Daelim SJ50 SERVICE MANUAL

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure
for the S-Five 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, service information,
and troubleshooting guide. If you cannot find the cause of
trouble, refer to Section 18: 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
INSPECTIONS/ADJUSTMENTS
EXTERNAL P ARTS
LUBRICA TION SYSTEM
FUEL SYSTEM
ENGINE REMOVAL/INST ALLATION

KICK STARTER/ CONTINUOUSLY
VARIABLE TRANSMISSION

CYLINDER HEAD/CYLINDER/PISTON
TRANSMISSION/CRANKSHAFT/CRANK CASE
FRONT WHEEL/FRONT FORK/STEERING
REAR WHEEL/BRAKE/SUSPENSION
BRAKE SYSTEM

GENERAL

ENGINE

FRAME

ELECTRICAL SYSTEM

BATTERY/CHARGING SYSTEM

STARTING SYSTEM
LIGHTS/METER/SWITCHES

IGNITION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

WIRING DIAGRAM

17

TROUBLESHOOTING

18

1-1

1. SERVICE INFORMATION

GENERAL SAFETY 1-1
SERVICE RULES

1-1

CAUTION WHEN WIRING

1-5

SERIAL NUMBER LOCATION

1-9

MAINTENANCE INFORMATION

1-10

TWIST TORQUE

1-14

SPECIALIZED TOOLS

1-16

LUBRICATION OIL

1-17

SYMBOLS

1-18

WIRING DIAGRAM

1-19

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

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 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?

1-9

SERVICE INFORMATION

SERIAL NUMBER LOCATION

ENGINE SERIAL NUMBER LOCA TION FRAME SERIAL NUMBER LOCA TION

1-10

SERVICE INFORMATION

MAINTENANCE INFORMATION

SPECIFICA TIONS

MAINTENANCE SPECIFICA TIONS

TYPE OF VEHICLE

OVERALL LENGTH

OVERALL WIDTH

OVERALL HEIGHT

WHEEL BASE
MOTOR TYPE

DISPLACEMENT

FUEL TYPE

FRONT AXLE

REAR AXLE

TOTAL

PASSENGERS

FRONT AXLE

REAR AXLE

TOTAL

GROUND CLEARANCE

CASTER

TRAIL

S-Five

1,795mm

698mm
1,114mm
1,260mm

SJ50E

49.5cc

UNLEADED GASOLINE

36.5kg

57.5kg
94kg

2(75kg)

58.5kg

100.5kg
159kg

131mm

26。

79mm

FRAME TYPE

BRAKING DISTANCE

MIN. REVOLUTION RADIUS

COOLING TYPE

STARTING

MOTOR TYPE

NO. OF CYLINDERS, MOUNTING

VALVE APPARATUS

BORE & STROKE

COMPRESSION RATIO

MAX. OUTPUT

MAX. TORQUE
PRIMARY SPEED REDUCTION RATIO
SECONDARY SPEED REDUCTION RATIO

TRANSMISSION

TRANSMISSION RATIO 1ST GEAR

FRAME NUMBER

ENGINE NUMBER

UNDER BONE

8.0m(30km/h VELOCITY)
1,800mm

AIR-COOLED

ST ARTER MOTOR, KICK

2-CYCLE

1 CYLINDER, TRANSVERSE

READ VAL VE PIST ON VALVE COMBINA TION

39.0X41.4mm

6.8:1

5.1PS/7,000rpm

0.55kgf·m/7,000rpm

4.083

3.615

GEARLESS TRANSMISSION

2.4~0.76

KMYSE1B4S1K000001~

SJ50E3000001~

DRY WEIGHT

GROSS WEIGHT

ITEM STANDARD

LUBRICATION SYSTEM

ENGINE OIL TANK CAPACITY FULL CAPACITY
RECOMMENDED ENGINE OIL
TRANSMISSION OIL CAPACITY FULL CAPACITY
RECOMMENDED TRANSMISSION OIL

LUBRICATION TYPE
OIL FILTER TYPE
OIL PUMP TYPE

COOLING TYPE

COOLING TYPE

1.2 liters
DMC Ultra 2 super oil, 2-Cycle Oil

0.09 liters
DMC Pure Mission Oil or
SAE 80W/90

Separation Lubrication
Current Filtration,
Plunger Type

Air-Cooled

USE LIMITS

1-11

SERVICE INFORMATION

ITEM STANDARD

FUEL SYSTEM

FUEL TANK CAPACITY FULL CAPACITY
AIR CLEANER TYPE
CARBURETOR SETTING MARK

VENTURI DIAMETER
AIR SCREW OPENING
FLOAT LEVEL
IDLING RPMS
NO. OF JET NEEDLES
MAIN JET
SLOW JET

THROTTLE GRIP CLEARANCE

CYLINDER HEAD, CYLINDER, PISTON

PORT OPEN/CLOSE PERIODS INHALATION OPEN

CLOSE

EXHAUST OPEN

CLOSE

SCAVENGING OPEN

CLOSE

CYLINDER HEAD COMPRESSION PRESSURE

CYLINDER ID MARK LOCATION

INSIDE DIAMETER ID MARK(A)

NO ID MARK
CYLINDRICAL DEGREE
OUT OF ROUNDNESS

PISTON

OUTSIDE DIAMETER MEASUREMENT LOCATION

OUTSIDE
DIAMETER

OUTSIDE DIAMETER ID MARK(A)

ID MARK(B)

NO ID MARK
CYLINDER AND PISTON CLEARANCE
PISTON PIN HOLE INSIDE DIAMETER

PISTON PIN OUTSIDE DIAMETER
PISTON AND PISTON PIN CLEARANCE

PISTON RING GAP TOP

SECOND

RING MARK

CONNECTING ROD SMALL END PORTION DIAMETER

6ℓ
Urethane Foam
PB11P

16.0mm
1 1/4 Rotation

8.0mm
1,800±100rpm
4
#75
#38
2-6mm

Auto Control
Auto Control

81.5。BBDC

81.5。ABDC

56.5。BBDC

56.5。ABDC
10kgf/㎠-600rpm

Side of Cylinder

39.000-39.005mm

39.005-39.010mm

-

-

38.955-38.960mm

38.965-38.970mm

38.960-38.965mm

0.035-0.050mm

12.002-12.008mm

11.994-12.000mm

0.002-0.014mm

0.10-0.25mm

0.10-0.25mm
Turning up

17.005-17.017mm

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

39.05mm

39.05mm

0.10mm

0.10mm

38.90mm

38.90mm

38.90mm

0.10mm

12.03mm

11.98mm

0.03mm

0.40mm

0.40mm

-

17.03mm

USE LIMITS

3mm

1-12

SERVICE INFORMATION

ITEM STANDARD

CLUTCH

CLUTCH AUTOMATIC

TYPE
CLUTCH OUTER DIAMETER
CLUTCH LINING THICKNESS

DRIVE BELT WIDTH
MOVABLE DRIVE FACE

BUSH INSIDE DIAMETER
BOSS OUTSIDE DIAMETER
WEIGHT ROLLER OUTSIDE DIAMETER

DRIVEN PULLEY FACE SPRING FREE LENGTH

FACE OUTSIDE DIAMETER
MOVABLE FACE INSIDE DIAMETER

CRANK SHAFT

CRANK SHAFT LARGE END SIDE CLEARANCE

CONNECTING ROD LARGE END RIGHT
ANGLE DIRECTION CLEARANCE

CRANK SHAFT SHAKING A

B

FRONT, REAR WHEELS

WHEELS

RIM RUNOUT RADICAL

AXIAL

AXLE DEFLECTION

TIRES TYPE

TIRE PRESSURE FRONT

REAR

TIRE SIZE FRONT

REAR

SUSPENSION

FRONT FRONT CUSHION FREE LENGTH
REAR REAR CUSHION FREE LENGTH

BRAKES

FRONT BRAKE LEVER FREE PLAY

BRAKE FLUID
BRAKE PAD THICKNESS
DISK THICKNESS
DISK SHAKING
DISK WEAR LINE
MASTER CYLINDER INSIDE DIAMETER
MASTER PISTON OUTSIDE DIAMETER
CALIPER CYLINDER INSIDE DIAMETER
CALIPER PISTON OUTSIDE DIAMETER

REAR BRAKE LEVER FREE PLAY

DRUM INSIDE DIAMETER
LINING THICKNESS

Automatic Centrifugal
Continuously Variable Transmission

107.0-107.2mm

3.0mm

17.5mm

20.035-20.085mm

20.011-20.025mm

15.920-16.080mm

98.1mm

33.965-33.985mm

34.000-34.025mm

0.15~0.55mm

0.010~0.02mm

0.03mm(70mm fromcenter)

0.05mm(40mm fromcenter)

-

-

­TUBELESS

1.75㎏

f/㎠ (2.00㎏f/㎠)

2.00㎏

f/㎠ (2.25㎏f/㎠)

120/70-12 58L
130/70-12 62L

263.5mm

234.8mm

10~20mm
DOT3 or DOT4

-

3.5mm

-

3.0mm

11.000-11.043mm

10.957-10.984mm

30.230-30.280mm

30.148-30.198mm
10~20mm
110mm

4.0mm

-

-

107.5mm

2.0mm

16.5mm

20.60mm

19.97mm

15.40mm

92.8mm

33.94mm

34.06mm

0.60mm

0.04mm

0.15mm

0.10mm

2.0mm

2.0mm

0.2mm

-

-

-

-

256.0mm

228.0mm

-

­to wear line

3.0mm

0.3mm

11.05mm

10.91mm

30.29mm

30.14mm

­111mm

2.0mm

USE LIMITS

1-13

SERVICE INFORMATION

ITEM STANDARD

B8HSA

0.6~0.7mm
BTDC 17。±2。/1,800rpm
over 120V
over 120V
over 1.5V

0.1-0.5Ω

6.5-9.5

㏀㏀

2.6±1.25

㏀㏀

500Ω±20%
100Ω±20%

AC
12V-9.5A/5,000rpm

0.8Ω±20%

0.55Ω±20%
Semi-conductor

12.6-13.6V/5,000rpm

14.0-15.0V/5,000rpm

6.3-7.1Ω

5.5-6.5Ω

12V-35/35W
12V-5/21W
12V-16W×2
12V-10W×2
12V-5W
12V-5W
12V-1.7W×2
14V-3W
14V-3W
14V-3W×2
7A

MF BATTERY
12V-3AH

13.0-13.2V

0.4A/5h
4A/0.5h

USE LIMITS

IGNITION SYSTEM

SPARK PLUG STANDARD

PLUG GAP

IGNITION TIMING F MARK
PEAK VOLTAGE IGNITION COIL(PRIMARY VOLTAGE)

EXCITE COIL
PULSE GENERATOR

IGNITION COIL RESISTANCE VALUES(20℃)

PRIMARY COIL
SECONDARY COIL

(PLUG CAP CONNECTION)

SECONDARY COIL

(PLUG CAP DISCONNECTION)
EXCITE COIL RESISTANCE VALUE(20℃)
PLUSE GENERATOR RESISTANCE VALUE(20℃)

CHARGING SYSTEM, AC GENERATOR

AC GENERATOR TYPE

OUTPUT
CHARGING COIL RESISTANCE VALUE(20℃)
LIGHTING COIL RESISTANCE VALUE(20℃)

REGULATOR/RECTIFIER

TYPE
CONTROL VOLTAGE LAMP SIDE

CHARGING SIDE

REGISTER RESISTANCE VALUE

REGISTER(6.7Ω 5W)
REGISTER(5.9Ω 30W)

LIGHTS, METER, SWITCHES

LIGHTS, BULBS HEADLIGHT

TAIL/STOP LIGHT
WINKER LIGHTS FRONT

REAR
POSITION LAMP
LICENSE LAMP
METER LIGHTS
HIGH BEAM PILOT
OIL PILOT
WINKER PILOTS
FUSE

BATTERY

TYPE
CAPACITY
TERMINAL VOLTAGE(20℃)
CHARGING CURRENT/STANDARD
CHARGING CURRENT/RAPID

1-14

SERVICE INFORMATION

TWIST TORQUE

ST ANDARD TWIST T ORQUE

ENGINE P ARTS

TYPE

5mm BOLT, NUT
6mm BOLT, NUT

8mm BOLT, NUT
10mm BOLT, NUT
12mm BOLT, NUT

TWIST TORQUE

0.5㎏f·m

1.0㎏f·m

2.2㎏f·m

3.5㎏f·m

5.5㎏f·m

TYPE

5mm SCREW

6mm SCREW
6mm SCREW FLANGE BOLT, NUT
8mm SCREW FLANGE BOLT, NUT

10mm SCREW FLANGE BOLT, NUT

TWIST TORQUE

0.4㎏f·m

0.9㎏f·m

1.2㎏f·m

2.7㎏f·m

4.0㎏f·m

TWIST PART

FLY WHEEL NUT
DRIVE FACE NUT
CYLINDER HEAD BOLT
SPARK PLUG
DRIVEN FACE NUT
CLUTCH OUTER NUT
OIL LEVEL CHECK BOLT
EXHAUST PIPE JOINT NUT
MUFFLER BRACKET BOLT
CRANK CASE BOLT

NUMBER

1
1
4
1
1
1
1
2
2
6

TWIST TORQUE

4.0㎏f·m

5.5㎏f·m

1.0㎏f·m

1.4㎏f·m

5.5㎏f·m

4.0㎏f·m

1.3㎏f·m

1.2㎏f·m

3.3㎏f·m

1.0㎏f·m

REFERENCESCREW DIAMETER (mm)

10
12

6
14
28
10

8

6

8

6

Bolts not appearing in the following table are tightened using standard torque.

1-15

SERVICE INFORMATION

FRAME P ARTS

TWIST PART

STEERING STEM LOCK NUT
HANDLE POST TWIST NUT
FRONT BRAKE LEVER PIVOT BOLT
FRONT BRAKE LEVER PIVOT NUT
REAR BRAKE LEVER PIVOT SCREW
REAR BRAKE LEVER PIVOT NUT
MASTER CYLINDER HOLDER BOLT
MASTER CYLINDER COVER SCREW
BRAKE HOSE BOLT
CALIPER MOUNT BOLT
CALIPER BREATHER VALVE
CALIPER PAD PIN
CALIPER SLIDE PIN BOLT
BRAKE SWITCH SCREW
STEERING STEM BOLT(FRONT FORK SIDE)
FRONT AXLE NUT
REAR AXLE NUT
SPEEDOMETER CABLE SETTING SCREW
REAR BRAKE ARM BOLT
FRONT BRAKE DISK BOLT
REAR CUSHION UPPER BOLT
REAR CUSHION LOWER BOLT
ENGINE HANGER BRACKET NUT

(FRAME SIDE)
EXHAUST PIPE JOINT NUT
MUFFLER BRACKET BOLT
EXHAUST PIPE PROTECTOR SCREW

NUMBER

1
1
1
1
1
1
2
2
2
2
1
2
1
1
4
1
1
1
1
3
1
1
2

3
2
4

TWIST TORQUE

7.0㎏f·m

5.0㎏f·m

1.0㎏f·m

1.0㎏f·m

0.3㎏f·m

0.4㎏f·m

1.2㎏f·m

0.2㎏f·m

3.5㎏f·m

2.7㎏f·m

0.6㎏f·m

1.8㎏f·m

2.3㎏f·m

0.12㎏f·m

3.5~4.5㎏f·m
6㎏f·m

11.0㎏f·m

0.2㎏f·m

0.6㎏f·m

3.9㎏f·m

4.0㎏f·m

4.0㎏f·m

5.0㎏f·m

(7.3㎏f·m)

1.2㎏f·m

3.3㎏f·m

0.5㎏f·m

REFERENCE

SCREW DIAMETER

-

10

6
6
5
5
6
4

10

8
8

10

8

4
10
12
14

4

6

8
10
10
10

6

8

6

1-16

SERVICE INFORMATION

SPECIALIZED TOOLS

TOOL NAME

FLOAT LEVEL GAUGE
BEARING DIRVER
BEARING REMOVER
REMOVER HANDLE
REMOVER WEIGHT
DRIVER HANDLE A
OUTER DRIVER 24×26mm
CLUTCH SPRING COMPRESSOR
SOCKET WRENCH 39mm
CLUTCH CENTER HOLDER
UNIVERSAL HOLDER
CRANK ASSEMBLY
DRIVER HANDLE A
OUTER DRIVER 37×40mm
DRIVER PILOT, 17mm
UNIVERSAL BEARING PULLER
CRANK CASE PULLER
CRANK ASSEMBLY
OUTER DRIVER 52×55mm
DRIVER PILOT 20mm
DRIVER HANDLE A
CRANK ASSEMBLY
LOCK NUT WRENCH A
LOCK NUT WRENCH B
BALL RACE REMOVER
OUTER DRIVER, 42×47mm
DRIVER HANDLE A
SHOCK ABSORBER COMPRESSER
COMPRESSER SCREW ASS’Y
SPRING COMPRESSER ATTACHMENT
SPRING COMPRESSER ATTACHMENT
UNIVERSAL HOLDER
A.G.G ROTOR PULLER

TOOL NO.

07401-001000

07945-GC80000

07936-3710300

07936-3710100
07741-0010201
07749-0010000
07746-0010700

07960-KM10000

0723-03900
07724-0050001
07725-0030000

0740-00001

0749-0010000
07746-0010200
07746-0040400

0755-00001
0751-00003

0740-00001
07746-0010400
07746-0040500
07749-0010000

0740-00001
07916-1870101

07916-KM10000

07946-GA70000

07746-0010300
07749-0010000

07GM-0010000

079GME-0010100

07967-GA70102

07JME-GW20100

07725-0030000

0750-00006

USAGE

Carburetor Oil Level Measurement
Change of Driven Face Outer Bearing
Disassembly of Driven Face Needle Bearing

Assembly of Driven Face Needle Bearing

Disassembly/Assembly of Clutch/Driven Face

Disassembly/Assembly of Driven Pulley/Driven Face
Disassembly/Assembly of

Clutch

/Driven Pulley
Assembly of Drive Shaft
Assembly of Drive Shaft Bearing

Disassembly of Crank Shaft Bearing
Disassembly of R/L Crank Case, Crank Shaft
Disassembly of R.Crank Case, Crank Shaft
Assembly of Crank Shaft Bearing

Assembly of R/L Crank Shaft Oil Seal
Disassembly of Top Cone Race

Assembly of Ball Race

Disassembly/Assembly of Rear Cushion

Disassembly/Assembly of Fly Wheel
Disassembly of Fly Wheel

CHAPTER

5

7

9

10

11

13

1-17

SERVICE INFORMATION

LUBRICATION OIL

ENGINE P ARTS

APPLICATION AREAS

CRANK CASE JOINING FACE
CRANK CASE REVOLUTION PART
CYLINDER BIG REVOLUTION PART, FRICTION PART
TRANSMISSION(FINAL REDUCTION)
KICK SPINDLE BUSH
STARTER PINION
STARTER DRIVE GEAR OPERATION PART
MOVEABLE DRIVEN FACE
(DRIVEN FACE OPERATION PART)
OIL PUMP DRIVE GEAR

CAUTIONARY SUGGESTIONS

Capacity : 0.09ℓ

Capacity : 5.0~5.6g

OIL TYPE

Gasket Fluid(TB 1215)
Ultra-2 Super, 2-Cycle Oil
(Separation Lubrication Use)
SAE 80W/90

Multi-Purpose Grease

Molybdenum Grease

FRAME P ARTS

APPLICATION AREAS

FRONT WHEEL DUST SEAL EDGES
FRONT PIVOT ARM BUSH FRICTION FACE
FRONT PIVOT ARM SEAL EDGES
REAR BRAKE CAM AXLE PART, CAM PART
WHOLE AREA OF REAR BRAKE CAM DUST SEAL
REAR BRAKE ANCHOR PIN AXLE PART
FRONT BRAKE OIL SEAL EDGES
FRONT BRAKE CAM AXLE PART, CAM PART
WHOLE AREA OF FRONT BRAKE CAM DUST SEAL

SPEEDOMETER GEAR/PINION INSIDE DIAMETER
PART, AXLE PART, GEAR TEETH PART

BALL RACE, BEARING REVOLUTION PART

HANDLE GRIP INSIDE AXLE PART

CAUTIONARY SUGGESTIONS

OIL TYPE

Multi-Purpose Grease

Adhesives ROYAL BOND 1300

SYMBOL

CAUTION

NOTE

SYMBOL

1-18

SERVICE INFORMATION

SYMBOLS

The following symbols appear in this manual and offer cautionary suggestions which need to be heeded when performing
maintenance work on the vehicle.

CAUTION

Indicates special caution needed.
Possibility of resulting in serious
malfuctioning of vehicle if ignored.

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

CAUTION

Use recommended cushion oil.

Use Specialized T ool.

Use Option T ool. These tools are needed for the part, see part list for tool number.

Indicates reference page. This particular symbol indicates chapter 3 page 1.

Indicates needed application of oil. When a designated brand is not listed, use the designated or
suggested engine oil when this symbol appears.
Indicates needed application of a molybdenum solution. The molybdenum solution is made by
mixing molybdenum grease with engine oil at a 1:1 ratio.
Indicates needed application of a multi purpose grease. (NLG 1 #2 using a lithium soap base)
Example brand: Shell Albania EP-2(Fire-proof Shell Oil)
Indicates needed application of molybdenum grease.
(containing over 3% of emulsified molybdenum, NCG 1 #2)
Indicates needed application of molybdenum paste.
(containing over 40% of emulsified molybdenum, NLG 1 #2)

Indicates needed application of silicon grease.

Indicates needed application of an antilock substance.
When a designated brand is not listed, use a medium-strength brand.

Indicates needed application of a sealant.

Indicates new part needed every time when disassembled.

Indicates brake fluid needed. Use recommended DOT3 or DOT4 brake fluid.

CAUTION

Indicates an important step or operation.
Possibility of resulting in minor
malfuctioning or damage to part if ignored.
Indicates general caution. Caution needed to
be taken when performing the maintenance
operation or in the handling of part.

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

( 3-1)

SYMBOL

WARNING

1-19

SERVICE INFORMATION

WIRING DIAGRAM

TUBELESS

TIRE

APPL.

KOREA

FUEL UNIT
CONNECTING COUPLER

R/L TAIL STOP RR. WINKER

AUTO BY STARTER 5W 6.7

Ω

OIL TANK

FUEL TANK

WIRE HARNESS

A.C.GENERATOR

THIS SECTION SHOULD NOT
BE PROJECTED THAN THE FRONT
OF THE FRAME AND NOT HAVE ANY
LOOSENESS.

BATTERY ASS'Y

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

I/G COIL

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

SEAT LOCK CABLE

COMBI LOCK S/W
CONNECTING COUPLER

COMBI LOCK S/W

REGULATE RECTIFIER

HEADLIGHT TIE-DOWN COUPLER

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

RESISTER CONNECTING COUPLER

HORN COMP

TIGHT AT THE SAME TIME WITH THE HORN.

FRAME EARTH

CDI UNIT ASS'Y

STARTER REALY ASS' Y

PRESS TO ATTACH THE
SEL. SECTION TO THE PIPE.

FR. BRAKE HOSE

SPEEDOMETER CORD

THROTTLE CABLE

LIGHTING S/W UNIT

WINKER REALY

DIMMER S/W UNIT

WINKER S/W UNIT

HORN S/W UNIT

HAZARD S/W UNIT

RR. STOP S/W CONNECTOR

SPEEDOMETER CABLE

SPEEDOMETER CORD

HORN COMP

FR. BRAKE HOSE

SEAT LOCK CABLE

COMBI LOCK S/W

RR.STOP S/W CONNECTOR

THROTTLE CABLE

FRAME EARTH
TIGHT AT THE SAME TIME WITH THE HORN.

RESISTOR

30W 5.6Ω

RR. BRAKE CABLE

SPEEDOMETER ASS'Y

STARTER S/W UNIT

RR. BRAKE CABLE

SPEEDOMETER CABLE

1-20

SERVICE INFORMATION

FRAME EARTH TERMINAL

HEADLIGHT
CONNECTING COUPLER

TIE-DOWN COUPLER

TIE-DOWN COUPLER

LIGHT COMP.
CONNECTING CONNECTOR

RESISTER CONNECTING CONNECTOR

AUTO BY STARTER S/W CORD 5W 6.7Ω

REGULATE RECTIFIER

COMBI LOCK S/W

WIRE HARNESS

SPEEDOMETER CORD

OIL PUMP CABLE

THROTTLE CABLE

AUTO BY STARTER CORD

THROTTLE CABLE

BATTERY ASS'Y

THIS SECTION SHOULD NOT
BE PROJECTED THAN THE FRONT
OF THE FRAME AND NOT HAVE ANY
LOOSENESS.

AUTO BY STARTER 5W 6.7Ω

FR. BRAKE HOSE

RESISTER

RR. BRAKE CABLE

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

SEAT LOCK CABLE

THROTTLE CABLE

RR. BRAKE CABLE

OIL PASS TUBE

SEAT LOCK CABLE

OIL TUBE

FUEL VENT TUBE

FUEL STRAINER

FUEL AUTO COCK ASS'Y

NEGATIVE PRESSURE TUBE

FUEL TUBE

RESISTER

II

VV

30W 5.6Ω

SIDE STAND SWITCH

1-21

SERVICE INFORMATION

RR. BRAKE CABLE

THROTTLE CABLE

SEAT LOCK CABLE

HIGH TENSION CORD

STARTER MOTOR

OIL PUMP CABLE

THROTTLE CABLE

OIL PASS TUBE

OIL TUBE

AUTO BY STARTER CORD

FUEL TUBE

NEGATIVE PRESSURE TUBE

FUEL AUTO COCK ASS'Y

FUEL STRAINER

FUEL TANK

FUEL VENT TUBE

SEAT LOCK CABLE

LH. RR. WINKER LIGHT

RH. RR. WINKER LIGHT

TAIL LIGHT ASS'Y

FUEL UNIT

TAIL LIGHT CONNECTING CONNECTOR

CDI.UNIT ASS'Y

OIL LEVEL S/W

AUTO BY STARTER
CONNECTING COUPLER

ACG. CONNECTING COUPLER

ACG. CORD CLAMP
ROLL THE WHITE TAPE AREA OF ACG CORD
CLAMP IN THE POSITION OF THE CLAMP FIRMLY.

I/G COIL

I/G COIL

BATTERY ASS'Y

WIRE HARNESS

STARTER REALY ASS'Y

ENGINE EARTH
TIGHT AT THE SAME TIME
WITH THE STARTING MOTOR.

PRESS TO ATTACH THE
SEL. SECTION TO THE PIPE.

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

ROLL THE HES. CLAMP
WITH THE CORD SECURELY.

MEMO

2-1

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.

SPECIFICA TIONS

TORQUE VALUES

SPARK PLUG

1.4㎏f·m

CYLINDER HEAD COVER BOLTS

1.0㎏f·m

2

SERVICE INFORMATION 2-1
REGULAR INSPECTION SCHEDULE

2-2

FUEL LINE (FUEL TUBE)

2-3

FUEL LINE FOR CLOGGING

2-3

THROTTLE GRIP OPERATION

2-3

AIR CLEANER

2-4

SPARK PLUG

2-5

CYLINDER COMPRESSION PRESSURE

2-5

CARBURETOR IDLING

2-6

AIR SCREW ADJUSTMENT

2-6

BRAKE FLUID

2-6

BRAKE PAD/SHOE

2-7

BRAKE SYSTEM

2-7

HEADLIGHT ADJUSTMENT

2-8

SIDE STAND

2-8

SUSPENSION

2-9

BOLTS, NUTS, FASTENERS

2-9

WHEELS/TIRES

2-9

STEERING HEAD BEARING

2-10

BATTERY

2-10

ITEM STANDARD VALUE REFERANCE
THROTTLE GRIP FREE PLAY 2-6mm
SPARK PLUG B8HSA
SPARK PLUG GAP 0.6〜0.7mm
CARBURETOR IDLE SPEED 1,800±100rpm
CYLINDER COMPRESSION PRESSURE 10㎏f/㎠ - 600rpm

NOTE

•Stand the main stand prior to beginning work.

2-2

INSPECTIONS/ADJUSTMENTS

REGULAR INSPECTION 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

＊ 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.

＊

＊



＊



＊

＊

＊

＊



＊

＊





＊

＊

＊

FUEL LINE(FUEL TUBE)
THROTTLE GRIP OPERATION
OIL PUMP, OIL LINE
CARBURETOR CHOKE
AIR CLEANER
SPARK PLUG
CARBON REMOVAL
CARBURETOR IDLE SPEED
TRANSMISSION OIL
BRAKE SHOE/PAD WEAR
BRAKE SYSTEM
BRAKE STOP SWITCH
HEADLIGHT ADJUSTMENT
CLUTCH SHOE WEAR
SUSPENSION
BOLTS, NUTS, FASTENERS
WHEELS/TIRES
STEERING HEAD BEARING
DRIVE BELT
WEIGHT ROLLER
SLIDE PIECE

NOTE 2

NOTE 3

I

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C

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C

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Every 8,000㎞ : C

FREQUENCY

ODOMETER READING(NOTE 1)

61218

14812 REMARK

ITEM

x 1000Km

MONTH

FUEL LINE(FUEL TUBE)

● Remove the luggage box.( 3-3)

● Check the fuel tube of the fuel auto cock connected to

the fuel tank and carburetor. If the fuel tube is cranked,
damaged or leaks, replace it.

FUEL LINE FOR CLOGGING

NOTE

•Refer to section 2 for fuel filter inspection.

● Check the fuel tank cap and/or fuel tank breather tube

for clogging.

● Visually inspect the fuel strainer for contamination.
Check the fuel flow with the fuel strainer installed and
with the strainer removed.
Replace the fuel strainer if it is excessively contaminated
or if the fuel flow is not smooth.

CAUTION

•Note the installation direction of the fuel strainer. Be
sure to install it as shown in the drawing, i.e., with
the cup facing down. Fuel flows even though the
strainer is installed upside down, but it contaminates
the inner wall of the strainer and prevents visual
inspection of the strainer .

● Remove the fuel valve lock nut and check the fuel
strainer screen for contamination. Tighten the lock nut
to the specified torque.

THROTTLE GRIP OPERA TION

● Check if the throttle grip operates smoothly in any
steering position

● If the throttle grip does not operate properly, lubricate
the throttle cable.

● 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 : 2~6mm

2-3

INSPECTIONS/ADJUSTMENTS

FUEL TUBE

FUEL AUTO COCK

(Inner walls get
contaiminated,
making visual
inspection
difficult.)

FUEL TANK

FUEL STRAINER

● 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

● Loosen the 5 setting screw assembled to the air cleaner
case cover, and then remove the air cleaner case cover.

● Remove the air cleaner element.

● Wash away any accumulated dust or dirt, by gently

squeezing it in non flammable or high flash point
solvent.

WARNING

•Using gasoline or low flash point solvents for
cleaning parts may result in a fire or explosion.

CAUTION

•Cleaning the element with gasoline or any acid,
alkaline, or organic, volatile type oil may cause
improper ignition, deterioration of the element, or a
loosening of the element adhesive.

● Be sure to allow the element to dry thoroughly before
applying oil. Otherwise, the oil will be diluted by the
and the filtering ability of the filter will be much
less effective.

● Spread clean #80~90 gear oil on the element, rubbing

inthoroughly over the surface with both hands, and then
squeeze out any excess oil.

CAUTION

•Using air filter oil when riding in extremely dusty
conditions prevents premature engine wear due to
dust/dirt drawn into the engine. Apply air filter oil to
the entire surface of the element and rub it with both
hands to saturate the element with oil. Squeeze out
excess oil.

2-4

INSPECTIONS/ADJUSTMENTS

LOCK NUT

ADJUSTER

AIR CLEANER COVER

WASHER SCREW

AIR CLEANER ELEMENT

SPARK PLUG

● Remove the plug maintenance cover.

● Remove the spark plug cap and disassemble the plug.

● Check the plug for damage, contamination or deposits.

● If the spark plugs are severely contaminated or

damaged, raplace with new ones. If the plugs can be
reused after removing only the carbon, use plug cleaner
and wire brush to clean the plugs.

● Always use a feeler gauge to check the gap.

SPARK PLUG GAP : 0.6~0.7mm

CAUTION

•Make sure there is no dirt or debris on the seat of the

spark plug hole before inserting the spark plug.

•To prevent damage to the cylinder head, hand-tighten

the spark plug before using a wrench to tighten to the
specified torque.(torque : 14kgf·m)

•Do not overtighten the spark plug.

CYLINDER COMPRESSION PRESSURE

● Start and warm up the engine.

● Remove the plug maintenance cover.

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

plug.

● Install a compression gauge.

● Open the throttle completely, and crank the engine with

the starter motor until the gauge reading rising.

NOTE

•The maximum reading is usually reached within 4~7

seconds.

COMPRESSION PRESSURE : 13.8kg/cm

2

● If the pressure is low, check the following:

-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.

TOOL : COMPRESSION GAUGE

2-5

INSPECTIONS/ADJUSTMENTS

SPARK PLUG CAP

PLUG MAINTENANCE COVER

COMPRESSION GAUGE

CARBURETOR IDLING

● Stand the vehicle on the main stand.

● Heat the engine to make accurate idling inspection and

adjustment.

● Verify all engine adjustments satisfy specifications.
Make adjustments, if necessary .

● Turn the throttle stop screw and make adjustments to

prescribed idling speed.

AIR SCREW ADJUSTMENT

NOTE

•The air screw is factory pre-set. Adjustment is not
necessary unless the carburetor is overhauled or a
new air screw is installed.

•Tightening the air screw against its seat will damage
the seat.

● Turn the air screw clockwise until it seats lightly then
back it out to the specification given. This is an initial
setting prior to the final air screw adjustment.

● Rev the engine up slightly from the idle speed and
make sure that engine speed rises and returns smoothly.

● Adjust by turning the air screw in or out within a 1/4
turn if necessary. If the engine cannot be adjusted by
turning the air screw within a 1/4 turn, check for other
engine problems.

CAUTION

•Excessive air screw adjustment may cause the engine
sticking and deteriorate the starting performance.

BRAKE 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 diaphragm and fill DOT 3 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.

CAUTION

•Brake fluid will damage painted, plastic or rubber
parts.

•Mixing incompatible fluids can impair braking
efficiency.

•Foreign materials can clog the system, causing a
reduction or complete loss of braking ability .

•A leak in the brake system can lead to reduced
braking effiency and possible loss of braking ability.

2-6

INSPECTIONS/ADJUSTMENTS

THROTTLE STOP SCREW

THROTTLE STOP SCREW

AIR SCREW

BRAKE HOSE BOLT

MASTER CYLINDER