Daelim SC125 SERVICE MANUAL

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure
for the SC125 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 3).
Sections 1 through 3 provide information on overall
vehicle; section 4, assembly and disassembly procedures
for external components, and section 5 describes
maintenance procedure for the engine, frame and electrical
systems.
To facilitate use of this manual, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide. If you cannot find the cause of
trouble, refer to Section 20: Troubleshooting.

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

LUBRICATION

INSPECTIONS / ADJUSTMENTS

EXTERNAL PARTS

FUEL SYSTEM

ENGINE REMOVAL

LH.CRANK CASE COVER / KICK STARTER /
CONTINUOUSLY VARIABLE TRANSMISSION

A.C.GENERATOR / STARTER CLUTCH

CYLINDER HEAD / VALVE

CYLINDER / PISTON

TRANSMISSION/CRANK SHAFT/CRANK CASE

FRONT WHEEL / FRONT FORK / STEERING

REAR WHEEL / BRAKE / SUSPENSION /
REAR SWING ARM

BRAKE SYSTEM

GENERAL

ENGINE

FRAME

ELECTRICAL SYSTEM

CHARGING SYSTEM / BATTERY

STARTER SYSTEM

LIGHTS/METER/SWITCHES

IGNITION SYSTEM

TROUBLESHOOTING

WIRING DIAGRAM

1-1

1. SERVICE INFORMATION

GENERAL SAFETY 1-1
SERVICE RULES

1-1

CAUTION WHEN WIRING

1-5

SERIAL NUMBER LOCATION

1-9

SPECIFICATIONS

1-10

TORQUE VALUES

1-12

SYMBOLS / ABBREVIATIONS

1-14

WIRING DIAGRAM

1-15

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.

1-2

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.

1-3

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.

’

1-4

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.

’

1-5

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

VALIDATION
OF CAPACITY!

REMOVE
THE
RUST!

1-6

SERVICE INFORMATION

Insert the lock of the coupler until the lock is fully
secured.

Turn off the main switch before connecting/dis­connecting.
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.

1-7

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.

1-8

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 care­fully 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?

1-9

SERVICE INFORMATION

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

1-10

SERVICE INFORMATION

ITEM SPECIFICATIONS

1,820 mm

685 mm

1,060 mm

1,300 mm

755 mm

110 mm

105 kg

235 kg

Underbone

Bottom link

Swing arm / 66mm

3.50 - 10 51J

3.50 - 10 51J

1.75 Kgf /

2.00 Kgf /

2.00 Kgf /

2.25 Kgf /

Hydraulic disk

Drum brake

8.0

1.0

26

Air cooled / 4stroke

1(Single cylinder), front angle 15

52.4 57.8 mm

124.6

9.2 : 1

SOHC 2valve

0.9

After disassembly

0.75

After Oil change

0.11

After disassembly

0.09

After Oil change

Forced pressure splash type

Dry process

13.0 kgf /

(570 rpm)

0

BTDC

25

ABDC

33

BBDC

0

BTDC

0.05 mm

0.05 mm

OVERALL LENGTH

OVERALL WIDTH

OVERALL HEIGHT

WHEEL BASE

SEAT HEIGHT

GROUND CLEARANCE

DRY WEIGHT

GROSS WEIGHT

TYPE

FRONT SUSPENSION / STROKE

REAR SUSPENSION / STROKE

FRONT TIRE SIZE / TYPE

REAR TIRE SIZE / TYPE

TIRE PRESSURE 1 PERSON FRONT

REAR

2 PERSON FRONT

REAR

FRONT / REAR BRAKE

PARKING BRAKE

FUEL TANK CAPACITY FULL CAPACITY

RESERVE CAPACITY

CASTER ANGLE

TYPE

CYLINDERS / ARRANGEMENT

BORE AND STROKE

DISPLACEMENT

COMPRESSION RATIO

VALVE TRAIN

OIL CAPACITY

TRENSMISSION OIL CAPACITY

LUBRICATION SYSTEM

AIR CLEANER TYPE

CYLINDER COMPRESSION PRESSURE

INTAKE VALVE OPEN

CLOSED

EXHAUST VALVE CLOSED

OPEN

VALVE CLEARANCE (COOLING-OFF PERIOD)

INTAKE

EXHAUST

DIMENSIONS

FRAME

ENGINE

SPECIFICATIONS

1-11

SERVICE INFORMATION

ITEM SPECIFICATIONS

CV type ( vacuum ) 23 mm

PD24J

Auto-bystarter

# 110

2 and

trust out

11 mm

1.600

100 ( rpm )

Automatic Transmission(V-belt)

2.800

3.077

AC-C.D.I Ignition

13

12V 8AH

P-Z9HC(CHAMPION)

0.6 - 0.7 mm

15A

Kick / starter motor

12V 35 / 35W

12V 10W

4

12V LED

12V1.7W

1

12V1.7W

2

12V 3.4W

2

12V 5W

TYPE / VENTURI BORE

MODEL MARK

CHOKE TYPE

MAIN JET

PILOT SCREW INITIAL SETTING

FLOAT LEVEL

IDLE SPEED

CLUTCH TYPE

PRIMARY REDUCTION

SECONDARY REDUCTION

IGNITION SYSTEM

IGNITION TIMING F MARK

BATTERY TYPE / CAPACITY

SPARK PLUG

SPARK PLUG GAP

FUSE CAPACITY

STARTING SYSTEM

HEADLIGHT ( HIGH / LOW )

WINKER LIGHTS ( FR / RR )

TAIL / STOP LIGHT

HIGH-BEAM PILOT

WINKER PILOT LAMP

SPEEDOMETER LAMP

LICENSE LAMP

CARBURETOR

DRIVE TRAIN

ELECTRICAL

SYSTEM

1-12

SERVICE INFORMATION

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

1.5 kgf m

2.5 kgf

m

1.1 kgf

m

1.1 kgf

m

5.5 kgf

m

7.5 kgf

m

5.5 kgf

m

1.0 kgf

m

1.2 kgf

m

5.5 kgf

m

2.9 kgf

m

1.0 kgf

m

0.4 kgf

m

0.9 kgf

m

1.2 kgf

m

1.0 kgf

m

0.9 kgf

m

1.0 kgf

m

5.5 kgf

m

0.9 kgf

m

APPLY ENGINE OIL

APPLY ENGINE OIL

30

12

5

6

12

12

12

8

12

30

8

6

6

6

6

8

8

6

22

6

1

1

4

2

1

1

1

1

1

1

4

2

1

4

8

1

1

3

1

2

OIL FILTER CAP

OIL DRAIN PLUG BOLT

VALVE ADJUST SCREW LOCK NUT

CYLINDER HEAD BOLT

FLYWHEEL BOLT

DRIVE FACE NUT

CLUTCH OUTER BOLT

CAM CHAIN TENSIONER PIVOT 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

STARTING CLUTCH NUT

STARTER MOTOR FLANGE BOLT

TORQUE VALUES

ENGINE

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

7.0 kgf m

0.25 kgf

m

6.0 kgf

m

6.0 kgf

m

3.1 kgf

m

1.2kgf

m

4.25 kgf

m

12.5 kgf

m

0.4 3kgf

m

2.25kgf

m

4.0 kgf

m

4.0 kgf

m

3.5kgf

m

5.25 kgf

m

4.5 kgf

m

4.0 kgf

m

1.5 kgf

m

4.5 kgf

m

26

26

10

12

8

6

8

16

5

22

10

10

10

12

10

10

10

10

1

1

2

1

1

2

3

1

1

2

2

2

2

2

1

2

1

1

STEERING STEM NUT

STEERING TOP THREAD NUT

HANDLE POST

FRONT AXLE NUT

FRONT CALIPER BRACKET BOLT

FRONT MASTER CYLINDER HOLD BOLT

FRONT DISK PLATE BOLT

REAR AXLE NUT

SPEEDOMETER GEAR BOX SCREW

FRONT FORK BOLT

REAR CUSHION UPPER BOLT

REAR CUSHION UNDER BOLT

REAR CUSHION ROD LOCK NUT

ENGINE HANGER UPPER BOLT

ENGINE HANGER LAWER 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.

1-13

SERVICE INFORMATION

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 FLANGE BOLT, NUT

8mm FLANGE BOLT, NUT

10mm FLANGE BOLT, NUT

SH (Small Head) : Indicates 6mm bolt of 8mm flange head.

SYMBOL

CAUTION

NOTE

SYMBOL

1-14

SERVICE INFORMATION

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

Add oil. If there is no specific oil indicated, use the designated or recommended engine oil.

Apply grease

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

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.

( 3-1)

ASS’Y

The following abbreviations are used in this manual.

ASSEMBLY

Left

Right

LH.

RH.

SYMBOL

WARNING

OIL

GREASE

1-15

SERVICE INFORMATION

WIRING DIAGRAM

FR.WINKER

FUEL TANK

FUEL STRAINER COMP.

FUEL TANK

SAI PIPE

C.D.I UNIT

MUFFLER

FUEL PUMP

AIR CLEANER

ENGINE

KICK

KEY SET

IGNITION COIL COMP.

1-16

SERVICE INFORMATION

SPEEDOMETER CABLE

FR. BRAKE HOSE

CARBURETOR

INSULATOR

START
MAGNETIC SWITCH

C.D.I UNIT COMP.

IGNITION COIL COMP.

SAI PIPE COMP.

GAS
RATIO CONTROLLER

WINKER RELAY

HEADLIGHT
CONTROLLER

KEY SET

REG.
RECTIFIER

2-1

2. LUBRICATION

SERVICE INFORMATION

GENERAL SAFETY

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.

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after
handling the used oil.

The oil pump can be serviced without removing the engine from the frame.

ENGINE OIL

TRANSMISSION OIL

TORQUE VALUES

OIL FILTER SCREEN CAP

1.5 f m

OIL PUMP BOLT

1.1 f m

OIL DRAIN PLUG BOLT

2.5 f m

SERVICE INFORMATION 2-1
TROUBLE SHOOTING

2-2

ENGINE OIL LEVEL INSPECTION

2-3

ENGINE OIL CHANGE

2-3

OIL FILTER ELEMENT CHANGE

2-3

OIL PUMP

2-4

TRANSMISSION OIL INSPECTION

2-7

LUBRICATION POINTS

2-8

OIL CAPACITY

RECOMMENDED

OIL

0.9 (After disassembly)

0.75

(After Oil change)

API service classification : SL grade
Viscosity : SAE10W-40
(Use appropriate type of oil with viscosity satisfying

the atmospheric temperature
In your riding area based on the table shown on the
right side.)

OIL CAPACITY

RECOMMENDED OIL

0.11

(Full capacity)

0.09

(After oil change)

DMC Genuine mission oil or SAE 80W/90

-10 0 10 20 30 40

2-2

LUBRICATION

TROUBLE SHOOTING

Oil level low

Oil consumption naturally.
External oil leaks.
Worn piston ring or incorrect piston ring installation.
Worn valve guide or seal.

Oil contamination

Oil or filter not changed often enough.
Faulty head gasket.
Worn piston rings.

Low or no oil pressure

Clogged oil orifice.
Incorrect oil being used.

ENGINE OIL LEVEL INSPECTION

Erect the motorcycle on the main stand.
Warm up the engine to heat the engine oil to an
appropriate level.
Stop the engine, and loosen the oil level gauge and
check the oil level line.

ENGINE OIL CHANGE

NOTE

To completely and rapidly drain engine oil, warm up
engine and erect the motorcycle on side stand.

Loosen the oil drain bolt and drain engine oil.
Operate the kick starter arm for several times to
remove the remaining oil from the engine.
Tighten the oil drain bolt.

TORQUE VALUE : 2.5 kgf m

CAUTION

It is extremely important to replace oil filter or clean
the oil filter screen at the first maintenance interval
(after 1,000Km).
Clean the oil filter screen every 4,000Km.
Clean the filter screen with fresh cleaning oil.
Check the hole cap O-ring for satisfactory condition
if necessary replace it with new one.
Tighten the hole cap with specified torque.

TORQUE VALUE : 1.5 kgf m

Fill the recommended engine oil to oil inlet.

OIL CAPACITY : 0.9 (After disassembly)

0.75 (After Oil change)

Tighten the oil level gauge.
API service classification : SL grade.
Start the engine and keep it idle for a few minutes.
Stop the engine and check the oil level. If the oil level
is low, add the recommended engine oil.
Check on oil leaks.

2-3

LUBRICATION

OIL PUMP

REMOVAL

Drain the engine oil.
Remove the following parts :

-Muffler (

4-3)

-Cooling fan cover

-Cooling fan (

8-2)

-A.C. generator (

8-4)

-RH. crankcase cover (

8-4)

-Starter driven gear (

8-6)

-Reduction gear (

8-5)

-Starting clutch assembly (

8-6)

Remove the oil separator.
Remove the oil pump drive gear nut.
Remove the oil pump drive gear chain.

Loosen the 2 flange bolts securing the oil pump.
Remove the oil pump.

2-4

LUBRICATION

DISASSEMBLY

Loosen the screw securing the oil pump plate.
Remove the oil pump body and the oil pump plate.
Clean the oil pump body, inner and outer rotors with
fresh cleaning oil.

INSPECTION

Assemble the inner and outer rotors to the oil pump
body correctly.
Measure the clearance between the pump body and
outer roter.

SERVICE LIMIT : 0.23mm
TOOL : FEELER GAUGE

Measure the clearance between lnner and outer rotor.

SERVICE LIMIT : 0.18mm

Measure the clearance between many faces of rotor and
the pump body

SERVICE LIMIT : 0.12mm

2-5

LUBRICATION

2-6

LUBRICATION

ASSEMBLY

Clean all parts with fresh cleaning oil.

Install the inner and outer rotors to the pump body.

Install the oil pump plate to the pump body.
Tighten the pan screw.

NOTE

After installing, check the oil pump to operate
smoothly.

INSTALLATION

Install the oil pump to the RH. crankcase.
Install the following parts.

-Oil pump drive gear and chain

-Starting clutch assembly

-Starter driven gear and reduction gear

-RH. crank case cover

-A.C. generator

-Cooling fan and cooling fan cover

-Muffler

2-7

LUBRICATION

TRANSMISSION OIL

INSPECTION

Check the body and the connection of each engine
component for any leak.
Remove the oil check bolt and check to see if the oil
overflows from the oil check hole.
If only the small amount of oil overflows. fill the
recommended transmission oil through the oil filler
hole gradually.

OIL CAPACITY : 0.11

(FULL)

0.09

(CHANGE)

NOTE

Oil level inspection must be performed in the flat
ground with the vehicle being straight by raising the
main stand.

RECOMMENDED OIL : SAE 80W/90

Tighten the oil check bolt.

TORQUE VALUE : 0.9 kgf m

Start the engine and check for leak.

LUBRICATION POINTS

Unless specifically designated, use general grease to
lubricate the lubrication points. For sliding parts not
shown here, add oil or grease.

CONTROL CABLE LUBRICATION

Remove and clean the upper assembly of the throttle
cable, and apply oil. If the cable has expanded, replace it.

2-8

LUBRICATION

3-1

3. 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.

SPECIFICATIONS

TIRES

SERVICE INFORMATION 3-1
MAINTENANCE SCHEDULE 3-3
FUEL LINE (FUEL TUBE) 3-4
THROTTLE GRIP OPERATION

3-4

AIR CLEANER

3-4

SPARK PLUG

3-5

VALVE CLEARANCE

3-5

CYLINDER COMPRESSION PRESSURE

3-6

CARBURETOR IDLE SPEED

3-6

BRAKE FLUID

3-6

BRAKE PAD/SHOE

3-7

SIDE STAND

3-7

SUSPENSION

3-8

BOLTS, NUTS, FASTENERS

3-8

WHEELS/TIRES

3-8

STEERING HEAD BEARING

3-9

BATTERY

3-9

THROTTLE GRIP PLAY 2- 6mm
SPARK PLUG P-Z9HC
SPARK PLUG GAP 0.6-0.7mm

IN 0.05mm
EX 0.05mm

CARBURETOR IDLE SPEED 1,600

100rpm

CYLINDER COMPRESSION PRESSURE 13kgf/

( 570rpm )

NOTE

For information on engine oil and oil filter, refer to section 4.
Stand the main stand prior to beginning work.

VALVE CLEARANCE

COLD TIRE

PRESSURE

TIRE SIZE

DRIVER ONLY

DRIVER AND A

PASSENGER

FRONT TIRE

REAR TIRE

FRONT TIRE

REAR TIRE

FRONT TIRE

REAR TIRE

1.75kgf/

2.00kgf/

2.00kgf/

2.25kgf/

3.50 - 10 51J

3.50 - 10 51J

TORQUE VALUES

SPARK PLUG 1.2kgf m
CYLINDER HEAD COVER BOLTS 0.9kgf m
VALVE ADJUSTING NUTS 1.1kgf m

TOOLS

WRENCH 8X9mm
ADJUST WRENCH
COMPRESSION GAUGE

3-2

INSPECTIONS / ADJUSTMENTS

FUEL LINE(FUEL TUBE)

THROTTLE GRIP OPERATION

AIR CLEANER

SPARK PLUG

VALVE CLEARANCE

TRANSMISSION OIL

ENGINE OIL

ENGINE OIL FILTER SCREEN

CARBURETOR IDLE SPEED

BRAKE FLUID

BRAKE SHOE/PAD WEAR

BRAKE SYSTEM

BRAKE STOP SWITCH

HEADLIGHT AIM

SIDE STAND

SUSPENSION

BOLTS, NUTS, FASTENERS

WHEELS/TIRES

STEERING HEAD BEARING

DRIVE BELT

WEIGHT ROLLER

SLIDE PIECE

MOVABLE DRIVE FACE INNER PART

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3-3

INSPECTIONS / ADJUSTMENTS

MAINTENANCE SCHEDULE

Carry out pre-operation check at each scheduled maintenance period based on the information described in the owner’s
manual.

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

These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose.
Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service
than specified in the following chart.

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.

NOTE 2

NOTE 3

NOTE 3

FREQUENCY

ODOMETER READING(NOTE 1)

61218

1 4 8 12 REMARK

ITEM

x 1000Km

MONTH

FUEL LINE(FUEL TUBE)

Remove the luggage box.( 4-4)
Check the fuel tube of the fuel pump connected to the
fuel tank and carburetor. If the fuel tube is cracked,
damaged or leaks, replace it.

THROTTLE GRIP OPERATION

Check 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 bending.
Check the throttle grip free play.

FREE PLAY : 2~6mm

For adjustment, loosen the lock nut and turn adjuster.
After adjusting, tighten lock nut. After adjustment is
completed, recheck the throttle grip free play.

AIR CLEANER

Remove the luggage box.
Loosen the 5 screws securing the air cleaner case cover,
remove the air cleaner case cover.

Loosen the 3 screws securing the air cleaner element
holder.
Remove the air cleaner element.
Check the element for dirty or damage, if necessary
replace it with new one.

CAUTION

Do not clean by compressed air blowing.

3-4

INSPECTIONS / ADJUSTMENTS