DAELIM S4 50cc, S4 four Service Manual

 Contents of this manual and specifications are

subject to change without prior notice for improvement of vehicle quality.

 No part of this publication may be reproduced

without written permission of DAELIM Motor Co., Ltd.,

CONTENTS

SERVICE INFORMATION INSPECTIONS / ADJUSTMENTS EXTERNAL P ARTS LUBRICA TION SYSTEM FUEL SYSTEM ENGINE REMOV AL/INSTALLA TION

LH. CRANK CASE COVER / KICK STARTER / CONTINUOUSLY V ARIABLE TRANSMISSION

AC GENERA TOR CYLINDER HEAD / VALVE CYLINDER / PISTON

TRANSMISSION / CRANKSHAFT / CRANKCASE

GENERAL

ENGINE

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

FRONT WHEEL / FRONT FORK / STEERING / BRAKE

REAR WHEEL / REAR BRAKE / REAR CUSHION

CHARGING SYSTEM

FRAME

ELECTRICAL SYSTEM

IGNITION SYSTEM

LIGHTS / SWITCHES / HORN TROUBLE SHOOTING WIRING DIAGRAM

ST ARTER SYSTEM

18

19

1.

SERVICE INFORMATION

ENGINE SERIAL NUMBER LOCA TION

FRAME SERIAL NUMBER LOCA TION

SERIAL NUMBER LOCATION

······

1-1

SPECIFICATIONS

··················

1-2

TWIST TORQUE

····················

1-4

SYMBOLS / ABBREVIATIONS

········

1-5

LUBRICATION OIL

····················

1-6

WIRING DIAGRAM

····················

1-7

GENERAL SAFETY

····················

1-1 1

CAUTION WHEN WIRING

············

1-15

1

SERIAL NUMBER LOCATION

SERVICE INFORMATION

SPECIFICATION

ITEM

DIMENSIONS

FRAME

ENGINE

OVERALL LENGTH

OVERALL WIDTH

OVERALL HEIGHT

WHEEL BASE

SEAT HEIGHT

GROUND CLEARANCE

DRY WEIGHT

GROSS WEIGHT

TYPE

FRONT SUSPENSION

REAR SUSPENSION

FRONT TIRE SIZE/TYPE

REAR TIRE SIZE/TYPE

TIRE PRESSURE 1 person FRONT

REAR

2 persons FRONT

REAR

FRONT BRAKE

REAR BRAKE

FUEL TANK CAPACITY Full capacity

Reserve capacity

CASTER ANGLE

TYPE

CYLINDERS, ARRANGEMENT

BORE X STROKE

DISPLACEMENT

COMPRESSION RATIO

VALVES

ENGINE OIL CAPACITY

TRANSMISSION OIL CAPACITY

LUBRICATION TYPE

AIR CLEANER TYPE

COMPRESSION PRESSURE

INTAKE VALVE IN VALVE OPEN

CLOSE

EX VALVE OPEN

CLOSE

VALVE CLEARANCE INTAKE

EXHAUST

1.790mm

670mm

1.102mm

1.250mm

750mm

120mm

94kg

224kg

Underbone

Telescopic

Swing Arm

3.50 -10 51J

2.00kg/㎠

2.25kg/㎠

-Hydraulic

-Mechanical Drum

5.0L

1.5L

27°

Air cooled 4cycle SOHC engine

1(single cylinder), front angle 90°

39.0×39.5mm

49.5cc

10.5 : 1

SOHC chain drive

0.85L (Full capacity)

0.70L (at changing)

0.12L (Full capacity)

Forced pressure splash type

Paper filter

10kg/cm

2

(600rpm)

0°BTDC 25°ABDC 33°BBDC

0°ATDC

0.1mm

SPECIFICATION

SERVICE INFORMATION

ITEM

CARBURETOR

ELECTRICAL

SYSTEM

DRIVE TRAIN

TYPE/ VENTURY BORE

MODEL MARK

CHOKE TYPE

MAIN JET

PILOT SCREW REVERSE REVOLUTION SPEED

FLOAT LEVEL

IDLE SPPED

IGNITION SYSTEM

IGNITION TIMING F MARK

BATTERY CAPACITY

SPARK PLUG

SPARK PLUG GAP

FUSE CAPACITY

STARTING SYSTEM

HEADLIGHT(HIGH / LOW)

WINKER LIGHT(HIGH/LOW)

TAIL/ STOP LIGHT

HIGH-BEAM PILOT LAMP

WINKER PILOT LAMP

SPEEDOMETER LAMP

CLUTCH TYPE

PRIMARY REDUCTION

SECONDARY REDUCTION

CV type(vacumm)/Φ16mm

PD19J

Auto-bystarter

#110

1 3/4

11mm

1,700±100 rpm

Automatic Transmission(V-belt type)

3.533

3.714

AC-CDI

BTDC 14°

12V 6Ah

CR6HSA

0.6~0.7mm

15A

STARTER MOTOR / KICK

12V 35 / 35W

12V 10W

12V 21 / 5W

12V 3W

12V 3W X 2

12V 1.7W X 2

SPECIFICATION

SERVICE INFORMATION

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

1.5 kgf·m

2.5 kgf·m

1.1 kgf·m

5.5 kgf·m

4.0 kgf·m

1.2 kgf·m

5.5 kgf·m

2.0 kgf·m

1.0 kgf·m

0.4 kgf·m

1.1 kgf·m

1.2 kgf·m

1.0 kgf·m

0.9 kgf·m

1.0 kgf·m

0.9 kgf·m

30

12

5

6

12

10

28

7

6

8

6

1

2

1

4

2

1

4

8

1

3

2

TAPPET ADJUSTING ROLL CAP

OIL DRAIN PLUG BOLT

VALVE ADJUST SCREW LOCK NUT

CYLINDER HEAD BOLT

FLYWHEEL NUT

DRIVE FACE NUT

CLUTCH OUTER BOLT

SPARK PLUG

DRIVE PLATE

CAM SHAFT HOLDER NUT

CAM CHAIN TENSIONER FLANGE BOLT

CAM CHAIN TENSIONER PAN SCREW

CYLINDER HEAD COVER BOLT

MISSION COVER BOLT

MISSION COVER DRAIN BOLT

MISSION COVER CHECK BOLT

COOLING FAN BOLT

STARTER MOTOR FLANGE BOLT

TORQUE VALUES

ENGINE

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

7.0 kgf·m

0.25 kgf·m

4.5 kgf·m

6.0 kgf·m

3.0 kgf·m

1.2 kgf·m

4.25 kgf·m

2.25 kgf·m 12 kgf·m

4.0 kgf·m

3.5 kgf·m

4.5 kgf·m

4.0 kgf·m

1.5 kgf·m

4.5 kgf·m

26

10

12

10

6

8

22

16

8

10

1

2

3

2

1

STEERING LOCK NUT

STEERING TOP NUT

HANDLE BAR LOCK NUT

FRONT AXLE NUT

FRONT CALIPER BRACKET BOLT

FRONT MASTER CYLINDER HOLDER BOLT

FRONT DISK PLATE BOLT

FRONT FORK BOLT

REAR WHEEL AXLE NUT

REAR CUSHION UPPER BOLT

REAR CUSHION UNDER BOLT

REAR CUSHION UPPER METAL LOCK NUT

ENGINE HANGER UPPER BOLT

MAIN STAND BOLT

SIDE STAND PIVOT SCREW

SIDE STAND PIVOT NUT

FRAME

Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.

Apply the engine oil

ITEM ITEMTORQUE VALUE

TORQUE VALUE

0.5 kgf·m

1.0 kgf·m

2.2 kgf·m

3.5 kgf·m

5.5 kgf·m

0.4 kgf·m

0.9 kgf·m

1.2 kgf·m

2.7 kgf·m

4.0 kgf·m

5mm BOLT, NUT

6mm BOLT, NUT

8mm BOLT, NUT

10mm BOLT, NUT

12mm BOLT, NUT

5mm SCREW

6mm SCREW

6mm SCREW BOLT, NUT

8mm SCREW BOLT, NUT

10mm SCREW BOLT, NUT

SERVICE INFORMATION

SYMBOL

CAUTION

NOTE

SYMBOLS / ABBREVIATIONS

The following symbols are used in this manual to represent job-related warnings or cautions.

MEANING

Indicates dangerous area. Serious

accident may result if instructions are not

followed.

The following symbols indicate oil adding, oil change, or parts.

MEANING

Indicates important work. Minor injury or

vehicle part damage may result if instruction

are not followed.

Indicates general safety matters. Provides

safety and appropriate handling procedures.

ASS’Y

The following abbreviations are used in this manual.

ASSEMBLY

Left

Right

LH.

RH.

SYMBOL

WARNING

SYMBOL CAUTION

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

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

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 NLG #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 Fork or Suspension Fluid

Use special tool

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

(󱐇3-1)

LUBRICATION OIL

APPLICATION AREA REMARKS

VALVE GUIDE / VALVE STEM WORKING AREA

CONTACT AREA OF CAM SHAFT

CONTACT AREA OF VALVE ROCKER ARM

CAM SHAFT DRIVE CHAIN

PISTON & PISTON RING GROVE

INSIDE CYLINDER

CONNECTING ROD PISTON PIN HOLE

CONNECTING ROD

CRANK SHAFT

OIL PUMP DRIVE CHAIN

COUNTER SHAFT GEAR

FINAL GEAR

BEARING

SURFACE OF O-RING

OIL SEAL

AREA OF FRICTION SPRING WORK / SHAFT WORK

AREA OF SHAFT WORK

•SAE15W-40 or SAE10W-40

•API SL

HEAT RESISTENT GREASE

ENGINE PARTS

SERVICE INFORMATION

WIRING DIAGRAM

SERVICE INFORMATION

WINKER RELAY

SAI PIPE

FUEL COCK

CDI UNIT

FUEL TANK

SIDE STAND

SPEEDOMETER CABLE

REAR BRAKE CABLE

MAGNETIC SWITCH

REGULATOR RECTIFIER

FUEL HOSE

SERVICE INFORMATION

REGULATOR RECTIFIER

MAGNETIC SWITCH

IGNITION COIL

ACG COUPLER

FUEL TANK

SAI PIPE

CDI UNIT

FRONT BRAKE CALIPER

MUFFLER

HORN

WINKER RELAY

SERVICE INFORMATION

SPEEDOMETER

WINKER RELAY

HORN

KEY SET

MASTER CYLINDER

BRAKE HOSE

SERVICE INFORMATION

FUEL TANK

BATTERY CABLE

ACG COUPLER

CDI UNIT

MAGNETIC SWITCH

REGURATOR RECTIFIER

SAI PIPE

CARBURATOR

SERVICE INFORMATION

GENERAL SAFETY

WARNING

1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide.

2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children)

3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops.

4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.

5. When more than two person are working, always pay attention to other worker’s action and alway have safety in mind.

6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash carefully with soap and water after handling.

7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc.

8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark.

SERVICE RULES

1. Parts and lubrication oil must be DAELIM genuine or recommended parts.

2. Before maintenance, remove deposit or dust from the chasis.

SERVICE INFORMATION

9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils.

10. Recommended grease must be applied to or filled in the specified place.

7. Align the bolts to uniform the tightening points before tightening them when you don’t know the bolt length.

8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque.

5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation.

6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing.

3. Store the parts of each system discriminatively to install each part in the right place.

4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.

SERVICE INFORMATION

11. Maintenance needed to use the specialized tools must performed with the right tool.

12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing.

13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually.

• Replace the ball bearing having excessive axial/

longitudinal hanging.

•Wipe the ball bearing likely to have hanging with

cleaning oil.(except double-sided sealed type ball bearing)

• Replace the ball bearing of which press-fitted part is

slacked at the case or shaft.

14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle.

15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing.

16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring.

17. Check each part for proper tightening and operation after installation.

18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact.

SINGLE-SEALED TYPE

DOUBLE-SEALED TYPE

OPEN TYPE

SNAP RING

CHAMFERED EDGE

MANUFACTURER’S NAME, BEARING No.

SERVICE INFORMATION

21. Keep the pneumatic system interior or the engine interior from the infiltration of dust.

22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally.

19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil)

• Pay attention not to bend or damage the lip

• Apply the grease to the lip

20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end.

23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage.

24. Install the boots with the installing groove by inserting the boots into the groove.

MANUFACTURER’S NAME

CAVITY

CLIP

FITTING

BOOTS

SERVICE INFORMATION

•Each cord must be connected depending on its color.

When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number.

•Identify the two-colored cord by main color first and

then spriped color .

•When measuring voltage or resistance of the cord

terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler.

•Recheck the condition of contact, securing and

continuity of each part after maintenance.

•When connecting the battery, the plus terminal must be

connected first.

•After connecting the terminal, apply the grease to the

terminal.

•When disconnecting the battery, the minus terminal

must be disconnected first.

•Make sure that the tool such as spanner do not contact

with the frame.

•Connect covers to the terminal after maintenance.

•If the fuse is short-circuited, find out the cause and

repair. Replace with the fuse having the specified capacity.

•If there is rust in the terminal, remove the rust with sand

paper prior to connecting.

CAUTION WHEN WIRING

BLACK CORD

WHITE COUPLER.

WHITE

RED STRIPE

WHITE / RED CORD

TESTER PLUG

WHITE TUBE

BLACK TUBE

VALIDATION OF CAPACITY!

REMOVE THE RUST!

SERVICE INFORMATION

•Insert the lock of the coupler until the lock is fully

secured.

•Turn off the main switch before connecting/dis-

connecting.

•Release the lock to disconnect the lock of the coupler.

•The lock of the coupler has two types according to

releasing method(press type and pull type) so release it properly according to the shape.

- Typical releasing method of the coupler is illustrated in the following.

•When disconnecting the coupler, disconnect it while

holding the coupler body. Pull while holding the wire harness cord and do not remove the coupler connection.

•Release the lock by inserting the coupler slightly and

then narrowing connection to remove the coupler.

•Pay attention not to damage the vinyl cover of the

coupler.

•Check to see if there is bended terminal and secure it to

avoid disconnecting.

•If the wire harness coating is damaged, repair by

winding vinyl tape or replace it.

•Prior to connecting the connector, make sure that the

cover is not damaged and the mess terminal is not opened.

SERVICE INFORMATION

•Wire band must be secured firmly in the specified

location of the frame. In case of aluminium band, secure the wire harness to the coated part.

•Secure the wire harness firmly using the clamp.

•Insert the connector until the vinyl cover is fully

inserted into the terminal.

•The opening of the vinyl cover must face at the ground

direction but in case of the plain connector, the draining opening must face at the sky direction.

•When removing T-start, broaden the groove of T-start

using the wiring driver and release the torque.

•Connect the harness and the hose to T-start and then

insert until the groove is locked.

•When removing T-start from the frame, replace it with

the new one.

•In case of the weld clamp, do not clamp in the welded

part.

•When clamping the wire harness, make sure that the

harness is not contacted with the shaft or rotating part.

•When clamping the wire, pay attention not to contact

with hot part.

•The wire harness must be routed without contacting

with the end of the lamp or any sharp edge.

•The wire harness must be routed without contacting

with the end of the bolt or the piece.

WIRING DRIVER

DRAINING HOLE

GROOVE SIDE

SERVICE INFORMATION

•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness

is not pressed by the parts.

•In case that the wire harness is contacted with the end or

the sharp edge, protect both parts with tube or tape.

•The wire must not hang down or be pulled excessively.

•Do not twist the wire harness. •Wire the wire harness not to be pulled or expanded

when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine.

•Prior to using the tester, please read the manual care-

fully and understand the contents.

•When testing the resistance of the tester, the zero

adjustment must be performed before testing.

•Do not drop or throw the parts especially

semiconductor contained parts because these parts may be damaged by the impact of the drop.

NOT TO PULL!

Is this measurement range or configuration in accord

with the manual?

EP AIR STANDARDS

THROTTLE GRIP DIFFE SP ARK PLUG SP ARK PLUG GAP

V ALVE GAP CARBURETOR IDLE SPEED

CYLINDER COMPRES SION PRESSURE

2-6mm CR6HSA

0.6~0.7mm

0.1mm

1,700±100rpm

10kg/cm

2

(600rpm)

IN

EX

2.00 kgf /cm2 (28psi)

2.00 kgf·cm

2

(28psi)

2.00 kgf·cm

2

(28psi)

2.25 kgf·cm

2

(33psi)

3.50 -10 51J

FRONT

REAR

FRONT

REAR

FRONT

REAR

ONE PERSON

TWO PERSONS

TIRE PRESSUR A T COLD

ROLLING

TIRE SIZE

2. INSPECTIONS/ADJUSTMENTS

SERVICE INFORMATION

WARNING

●The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a

long period of time.

●Refer to the chapter 4 about the engine fluid

●Stand the main stand prior to the beginning work

2

SERVICE INFORMATION

···

2-1

MAINTENANCE SCHEDULE

··

2-3

FUEL LINE

··········

2-4

THROTTLE GRIP OPERATION

··

2-4

AIR CLEANER

·······

2-5

SPARK PLUG

·······

2-5

VALVE GAP

········

2-5 CYLINDER COMPRESSION PRESSURE·2-6 CARBURETOR IDLING

····

2-7 TRANSMISSION OIL

·····

2-7 ENGINE OIL

·········

2-7

DRIVE BELT

·········

2-7

BRAKE FLUID

········

2-8

BRAKE PAD/SHOE

·····

2-8

SIDE STAND

········

2-9

SUSPENSION

·······

2-9

FASTENING BOLTS, NUTS

·· ·

2-9

WHEELS/TIRES

·······

2-10

STEERING STEM

······

2-10

BATTERY

·········

2-10

LUBRICATION POINTS

····

2-11

SPARK PLUG 1.2㎏f·m CYLINDER HEAD COVER BOLT 0.9㎏f·m VALVE ADJUSTING NUT 1.1㎏f·m

TORQUE

WRENCH 8×9mm

ADJUST WRENCH

COMPRESSION GAUGE

TOOL

INSPECTIONS / ADJUSTMENTS

● Carry out pre-operation check at each scheduled maintenance period based on the information described in the

owner’s manual.

I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN

＊ If there are no appropriate type of tools and maintenance data available, or if you do not have mechanical technology

contact authorized maintenance shops, dealers or other designated repair shops for maintenance and inspections.

 To ensure safety, inspections and maintenance of these parts must be carried out by authorized maintenance shops,

dealers or other designated repair shops.

NOTE

1. After the odometer reading exceeds 12,000km, repeat maintenance service at intervals indicated in the table.

2. After riding in areas with high humidity or pollution, carry out maintenance service more frequently.

3. Replace every 2 years. Proper technology is required for this job.

FREQUENCY

ODOMETER READING(NOTE 1)

NOTE

ITEM

FUEL LINE(FUEL TUBE)

THROTTLE GRIP OPERATION

AIR CLEANER

SPARK PLUG

VALVE GAP

TRANSMISSION OIL

ENGINE OIL

ENGINE OIL FILTER SCREEN

CARBURETOR IDLE SPEED

DRIVE BELT

WEIGHT ROLLER

SLIDE PIECE

BRAKE FLUID

BRAKE SHOE/PAD WEAR

BRAKE SYSTEM

BRAKE STOP SWITCH

HEADLIGHT ADJUSTMENT

SIDE STAND

SUSPENSION

BOLTS, NUTS, FASTENERS

WHEELS/TIRES

STEERING HEAD BEARING

󱄿 󱄿

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I

C

I I

R C

I

I I

I

I I

C

I I

R C

I I I I

L

I I I I I I I

I I

R

I I

R C

I I I I L I I I I I I I I I I

I I

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I

I R R C

I

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NOTE 2

NOTE 3

500km 4,000km 8,000km 12,000km

6

months

1

month

12

months

18

months

REGULAR INSPECTION SCHEDULE

GREASING AT INNER PART OF MOVABLE DRIVE FACE

INSPECTIONS / ADJUSTMENTS

CARBURETOR

FUEL TUBE

FUEL COCK

FUEL STRAINER

FREE PLAY

CARBURETOR

ADJUST NUT

THROTTLE CABLE

RUBBER

LOCK NUT

THROTTLE CABLE

FUEL LINE(FUEL TUBE)

● Remove the luggage box.

● Check the fuel line connected to the fuel cock and

carburetor. If the fuel line is cracked, damaged or leaks, replace it.

THROTTLE GRIP OPERA TION

● Check to see if the throttle grip operates smoothly in

any steering position.

● If the throttle grip does not operate properly, check

the throttle cable for aging, damage or kinking.

● Check the throttle grip free play.

FREE PLAY : 2~6 mm

● For main adjustment of the throttle grip freeplay,

adjust the nut on the carburetor side.

● Loosen the lock nut, turn the adjuster nut and adjust

of it.

● For minute adjustment, to adjust the adjuster nut

under the throttle grip.

● Remove the rubber.

● Loosen the lock nut, turn adjuster nut and adjust of it.

INSPECTIONS / ADJUSTMENTS

0.6 ~ 0.7mm

CHECK THE DAMAGE OF

SEALING WASHER. CHECK THE CRACK.

CHECK THE CAP,

CONTAMINATION.

AIR CLEANER ELEMENT

CAP NUT 6mm

SAI PIPE

FRANGE BOLTS

AIR CLEANER

CYLINDER HEAD COVER

INSPECTIONS / ADJUSTMENTS

AIR CLEANER

● Loosen the 6 screws securing the air cleaner case

cover and remove it.

● Remove the air cleaner element.

● Check the element, if it is dirty or damaged, replace it

.

CAUTION

•Clean away dirt by tapping slightly the paper

element if its surfae has very dirty or there is much dirty on it. Also, blow away dirt sticked to the surface of filter from the inner side (carburetor) of the filter.

SPARK PLUG

● Remove the center cover.

● Remove the spark plug cap and disassemble the plug.

● If the spark plug is severely contaminated or

damaged, replace with a new one. If the plug can be reused after removing only carbon, use plug cleaner and wire brush to clean the plug.

● Always use the feeler gauge to check the gap.

GENUINE PLUG : CR6HSA SPARK PLUG GAP : 0.6~0.7mm TORQUE :1.2

kgf·m

CAUTION

•First, assmeble it temporarily by hand and tighten

completely the spark plug by using of the spark plug wrench.

VAL VE CLEARANCE

● Remove luggage vox

● Remove center cover

● Disassemble 4 cylinder head cover bolts

● Disassemble 2 cap nut 6mm

VALVE ROCKER ARM, LOCK NUT

ROCKER ARM

SPARK PLUG WENCH

COMPRESSION GAUGE

TURN

REMOVE FAN COVER RUBBER PLUG

INSPECTIONS / ADJUSTMENTS

CAUTION

•Inspect and adjust the valve clearance when the

engine is cold(35

℃).

•Remove cooling fan cover.

•Turn the flywheel counterclockwise , and align the

“T” mark of the flywheel with index mark of the RH. crankcase cover.

•Verify that the piston is located at the top dead

center.

● Measure the valve clearance with feeler gauge.

VALVE CLEARANCE : INTAKE 0.1±0.02MM

EXHAUST0.1±0.02MM

● Loosen the lock nut with a valve wrench,and set

valve clearance to the prescribed level by turning the adjusting screw with a valve adjusting wrench,and tighten the lock nut.

● After setting clearance to the prescribed level, hold

the adjuster screw with a valve adjusting wrench,and tighten the lock nut.

TORQUE :1.1 kgf.m TOOL: WRENCH 8X9 MM

ADJUST WRENCH FILLER GUAGE

● Measure the valve clearance again.

● Install the cylinder head cover and tighten the bolts.

TORQUE :0.9

kgf·m

CYLINDER COMPRESSION PRESSURE

● Start and warm up the engine.

● Stop the engine, and remove the spark plug cap and

spark plug.

● Install the compression gauge.

● Open the throttle completely, and crank the engine

with the starter motor until the gauge reading rising.

TOOL : COMPRESSION GAUGE

COMPRESSION PRESSURE : 10 kgf/cm

2

(600RPM)

● If the pressure is low, check the following:

-Inadequate valve clearance adjustment

-Valve leakage

-Leakage from the cylinder head gasket

-Piston/ cylinder worn.

● If pressure is high, check the following:

-Carbon deposits on the piston head, and cylinder head

NOTE

•The maximum reading is usually reached within

4~7 seconds.

THROTTLE STOP SCREW

TRANSMISSION OIL CHECK HOLE

DRAIN BOLT

OIL LEVER GAUGE

BOTOM LINE

BOTOM LINETOP LINE

TOP LINE

DRIVE BELT

DRIVEN PULLEY

DRIVE FACE

CARBURETOR

INSPECTIONS / ADJUSTMENTS

CARBURETOR IDL SPEED

● Turn the main key to the left , disassemble the lock

nut and raise up the seat.

● Remove the carburetor maintenance cover on the

luggage box.

● Connect to the ignition code

● Meet the speficied RPM by adjusting the throttle stop

screw with the ⊕screw driver.

NOTE

•Erect the motorcycle on the main stand.

•After checking all engine adjustments whether

satisfying cifications, adjust them.

•Heat the engine to make accurate idling inspection

and adjustment.

•Turn the throttle stop screw and make adjustments

to the prescribde speed. IDLE : 1,800±100 rpm

NOTE

•Make sure that the oil sealing washer is in good

condition.

•Replace the transmission when it is contaminated

seriously.

•Erect the transmission when it is contaminated

seriously.

NOTE

•Erect the motorcycle on the main stand and try.

CAUTION

•Do not excessive adjustment the pilot screw it

could be effect to starting.

•Refer to the page 5-9 for adjusting the pilot screw.

TRANSMISSION OIL

INSPECTION

● Loosen the oil check blot and measure the oil level.

● If the oil level is low, add the oil(SAE80W-90).

● Tighten the oil check bolt.

TRANSMISSION OIL CAPACITY : 0.12 L

DRIVE BELT

● Remove the 2 air cleaner mounting bolts.

● Remove the kick arm.

● Remove the LH. Crankcase cover.

● Check the drive belt for excessive wear or damage

● Check the schedule maintenance period, replace the

new drive belt if possible.

ENGINE OIL

INSPECTION

● Warm up the engine so that heat up the engine oil

fully.

● Stop the engine and loosen the oil level gauge then,

check the oil level.

● It is good if the oil surface is between the lower level

line and upper that of the sight glass. If the oil level is near the lower level line or below that, refuel the recommended oil to the upper level line.

ENGINE OIL CAPACITY : 0.8 L

BRAKE FLUID CHECK WINDOW

ABRASION LIMIT

ADJUST NUT

MASTER CYLINDER

CLEARANCE

INSPECTIONS / ADJUSTMENTS

BRAKE FLUID

● Check the oil level of front master cylinder.

● I f the oil level is near the lower limit level , remove

the oil cup cap, diaphragm and fill DOT3 or DOT4 brake fluid to the top limit line.

● If the brake fluid reaches to the lower limit line,

check the leaking of the brake system entirely.

NOTE

•If the brake pad is worn severely, brake fluid level

can be down.

NOTE

•Replace the brake pads in sets.

BRAKE PAD / SHOE

BRAKE P AD REPLACEMENT

● Check the brake pads for wear.

● If the red mark on the pad reaches to the brake disk,

replace the pads.

● Check the front brake hose for crack and damage,

replace it immediately if the brake fluid leaks.

BRAKE SHOE REPLACEMENT

● If the arrow mark of the wear limit with the

indication mark when the parking brake lever is tightly depressed, it indicates the brake lining has reached to the service limit. Replace the brake shoes.

● Adjustment of rear brake tolerance.

- Adjust the tolerance by turning adjust nut.

BRAKE LEVER CLEARANCE

● Check the clearance after pulling the lever.

FRONT: 10~20 MM REAR : 10~20 MM

DAELIM S4 50cc, S4 four Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual