

8

9

10

11

14

15

16

17

18

Inspections / Adjustments

External Parts

Lubrication System

5

EMS(Engine Management System)

Fuel System

Engine Removal / Installation

LH, Crank Case Cover Continuously Variable Transmission

A.C Generator / Starter Clutch

Cylinder Head / Valves

Cylinder Head / Piston

12

Transmission / Crank Shaft Crank Case

Rear Wheel / Rear Brake / Suspension / Rear Swing Arm

Charging System

Ignition System

Starter System

Lights / Switches / Horn

19

Wiring diagram

Contents

Engine

FrameElectrical

General

13

Front Wheel / Front Fork / Steering / Brake

SERVICE INFORMATION

1

1-1

1-2

SERVICE INFORMATION

1-3

1-4

SERVICE INFORMATION

1-5

SERVICE INFORMATION

1-6

SERVICE INFORMATION

1-7

SERVICE INFORMATION

1-8

SERVICE INFORMATION

1-9

SERVICE INFORMATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION

FRAME SERIAL NUMBER LOCATION

1-10

SERVICE INFORMATION

1,965mm

743mm

1,120mm

1,350mm

770mm

126mm

127kg

277kg

60

1.75

2.25

9.6

2.2 25

80

90/70

13.8

stroke SOHC

380

AT D C

1-11

SERVICE INFORMATION

, 30A

LED

LED LED

1-12

SERVICE INFORMATION

1-13

SERVICE INFORMATION

1-14

SERVICE INFORMATION

SEAT LOCK CABLE

HORN COMP.

THROTTLE CABLE

HAZARD RELAY

HEAD LIGHT

(COUPLER)

RADIATOR ASS'Y.

BRAKE HOSE CLAMP

FR.BRAKE HOSE C

FR. BRAKE HOSE

Y

RR.BRAKE HOSE A

RR. BRAKE HOSE PIPE FR.BRAKE HOSE C THROTTLE CABLE

SEAT LOCK CABLE

FUEL BREATHER TUBE

FUEL SUPPLY TUBE

LH. RADIATOR HOSE

SIDE STAND SW.ø¨∞·∫Œ COUPLER

FUEL HOSE(TO. INJECTOR)

FUEL PUMP(TO. INJECTOR)

THROTTLE CABLE

BREATHER TUBE

BATTERY + CABLE

EARTH CABLE

ECU UNIT

FRM.EARTH CORD

SEAT LOCK CABLE

TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER

COUPLER

RR.BRAKE HOSE

START MOTOR CABLE

ACG. & CPS CORD

SIDE STAND SW.

DRAIN TUBE(AIR CLEANER)

SPEEDOMETER CABLE

SEAT LOCK CABLE

HORN COMP.

X

Z

TRUNK LAMP COUPLER

IGNITION COIL EARTH CORD

EARTH CABLE

BATTERY + CABLE

JUNCTION VALVE

RR. BRAKE HOSE PIPE

RADIATOR ASS'Y.

MAIN WIRE HARNESS

FUEL SUPPLY TUBE

FUEL BREATHER TUBE

HIGH TENSION CORD

NOISE SUPPRESSOR CAP

THROTTLE CABLE

FUEL HOSE(TO. INJECTOR)

FUEL PUMP(TO. INJECTOR)

FRAME EARTH

RH. RADIATOR HOSE

SPEEDOMETER CABLE

O2 SENSOR COUPLER

FR. BRAKE HOSE

CHARGE SOCKET COUPLER

HARNESS POSITION CLAMP

1-15

SERVICE INFORMATION

SEAT LOCK CABLE

REGULATE RECTIFIER

TAIL & STOP, RR. WINKER R/L REGULATE RECTIFIER

COUPLER

LIGHTING S/W UNIT

STARTER S/W UNIT

FUEL PUMP RELAY

RR.BRAKE HOSE

ACG. & CPS CORD START MOTOR CABLE

IGNITION COIL CORD

IGNITION COIL EARTH CORD

SPEEDO METER ASS'Y

A.P. WINKER RELAY

12V 10AH BATTERY(MF)

ECU UNIT

FRM.EARTH CORD

FUSE

O2 SENSOR COUPLER

FUEL HOSE(TO. INJECTOR)

CAN(≈ÎΩ≈øÎ) CORD

¡∂∏≥πÊ«‚¿∏∑Œ WIRING¿ª Ω«Ω√«“ ∞Õ.

HIGH TENSION CORD

START-MAG. SW. COUPLER

TRUNK LAMP COUPLER

IGNITION COIL

DIMMER S/W UNIT

WINKER S/W UNIT

HORN S/W UNIT

SIDE STAND SWICH COUPLER

THROTTLE CABLE

RH/LH RADIATOR HOSE

FUEL PUMP(TO. INJECTOR)

FUEL SUPPLY TUBE

MAIN WIRE HARNESS

FUEL BREATHER TUBE

RR. BRAKE HOSE PIPE

FR. STOP SW.

THROTTLE CABLE

SEAT LOCK CABLE

HORN COMP.

COMB. & LOCK SW.

CHARGE SOCKET

FR. BRAKE HOSE

SPEEDOMETER CABLE

RR. STOP SW. HAZARD S/W UNIT

FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3.

SPEEDO METER EARTH

HAZARD RELAY

RR.BRAKE HOSE A

HEAD LIGHT

(∞·º±øÎ COUPLER)

FR.BRAKE HOSE C

1-16

SERVICE INFORMATION

SEAT LOCK CABLE

THROTTLE CABLE

RR.BRAKE HOSE A

FUEL SUPPLY TUBE

HEAD LIGHT

(∞·º±øÎ COUPLER)

FUEL BREATHER TUBE

FR.BRAKE HOSE C

SPEEDO METER ASS'Y

A.P. WINKER RELAY

THROTTLE CABLE

FR. BRAKE HOSE

COMB.METER SOCKET

COMB. & LOCK SW.

JUNCTION VALVE

RR. BRAKE HOSE PIPE

HARNESS ~x_1~/_5 ^!`'|(^-`%|5^R`-|P CLAMP

MAIN WIRE HARNESS

VIEW Y

FR. BRAKE HOSE

THROTTLE CABLE

COMB. & LOCK SW.

VIEW X

RR.BRAKE HOSE A

SPEEDOMETER CABLE

SEAT LOCK CABLE

HORN COMP.

1-17

SERVICE INFORMATION

FUEL HOSE(TO. INJECTOR)

RR. BRAKE HOSE PIPE

MAIN WIRE HARNESS

O2 SENSOR CORD

THROTTLE CABLE

RH/LH RADIATOR HOSE

FUEL PUMP(TO. INJECTOR)

FRAME EARTH HORN~m_? ^J`)|P~*_5 ~B_&^!`'|( ^3`!|(^!`%|3.

O2 SENSOR COUPLER

BREATHER TUBE

MAPAT COUPLER

ECU UNIT

FRM.EARTH CORD

DETAIL OF O2 SENSORS PART

INJECTOR

ISA

THROTTLE CABLE

FUEL HOSE(TO. INJECTOR)

BATTERY + CABLE

START-MAGNET SW. ASS'Y.

MAIN WIRE HARNESS

ACG. & CPS CORD

START MOTOR CABLE

RR.BRAKE HOSE

TPS

VIEW Z

DETAIL OF SENSORS PART

MEMO

2-1

INSPECTIONS/ADJUSTMENTS

2

2-2

INSPECTIONS/ADJUSTMENTS

2-3

INSPECTIONS/ADJUSTMENTS

2-4

INSPECTIONS/ADJUSTMENTS

NUTS

2-5

INSPECTIONS/ADJUSTMENTS

2-6

INSPECTIONS/ADJUSTMENTS

FEELER GAUGE

COMPRESSION GAUGE

TIMINCT HOlLE CAP

COOLING FAN

ADJUST WRENCH

SPARK PLUG CAP

TAPPET ADJUST SCREW

2-7

INSPECTIONS/ADJUSTMENTS

OIL CHECK HOLE

OIL SIGHT GRASS

DRIVE FACE

DRIVE BELT

UPPER MIDDIE LOWER

UPPER MIDDLE LOWER

DRIVEN PULLEY

2-8

INSPECTIONS/ADJUSTMENTS

BRAK FLUID

Remove the brake fluid cover. Check the oil level inside the front brake reservoir.

If the oil level is near the lower limit line, remove the reservoir diaphrag mand fill DOT3 and DOT 4 brake fluid to the top limit line.

If the brake fluid reaches the lower limit line, check

the entire brake system for leaks.

BRAKE PAD/SHOE

BRAKE PAD REPLACEMENT

Check the brake pads for wear. If the rod mark on the pad reaches the brake disc, replace the pads.

BRAKE SYSTEM

Check the front brake hose for cracks or damage. If any leaks are found,replace immediately Check the brake rod for looseness or damage, and replace it if necessary.

BRAKE LEVER FREE PLAY

Check the free play after pulling the lover.

FRONT: 10~20mm REAR: 10~20mm

DUBLE BRAKE HOSE

FRONT CALLIPE

REAR BRAKE HOSE

DRIVEN LEVER

FRONT BRAKE HOSE

REAR CALLIPE

ROD MARK

BRAKE PAD

ROD MARK

BRAKE PAD

0IL CUP CAP

BRAKE FLUID CHECK WINDOW

Daelim S1 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual